Machine Tool Controller Voltage Abnormality Detection
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Solution Overview
Problem
Machine tools face challenges in detecting and addressing slight power supply abnormalities, which can affect machining precision but are not adequately detected by current systems, leading to difficulties in identifying the cause of defects and potentially causing unnecessary shutdowns.
Innovation Solution
A machine tool controller with a voltage detection unit, time measurement unit, abnormality determination unit, machining management unit, and storage unit that sets specific threshold values for low voltage and power failure conditions, allowing for the detection and storage of voltage abnormalities and their impact on machining, enabling better traceability and prevention of defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If power failure determination conditions are set to detect slight power supply abnormalities, then detection capability is improved, but false alarms increase causing unnecessary shutdowns
Solution Approach 1:
The power supply abnormality detection is segmented into multiple levels: slight abnormalities (voltage drops not meeting power failure conditions) and power failures (voltage drops meeting power failure conditions). This segmentation allows the system to detect and record all abnormalities without triggering shutdowns for minor issues, while still protecting against severe failures.
Solution Approach 2:
The system dynamically adjusts its response based on the severity of the detected abnormality. For slight abnormalities, the system performs recording and notification without shutdown. For power failures meeting predetermined conditions, the system executes protection operations. This dynamic response optimization resolves the contradiction between detection sensitivity and false alarm rate.
2Measurement precision
If power failure determination conditions are relaxed to easily detect abnormalities, then detection sensitivity is improved, but machine usage percentage decreases due to frequent shutdowns
Solution Approach 1:
The system segments abnormalities into two categories: slight power supply abnormalities that do not meet power failure determination conditions, and actual power failures that do meet the conditions. This segmentation enables high detection sensitivity for all abnormalities while maintaining high machine usage by only shutting down for severe cases.
Solution Approach 2:
The system changes the response parameter based on the severity of the abnormality. For slight abnormalities, the response is recording and notification. For severe power failures, the response is protection operation with shutdown. This parameter change strategy maintains both high detection sensitivity and high productivity.
3Ease of operation
If traditional power failure detection is used, then simple operation is maintained, but traceability of slight abnormalities is lost
Solution Approach 1:
The system performs preliminary recording of slight power supply abnormalities before they escalate to power failures. By recording voltage values, occurrence times, and machining information in advance, the system maintains simple operation while ensuring complete traceability for quality control and troubleshooting.
Data Source
AI summary
A machine tool controller includes: a voltage detection unit which detects a voltage value of an input power supply; a time measurement unit which measures an occurrence time and a duration time when a voltage drop state occurs with respect to the voltage value; an abnormality determination unit which determines whether a low voltage abnormality or a power failure occurs with respect to the input power supply based on the voltage value and the duration time of the voltage drop state; a machining management unit which acquires a machining condition command and machining information of the machine tool; and a storage unit which stores the voltage value detected by the voltage detection unit, the occurrence time of the voltage drop state measured by the time measurement unit, and the machining information when the abnormality determination unit determines that the low voltage abnormality occurs with respect to the input power supply.