Machine Tool Thermal Compensation for Uneven Workpiece Heating
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Solution Overview
Problem
Conventional machine tools face challenges in processing workpieces with inhomogeneous temperature distributions, leading to long waiting times for temperature equalization and limited precision due to the homogeneous temperature assumptions and neglect of local heat effects.
Innovation Solution
A machine tool system equipped with temperature sensors and a control unit that calculates actual workpiece dimensions based on nominal data, expansion coefficients, and real-time temperature data, allowing for precise compensation of thermal expansions and deformations during processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If workpiece is tempered to pre-defined normal temperature to eliminate temperature influence, then manufacturing precision is improved, but loss of time increases due to long waiting time for temperature equalization
Solution Approach 1:
The patent changes the approach from changing the workpiece temperature parameter (tempering) to changing the measurement and control parameters. Temperature sensors continuously monitor the workpiece temperature, and the control unit dynamically adjusts machining parameters based on real-time temperature data, eliminating the need for time-consuming temperature equalization while maintaining dimensional accuracy
Solution Approach 2:
The patent implements a feedback mechanism where temperature sensors continuously measure the workpiece temperature and feed this information to the control unit. The control unit processes this feedback and automatically adjusts the machining process in real-time, allowing precise machining without waiting for temperature equalization
2Device complexity
If temperature sensor is attached at a defined point or measurements are performed at individual points, then device complexity is reduced, but measurement precision deteriorates due to homogeneous view assumption that rarely corresponds to reality
Solution Approach 1:
The patent segments the temperature measurement into multiple discrete sensing points distributed across the workpiece. Instead of a single homogeneous measurement, multiple sensors capture local temperature variations at different locations, providing a detailed temperature distribution map that reflects the actual thermal state of the workpiece
Solution Approach 2:
The patent transitions from point-based temperature measurement to a multi-dimensional temperature distribution measurement. By arranging sensors in a spatial configuration and using interpolation algorithms, the system creates a comprehensive three-dimensional temperature field model of the workpiece, enabling precise compensation across the entire workpiece volume
3Measurement precision
If thermal imaging temperature sensor is used to determine temperature distribution, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent creates a thermal copy or digital model of the workpiece temperature distribution. Temperature sensors capture thermal data that is processed by the control unit to generate a virtual temperature map, which is then used to calculate and compensate for thermal deformations. This digital copying approach provides high measurement precision without requiring complex physical intervention
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables high-precision processing of workpieces with inhomogeneous temperature distributions without the need for tempering, reducing production time and improving accuracy by dynamically adjusting processing paths based on continuous temperature measurements.
Implementation Method 1
Deviations from this homogeneous normal temperature influence dimensions of the workpiece due to temperature-influence including local or overall deformations (e.g. expansions)
Data Source
AI summary
A machine tool for processing a workpiece having a temperature that deviates from a pre-defined processing temperature, the machine tool comprising a base to position the workpiece on, at least one processing means for processing the workpiece, one or more actuators for moving the processing means relative to the base, a control unit for controlling the actuators, the control unit comprising a data storage for storing nominal data providing nominal dimensions of the workpiece at the pre-defined processing temperature, and at least one temperature sensor that is configured to determine one or more actual temperature values of the workpiece, wherein the at least one temperature sensor is configured to generate temperature data based on the determined actual temperature values and to provide the temperature data to the control unit.