Machine Tool Wear Analysis Using Axis Load-Position Measurements
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Solution Overview
Problem
Machine tools experience decreased machining accuracy over time, requiring frequent replacement of parts to restore tolerances, which is costly and inefficient.
Innovation Solution
A method for controlling machine tools that involves storing data tuples with position and load values for specific working axes, allowing for tolerance measurements at different positions to determine wear, thereby identifying specific components causing deviations and enabling targeted maintenance rather than wholesale replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If tolerance measurements are performed at multiple positions with different load values, then wear information can be specifically assigned to particular components, but the measurement process and data processing become more complex
Solution Approach 1:
The patent segments the machine tool into multiple working axes (first, second, third working axes) and performs tolerance measurements at different positions along each axis. By dividing the measurement process into axis-specific segments with position-specific load values, the system can precisely identify which specific component on a specific axis is wearing, rather than treating the entire machine tool as a single unit. This segmentation enables component-specific wear diagnosis.
Solution Approach 2:
The patent introduces a new dimension of analysis by incorporating load values as a third parameter alongside position and measurement results. Instead of only measuring wear at different spatial positions, the system adds the load dimension to create a multi-dimensional wear analysis framework. This allows differentiation between components based on their operational load characteristics, enabling more precise wear source identification.
2Manufacturing precision
If all parts subject to wear are replaced to restore tolerances, then machining accuracy is restored, but operational costs increase and efficiency decreases
Solution Approach 1:
The patent extracts and identifies the specific worn component from the entire machine tool system by analyzing tolerance measurements at multiple positions with different load values. Instead of replacing all parts subject to wear, the system isolates the particular component (e.g., a specific bearing, guide rail, or spindle element on a specific axis) that is causing the tolerance deviation. This extraction principle enables targeted replacement of only the faulty component, reducing maintenance costs and downtime.
Solution Approach 2:
The patent applies local quality by treating different components of the machine tool differently based on their specific wear characteristics. Instead of uniform replacement of all worn parts, the system identifies which specific local component requires attention and focuses maintenance resources there. The load value analysis helps determine the local wear pattern, enabling differentiated maintenance strategies for different components based on their actual wear status and importance.
Data Source
AI summary
A method of controlling a machine tool comprising the steps of: providing a data memory containing, for at least one specific working axis of the plurality of working axes, a plurality of data tuples each assigning a load value to a position value relative to the specific working axis, selecting a first data tuple and a second data tuple whose load values are different, and generating at least one control command for the machine tool, wherein the control command is adapted to perform a first tolerance measurement at a first position value and a second tolerance measurement at a second position value, and wherein, based on a first result of the first tolerance measurement and a second result of the second tolerance measurement, information about wear of a part of the machine tool is output. A corresponding device is also be disclosed.