Machine Tool Tool Verification for Mismatch and Damage Detection
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Solution Overview
Problem
Current machine tools with tool changers cannot detect when a non-designated tool is mistakenly loaded or when a tool's cutting edge is damaged, leading to potential machine damage, defective products, and unnecessary downtime due to human error.
Innovation Solution
A machine tool equipped with a tool measuring device that measures tools before and after machining, and a judging unit that sends warning signals for improper or damaged tools, allowing for automatic tool replacement and preventing machining with unsuitable tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual tool loading is performed without automated detection, then ease of operation is improved, but reliability deteriorates due to human error causing tool mismatches
Solution Approach 1:
The system performs self-verification by automatically measuring tool dimensions and comparing them against machining program requirements without requiring operator intervention. The measuring device and judging unit work autonomously to detect tool mismatches, enabling the system to self-correct potential errors before machining occurs.
Solution Approach 2:
The system establishes a feedback loop where tool measurement results are immediately compared with program specifications, and warning signals are generated when mismatches are detected. This closed-loop feedback mechanism ensures that tool loading errors are detected and reported back to the operator in real-time.
2Reliability
If tool measurement and verification systems are added, then reliability is improved by detecting tool mismatches, but device complexity increases
Solution Approach 1:
The measuring device is designed to serve multiple functions: it measures tool dimensions, verifies tool identities, detects tool damage, and generates warning signals. By consolidating these functions into a single integrated system, the patent reduces the need for multiple separate devices while maintaining comprehensive tool verification capabilities.
Solution Approach 2:
The system replaces manual visual inspection and physical tool verification with automated optical or electronic measurement. The measuring device uses non-contact or minimal-contact measurement methods to detect tool dimensions, substituting complex mechanical verification procedures with simpler sensor-based detection.
3Manufacturing precision
If tool measurement is performed before machining, then manufacturing precision is improved by preventing defective products, but loss of time occurs during measurement process
Solution Approach 1:
The system performs tool measurement and verification before machining operations begin, ensuring that any tool mismatches or damage are detected in advance. This preliminary action prevents defective products from being manufactured while the measurement time is minimized through automated rapid measurement techniques.
Solution Approach 2:
The measurement process is designed to be rapid and efficient, using quick-scan measurement methods that minimize the time tools spend in the measurement device. The system quickly captures essential dimensional data without requiring prolonged measurement cycles, thus reducing time loss while maintaining verification accuracy.
4Productivity
If automated tool verification is implemented, then productivity is improved by preventing machine damage and downtime, but device complexity increases due to additional measuring and judging units
Solution Approach 1:
The control device automatically processes measurement data, compares it with program requirements, and generates warning signals without requiring operator intervention. This self-service capability streamlines the verification process and integrates seamlessly into the existing control system, minimizing the increase in operational complexity while maximizing productivity benefits.
Data Source
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AI summary
This machine tool has a tool changing device (40), and sequentially changes tools (5) to machine a workpiece. The machine tool comprises: an input unit (31) which receives a machining program output from a CAM system and tool basic data; a storage unit (32) which stores the tool basic data received from the input unit for each tool number; a tool measuring device (24) which measures the size of a tool loaded into a tool magazine (41) of the tool changing device; and a determination unit (33) which compares the tool basic data stored in the storage unit and the actual data measured by the measuring device, and determines that the measured tool is different from a desired tool if the difference between the two tool sizes is beyond a preset allowable range.