Machine Tool Warm-up Control via Thermal Displacement Feedback
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Solution Overview
Problem
Conventional warm-up control methods for machine tools are inefficient as they rely on operator experience and intuition to determine when thermal displacement is stable, leading to potential unnecessary re-warm-ups and lack of automatic restart capabilities, especially when operators are absent.
Innovation Solution
A warm-up control device that calculates and stores thermal displacement amounts over time, allowing for automatic restart and end of warm-up based on predetermined conditions, including differences between maximum and minimum displacement values, and operator-set permissible values, ensuring stable machining accuracy without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If warm-up is ended simply without automatic restart capability, then operator can leave the machine tool, but machining accuracy may deteriorate due to unnecessary re-warm-up or thermal displacement from cooling down
Solution Approach 1:
The system continuously monitors thermal displacement amounts during and after warm-up, using this feedback to determine when thermal stability is achieved and to control automatic restart. The restart determination part uses stored thermal displacement data to decide whether restart is necessary, preventing both unnecessary re-warm-ups and potential accuracy deterioration from cooling down.
Solution Approach 2:
The system performs preliminary monitoring of thermal displacement during the warm-up phase and stores this data before ending warm-up. This preliminary action enables the restart determination part to make informed decisions later without requiring continuous monitoring during the idle period, allowing operator convenience while maintaining precision.
2Productivity
If warm-up duration is determined by operator experience and intuition, then warm-up can be ended quickly, but thermal displacement stability cannot be guaranteed
Solution Approach 1:
The system uses continuous measurement of thermal displacement amounts as feedback to objectively determine when thermal stability is achieved. The warm-up end determination part compares monitored thermal displacement data against stability criteria, replacing subjective operator judgment with reliable automated detection, thus ensuring both efficiency and reliability.
Solution Approach 2:
The invention replaces the mechanical/subjective method of operator judgment with an automated measurement and control system. A measuring device (such as laser interferometer) objectively measures thermal displacement, and the control device automatically processes this data to determine warm-up completion, eliminating reliance on operator experience while improving both productivity and reliability.
3Extent of automation
If measuring device is used to control tool positioning automatically, then warm-up can be ended automatically, but device complexity increases and not all machine tools can be equipped
Solution Approach 1:
The system creates a simplified control implementation that copies the essential functionality of full automated tool positioning control. Instead of requiring complete measuring and positioning systems, the invention uses a streamlined approach that monitors thermal displacement and controls warm-up restart based on stored data patterns, making automation accessible to machine tools without expensive additional equipment.
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
This solution enables automatic and efficient warm-up control, reducing waiting times and preventing unnecessary re-warm-ups by accurately determining thermal displacement stability, thus improving machining accuracy and accommodating various machine tool environments.
Implementation Method 1
a thermal displacement amount calculation part for calculating a thermal displacement amount based on heat generated or released upon starting or ending the warm-up of the machine tool
Data Source
AI summary
Prior to machining a workpiece, a warm-up control device for a machine tool is activated to perform a warm-up in which a main shaft rotary drive part and axes drive parts are driven. The amount of displacement of heat that is generated upon starting of the warm-up and changes with time is calculated every predetermined time period. Whether to end the warm-up is determined based on the thermal displacement amount. Whether to restart the warm-up after the end of the warm-up is determined based on the thermal displacement amount. When it is determined to restart the warm-up, the warm-up is restarted.