Machine Tool Vibration Band Monitoring for Abnormal Spindle Detection

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Solution Overview

Problem

Existing machine tool vibration detection methods fail to accurately identify abnormal vibrations due to the consideration of varying frequencies and amplitudes, making it difficult for operators to recognize potential damage-causing issues.

Innovation Solution

A machine tool system that sets specific frequency bands for the spindle and mechanical structure systems, extracts vibration components within these bands, and applies distinct threshold values for clear abnormal vibration detection, facilitating operator recognition of potential damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If vibration amplitude is compared with a threshold value without considering frequency, then the detection method is simple, but the operator cannot accurately recognize abnormal vibrations

Engineering Contradiction:

Improvesimplicity of detection methodVSAvoidaccuracy of abnormal vibration recognition

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The vibration detection is segmented by dividing the frequency spectrum into multiple frequency bands. Each band is analyzed separately with its own threshold, allowing precise identification of abnormal vibrations at specific frequencies while maintaining operational simplicity through automated band-by-band comparison.

Inventive Principle:

Principle #1Segmentation

2Measurement precision

If frequency bands are divided and separate thresholds are applied, then abnormal vibration detection accuracy is improved, but the system complexity increases

Engineering Contradiction:

Improveaccuracy of abnormal vibration detectionVSAvoidcomplexity of frequency band processing system

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The vibration detection system is designed with multi-functionality to handle multiple frequency bands simultaneously using a unified processing framework. The same threshold comparison mechanism is applied across different frequency bands, reducing system complexity while maintaining high detection accuracy through comprehensive frequency coverage.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enhances the clarity and ease of detecting abnormal vibrations, allowing operators to promptly address issues that could lead to machine tool damage by visualizing amplitude data within defined frequency bands and triggering warnings based on threshold exceedance.

Implementation Method 1

a vibration sensor configured to measure vibration

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Data Source

PatentEP3401056B1Machine tool

Publication Date: 2022.10.12 MAKINO MILLING MASCH CO LTD

Figure 1
Figure 2

AI summary

A machine tool is configured so that: a first frequency band comprising the main shaft characteristic vibration frequency and a second frequency band comprising the mechanical structure characteristic vibration frequency are set; thresholds are stored for each of the set frequency bands; vibration components are extracted for each of the frequency bands from the output of a vibration sensor; and when the vibration amplitude exceeds a threshold in either of the frequency bands, an alarm is sounded.