Machine Tool Vibration Sensing for Machining Accuracy Fault Isolation
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Solution Overview
Problem
Conventional abnormality detection devices for machine tools face difficulties in easily identifying specific items whose machining accuracy is compromised during abnormal operations, such as tool vibration and overfeeding, due to complex calculations.
Innovation Solution
An abnormality detection device equipped with multiple vibration sensors mounted at specific positions on a machine tool, which analyzes vibration data to determine operation conditions and specifies the affected machining accuracy based on sensor positions, using a data table to correlate sensor positions with machining accuracy issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex calculation methods are used to diagnose machining conditions from abnormal machining operations, then the detection accuracy of abnormality improves, but the ease of specifying predetermined items whose machining accuracy lowers deteriorates
Solution Approach 1:
The patent segments the complex diagnostic process into two distinct parts: (1) a determination portion that performs complex calculations to detect abnormal machining operations, and (2) a specification portion that uses a data table to map sensor positions to affected machining accuracy items. This segmentation allows complex detection to coexist with simple specification, resolving the contradiction between detection accuracy and ease of operation.
Solution Approach 2:
The patent introduces a data table as an intermediary between the vibration sensors and the machining accuracy items. The data table stores correspondence relationships between sensor mounted positions and affected machining accuracy items, serving as a mediator that translates complex vibration data into easily interpretable results without requiring users to perform complex calculations themselves.
2Reliability
If multiple vibration sensors are mounted at multiple positions to detect abnormal vibration, then the reliability of abnormality detection improves, but the device complexity increases
Solution Approach 1:
The patent makes the data table serve multiple functions: it maps sensor positions to machining accuracy items, enables easy specification of affected items, and provides a structured format for storing correspondence relationships. This multi-functionality reduces the need for additional complex components while maintaining high detection reliability through multiple sensors.
3Measurement precision
If complex calculation methods are used to determine operation conditions, then the measurement precision of machining condition diagnosis improves, but the time required for analysis increases
Solution Approach 1:
The patent performs preliminary action by pre-establishing the data table that stores correspondence relationships between sensor positions and machining accuracy items before actual machining operations. This pre-prepared structure allows rapid lookup and specification of affected items during operation, significantly reducing analysis time while maintaining diagnostic precision through the underlying complex calculations.
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 straightforward identification of items with lowered machining accuracy by calculating affecting values from vibration sensor data, allowing for timely detection and correction of machining abnormalities.
Implementation Method 1
a plurality of vibration sensors mounted on a body of the machine tool at a plurality of positions and a determination portion that determines an operation condition of the machine tool based on vibration information detected by the vibration sensors
Data Source
AI summary
An abnormality detection device of a machine tool includes a plurality of vibration sensors mounted on a body of the machine tool at a plurality of positions; and a determination portion that determines an operation condition of the machine tool based on vibration information detected by the vibration sensors. The abnormality detection device detects abnormality of the machine tool according to determination information of the determination portion. The determination portion specifies a predetermined item whose machining accuracy lowers based on the mounted position of the vibration sensor that has detected abnormal vibration.