Machine Tool Thermal Accuracy Prediction for Energy-Saving Scheduling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for maintaining machining accuracy in machine tools are inefficient and energy-intensive, particularly when room temperature changes, and fail to accurately predict the duration of thermal displacement influence, making it difficult to create effective machining schedules.
Innovation Solution
A machining accuracy diagnosing device and method that predicts and diagnoses the influence of temperature regulating units on machining accuracy by using sensors to monitor and model temperature changes, allowing for the adjustment of air conditioner operation patterns and machining schedules to ensure accuracy while minimizing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the air conditioner is constantly operated for 24 hours to maintain room temperature, then the machining accuracy is maintained, but the energy consumption and cost burden increase
Solution Approach 1:
The system performs preliminary actions by predicting future room temperature changes and machine tool thermal displacements before they occur. The machining schedule is created in advance with built-in temperature compensation values, allowing the machine tool to maintain accuracy without continuous air conditioner operation. The prediction unit forecasts temperature changes, and the schedule creation unit pre-calculates corrected machining parameters.
Solution Approach 2:
The system changes parameters by dynamically adjusting machining parameters (such as cutting speeds, feed rates, and tool paths) based on predicted thermal displacements. The schedule creation unit generates corrected machining schedules with modified parameters that compensate for anticipated temperature changes, allowing accurate machining without maintaining constant room temperature.
2Use of energy by moving object
If the air conditioner power source is turned off during nighttime and weekends to reduce energy consumption, then the energy cost decreases, but the room temperature rapidly changes when restarted, causing the machine tool accuracy to take a long time to stabilize
Solution Approach 1:
The system performs preliminary actions by predicting future room temperature changes and machine tool thermal displacements before they occur. The machining schedule is created in advance with built-in temperature compensation values, allowing the machine tool to maintain accuracy without continuous air conditioner operation. The prediction unit forecasts temperature changes, and the schedule creation unit pre-calculates corrected machining parameters.
Solution Approach 2:
The system changes parameters by dynamically adjusting machining parameters (such as cutting speeds, feed rates, and tool paths) based on predicted thermal displacements. The schedule creation unit generates corrected machining schedules with modified parameters that compensate for anticipated temperature changes, allowing accurate machining without maintaining constant room temperature.
3Manufacturing precision
If thermal displacement compensation is used with temperature sensors mounted on structure parts to calculate and adjust axial movements, then the thermal displacement is compensated, but the accuracy is limited and errors occur when temperature changes are large
Solution Approach 1:
The system introduces an intermediary prediction unit that forecasts room temperature changes and machine tool thermal displacements before machining operations. This predictive intermediary allows the schedule creation unit to pre-calculate corrected machining schedules that compensate for anticipated thermal effects, rather than relying solely on real-time sensor feedback during temperature changes.
Solution Approach 2:
The system performs preliminary actions by predicting future room temperature changes and machine tool thermal displacements before they occur. The machining schedule is created in advance with built-in temperature compensation values, allowing the machine tool to maintain accuracy without continuous air conditioner operation. The prediction unit forecasts temperature changes, and the schedule creation unit pre-calculates corrected machining parameters.
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
Enables quantitative prediction of machining accuracy influence, allowing for optimized air conditioner operation and machining schedules that stabilize machine tool temperatures, ensuring accuracy and reducing energy use.
Implementation Method 1
temperature sensors are mounted on respective structure parts of the machine tool, displacement amounts are calculated based on measured temperatures
Implementation Method 2
it is effective to use an air conditioner, which includes an air-conditioning installation and air-conditioning equipment, such that the room temperature inside the plant does not significantly change
Data Source
AI summary
A machining accuracy diagnosing device includes a temperature regulation operating pattern setting unit, a cutting condition setting unit, a temperature information acquiring unit, and a machining accuracy influence amount predicting unit. The temperature regulation operating pattern setting unit sets an operating pattern of a temperature regulating unit. The cutting condition setting unit sets a scheduled machining start time and a scheduled machining end time. The temperature information acquiring unit acquires an influencing temperature of the temperature regulating unit on the machine body temperature and/or an air temperature outside the plant. The machining accuracy influence amount predicting unit predicts an influence amount of the temperature regulating unit on the machining accuracy based on the operating pattern, the scheduled machining start time and the scheduled machining end time, and at least one of the influencing temperature and/or the air temperature outside the plant and a set temperature of the temperature regulating unit.