Machine Tool Torque Monitoring for Cutting Tool Run-Out Detection
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Solution Overview
Problem
Machine tools face issues with detecting cutting tool run-out due to foreign material jamming, which can lead to machining errors, and existing solutions involving sensors are costly and prone to deterioration.
Innovation Solution
A machine tool system that measures driving torque during no-load operations to detect run-out without the need for additional sensors, using a torque measurement unit, reference value calculation, torque comparison, and alarm units to identify abnormalities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is installed to detect cutting tool run-out, then detection capability is improved, but device complexity and cost increase
Solution Approach 1:
The machine tool uses its own existing torque measurement system to detect cutting tool run-out, rather than adding external sensors. The torque measurement unit that already exists for monitoring machining processes is repurposed to detect abnormalities in cutting tool mounting, making the system self-diagnostic without requiring additional detection devices.
Solution Approach 2:
The torque measurement unit serves multiple functions: it monitors both normal machining processes and detects cutting tool run-out abnormalities. By making this existing component multi-functional, the patent eliminates the need for dedicated run-out detection sensors while maintaining detection capability.
2Measurement precision
If a sensor is installed to detect cutting tool run-out, then detection capability is improved, but cost increases
Solution Approach 1:
The machine tool uses its own existing torque measurement system to detect cutting tool run-out, rather than adding external sensors. The torque measurement unit that already exists for monitoring machining processes is repurposed to detect abnormalities in cutting tool mounting, making the system self-diagnostic without requiring additional detection devices.
Solution Approach 2:
The torque measurement unit serves multiple functions: it monitors both normal machining processes and detects cutting tool run-out abnormalities. By making this existing component multi-functional, the patent eliminates the need for dedicated run-out detection sensors while maintaining detection capability.
3Measurement precision
If a sensor is installed to detect cutting tool run-out, then detection capability is improved, but sensor reliability deteriorates due to cutting fluid exposure
Solution Approach 1:
The machine tool uses its own existing torque measurement system to detect cutting tool run-out, rather than adding external sensors. The torque measurement unit that already exists for monitoring machining processes is repurposed to detect abnormalities in cutting tool mounting, making the system self-diagnostic without requiring additional detection devices.
Solution Approach 2:
The patent uses torque as an intermediary parameter to indirectly detect cutting tool run-out. Instead of placing a sensor directly in the harsh environment near the cutting tool where it would be exposed to cutting fluid, the system measures torque variations through the drive system, which serves as a mediator between the cutting zone and the measurement point.
Data Source
AI summary
A machine tool for machining a workpiece includes a spindle configured to rotate a holder mounted with a tool used for machining, one or more moving shafts configured to move the holder and/or a work base on which the workpiece is placed, a torque measurement unit configured to measure driving torque of the spindle and/or the one or more moving shafts, a reference value calculation unit configured to use, as a reference value, the driving torque measured by performing a no-load operation by rotating the spindle in a normal state, a torque comparison unit configured to compare, to the reference value, the driving torque measured by performing a no-load operation by rotating the spindle before actual machining, and an alarm unit configured to determine whether to issue an alarm on the basis of results of the comparison.