Machine Tool Virtual Twin for Safe Setup and Training
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Solution Overview
Problem
Existing machine tools, such as lathes, pose a risk to personnel during setup and training due to the need for operators to ensure all manual controls are in a safe state before operations, which is often overlooked, leading to potential accidents.
Innovation Solution
A machine tool with a dual operating state system, allowing a safety-protected mode where manual controls remain active but drives are deactivated, enabling virtual simulations through a single HMI, and a safety switch ensuring safe transitions between states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If drives are deactivated in safety-protected operating state, then personnel safety is improved, but realistic operation simulation is worsened
Solution Approach 1:
The patent creates a virtual twin (copy) of the machine tool that replicates its operational behavior. In the safety-protected operating state, the control system generates virtual drive commands based on manual control inputs, allowing realistic simulation without activating actual drives. This copying approach maintains operational realism while ensuring personnel safety by keeping drives deactivated.
2Ease of operation
If manual controls remain active in safety-protected operating state, then ease of operation is improved, but risk of accidental drive start-up is worsened
Solution Approach 1:
The patent introduces a virtual twin as an intermediary between manual controls and actual drives. Manual controls remain active and accessible, but their commands are directed to the virtual twin instead of directly to the drives. This intermediary layer allows operators to interact with the system naturally while preventing accidental drive activation, as the virtual twin processes commands without physical execution.
3Reliability
If drives are deactivated for safety, then personnel safety is improved, but training effectiveness is worsened
Solution Approach 1:
The virtual twin serves as a training platform that replicates the actual machine tool's behavior. Trainees can practice operations on the virtual twin with full realism, including visual feedback and operational logic, without the risk of actual drive activation. This copying approach maintains training effectiveness by providing authentic operational experience while ensuring personnel safety through drive deactivation.
4Reliability
If dual operating state system is implemented, then safety protection is improved, but device complexity is worsened
Solution Approach 1:
The control system is designed to perform multiple functions: it controls actual drives during productive operation and generates virtual drive commands during safety-protected operation. By making the control system universal and capable of handling both operational modes, the patent avoids adding separate dedicated systems for each mode, thereby limiting the increase in device complexity while maintaining comprehensive safety protection.
Data Source
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AI summary
The invention relates to a machine tool, in particular a lathe or milling machine, e.g., a conventional lead screw lathe. This machine tool has drives as machine operating elements for performing workpiece machining and manual operating elements (BE) for the machine operating elements. According to the invention, a machine control (MS) provides a productive operating state for workpiece machining and a safety-protected operating state for realistic operation of the machine tool. The safety-protected operating state is characterized by active manual operating elements (BE), deactivated drives (AN) of the machine operating elements, and virtual simulations of the switching states of the manual operating elements and/or the movements of drives and/or the machining of workpieces.A machine control panel (HMI) allows the machine tool to be switched between productive and safety-protected operating states. The invention offers the advantage that, in the safety-protected operating state, realistic operation of the machine tool is possible via the machine control panel, i.e., with the drives switched off, but with unrestricted operability and virtual functionality. A person can thus simulate operating procedures, e.g., for training and testing purposes. This operating state is comparable to a flight or driving simulator and can be described as a virtual twin of the real machine tool.