Machine Tool Diagnosis Using Two-Level State Description Data
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Solution Overview
Problem
Current machine tool diagnosis systems face challenges in accurately identifying abnormalities, particularly in distinguishing between rough and detailed state-description data, which hinders effective maintenance and operation.
Innovation Solution
A machine tool system comprising an input interface, actuator, control circuitry, sensor, computer, and output interface that generates and transmits rough and detailed state-description data for abnormality diagnosis, facilitating identification of abnormal parts through a centralized configuration and communication network.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensor signal processing is performed on the controller, then abnormality diagnosis can be conducted, but the controller load increases
Solution Approach 1:
The patent divides the diagnosis system into two independent parts: a sensor signal processing device that performs rough and detailed diagnosis, and a controller that executes machining commands. This segmentation transfers the computationally intensive signal processing tasks from the controller to a dedicated processing device, reducing controller load while maintaining comprehensive abnormality diagnosis capability.
2Measurement precision
If detailed state-description data is generated and transmitted, then abnormal part identification accuracy improves, but communication data volume increases
Solution Approach 1:
The system implements a two-level diagnosis approach where rough state-description data provides basic abnormality detection, and detailed state-description data is generated only when needed for specific abnormal part identification. This partial action approach ensures high identification accuracy when required while minimizing unnecessary data transmission during normal operation.
3Ease of operation
If rough and detailed diagnosis are separated, then operator-friendliness improves, but system complexity increases
Solution Approach 1:
The sensor signal processing device acts as an intermediary between the sensor and the controller/operator. It automatically performs both rough and detailed diagnosis, processes sensor signals, and presents results in an operator-friendly format. This intermediary handles the system complexity internally while maintaining simplicity for the operator.
Data Source
AI summary
A machine tool includes an input interface configured to receive an instruction, an actuator configured to actuate, control circuitry configured to control an actuation of the actuator based on the instruction, a component having a physical state to be affected by the actuation, a sensor configured to detect the physical state, and a computer connected to the control circuitry via an external communication interface. The computer is configured to receive a signal from the sensor, generate, based on the signal, rough state-description data relevant to an occurrence of an abnormality in the component, transmit the rough state-description data to the control circuitry, generate detailed state-description data based on the signal, the detailed state-description data being more informative than the rough state-description data such that the detailed state-description data facilitates identifying an abnormal part in the component, and transmit the detailed state-description data to a monitoring computer via a communication network.