Machine Tool Tool Verification Using Image-Model Interference Checks
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Solution Overview
Problem
Existing machine tool systems fail to accurately determine if a wrong or damaged tool is mounted on the tool magazine, leading to potential collisions and interference with the workpiece or machine tool, which can cause damage.
Innovation Solution
A machine tool system that images the tool mounted on the tool holder, generates a two-dimensional tool model from shape data, and compares it with image data to ensure the tool is correct and undamaged, using a backlight imaging system and a controller to analyze dimensions and issue warnings for incorrect tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the operator visually confirms and manually mounts tools in the tool magazine, then the system can identify tool placement errors, but the process is time-consuming and prone to human error
Solution Approach 1:
The patent replaces the manual visual inspection and identification process with an automated optical imaging system. A camera captures images of tools in the magazine, and image processing automatically extracts tool features and identifies them, eliminating the need for operator visual confirmation while maintaining high accuracy.
Solution Approach 2:
The system enables self-service by allowing the tool magazine to automatically identify and verify tool placements without human intervention. The imaging device and image processing system work autonomously to detect tool positions, extract features, and compare them with database information, making the system self-checking and self-verifying.
2Device complexity
If automatic collation uses only tool dimensional data from image data, then the recognition process is simple, but it cannot prevent collisions or interference between tool and workpiece
Solution Approach 1:
The patent merges two types of data: tool dimensional data extracted from images and tool shape data from the NC machining program. By combining these data sources, the system not only identifies tools based on dimensions but also verifies tool shapes against the machining program requirements, enabling collision prevention while maintaining relatively simple system complexity.
Solution Approach 2:
The system performs preliminary verification by comparing tool shape data with the NC machining program before machining begins. This advance checking ensures that the correct tool with the proper shape is selected, preventing potential collisions or interference during the actual machining operation.
3Measurement precision
If the system compares tool images with master data, then tool identification can be performed, but it cannot determine if the tool is damaged or if incorrect tool/pot numbers are assigned
Solution Approach 1:
The system implements feedback by comparing three elements: extracted tool features from images, tool shape data from the NC machining program, and tool database information including tool and pot numbers. This multi-layer feedback mechanism provides comprehensive validation, detecting not only identification errors but also tool damage and incorrect number assignments.
Solution Approach 2:
The system performs preliminary comprehensive validation before machining by checking tool identity, shape conformity, tool number correctness, and pot number correctness. This advance multi-parameter verification ensures that only properly matched and undamaged tools are used, preventing machining errors.
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
Ensures accurate determination of the correct tool and detects damage, preventing collisions and ensuring proper machining by comparing tool dimensions from image data with pre-simulated tool models, thus preventing tool and workpiece damage.
Implementation Method 1
an imaging device which images the tool mounted on a tool holder
Implementation Method 2
using a backlight imaging system
Data Source
Figure 1
Figure 2
Figure 3(a)~4(b)
AI summary
A machine tool (1) is provided with a main shaft (4) configured to have a tool (5) fitted to a distal end portion thereof, a tool magazine (41) for holding a plurality of tools, a tool exchanging arm (43) for exchanging tools between the tool magazine and the rotary main shaft, and a table (14) for attaching a workpiece, wherein the machine tool (1) machines the workpiece by causing the main shaft and the table to move relative to one another in accordance with a machining program, and wherein the machine tool (1): is provided with an image capturing device (24) for capturing an image of the tool fitted to a tool holder, and an interference checking device (110) which uses the machining program, and shape data relating to the workpiece, the tool, and the machine tool to simulate machining before machining is carried out, to check for the presence or absence of interference between at least the tool and the workpiece; and acquires the shape data relating to the tool from the interference checking device, generates a two-dimensional tool model from the acquired shape data relating to the tool, compares the two-dimensional tool model with an image of the tool captured by the image capturing device, and determines that the tool is invalid if an amount of displacement between the two-dimensional tool model and the image data is equal to or greater than a prescribed threshold.