Machine Tool Vibration Diagnosis for Surface Defect Prevention

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Solution Overview

Problem

Current machining processes for high-quality machining, such as those involving IT and exterior components, face challenges in identifying and addressing vibration-related defects in machined surfaces, which often require skilled operators and extensive analysis, leading to increased costs and production halts.

Innovation Solution

A machining environment measurement device that automatically evaluates the vibration states of machine tools and peripheral devices by comparing measured data to reference data from an ideal machining environment, providing a score indicating the suitability of the machining environment for high-quality machining, allowing for preventive maintenance and quick identification of defects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If vibration measurement and analysis are performed using external devices and skilled operators, then the accuracy of identifying vibration sources is improved, but the cost and time consumption increase significantly

Engineering Contradiction:

Improvevibration source identification accuracyVSAvoidanalysis time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The machine tool performs self-diagnosis by automatically comparing its own vibration data against stored reference data, eliminating the need for external measurement devices and skilled operators to conduct manual analysis

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual analysis by skilled operators is replaced by an automated computer-based system that uses algorithms to compare vibration data and identify abnormal conditions, substituting human expertise with automated computational analysis

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If skilled operators and external analysis devices are used to examine vibration factors, then the identification of machining environment issues is improved, but the manufacturing cost increases

Engineering Contradiction:

Improvemachining environment evaluation accuracyVSAvoidmanufacturing cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The system enables the machine tool to autonomously evaluate its own machining environment by comparing operational data with reference data, eliminating dependency on external experts and reducing service costs

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Reference vibration data from ideal machining environments is stored and reused for comparison, creating a digital reference model that eliminates the need for repeated manual analysis and expert intervention

Inventive Principle:

Principle #26Copying

3Manufacturing precision

If manual vibration analysis is performed to identify defects, then the quality of machining process optimization is improved, but the productivity decreases due to production halts

Engineering Contradiction:

Improvemachining qualityVSAvoidproduction continuity

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system performs continuous automated monitoring and comparison of vibration data against reference values, enabling early detection of abnormal conditions before they cause defects or require production halts

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously compares real-time vibration data with reference data and provides automated feedback on machining environment quality, enabling real-time adjustments without stopping production

Inventive Principle:

Principle #23Feedback

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 automatic identification of vibration sources causing defects, reduces the need for skilled operators, and facilitates preventive maintenance, thereby minimizing production halts and costs associated with high-quality machining.

Implementation Method 1

a holder measurement sensor that detects vibration of the holder

Methodology Applied

Scientific EffectVibration detection: Vibration

Data Source

PatentUS11440152B2Machining environment measurement device

Publication Date: 2022.09.13 FANUC LTD

AI summary

A machining environment measurement device, which enables automatic identification of a vibration source which may cause defects in a machined surface based on pieces of vibration data without performing an actual machining process, includes a reference machining data storage unit that stores reference machining data computed based on time-series data of vibration measured in advance in an ideal machining environment; a data acquisition unit that acquires time-series data of vibration of at least a holder attached to a spindle of the machine tool detected by a holder measurement sensor; an analysis unit that analyzes the time-series data and computes feature data indicating a feature of the time-series data; a comparative determination unit that compares the feature data with the reference machining data and determines a machining environment of the machine tool; and a display unit that displays the determination result of the comparative determination unit.