Machine Tool Wear State Determination via Simulation
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Solution Overview
Problem
Current machine tool controllers can only partially compensate for tool wear, leading to deviations in workpiece geometry due to changes in cutter diameter or milling head contour, necessitating manual and time-consuming simulation updates for accurate wear assessment.
Innovation Solution
A system that connects machine tools, production control computers, and tool databases via internet or intranet for real-time data exchange, allowing a simulation computer to accurately determine tool wear state by emulating machine behavior and displaying results for maintenance decisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual simulation updates are performed to assess tool wear, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The patent creates a virtual copy of the machine tool and tool geometry in a simulation environment. This digital model allows automated wear assessment by comparing simulated workpiece geometry with nominal geometry, eliminating manual simulation updates while maintaining high measurement precision.
Solution Approach 2:
The system establishes a feedback loop where tool wear is continuously monitored by comparing actual workpiece geometry with nominal geometry. This automated feedback mechanism enables real-time wear state determination without manual intervention, resolving the time loss issue while maintaining precision.
2Ease of operation
If fixed wear variables are specified based on user experience, then ease of operation is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent replaces experience-based manual wear specification with an automated simulation-based wear determination system. The simulation computer automatically calculates tool wear effects on workpiece geometry, providing precise, objective wear assessment that improves manufacturing precision while maintaining ease of operation through automated processes.
Solution Approach 2:
The system enables self-service wear assessment where the simulation computer automatically determines tool wear state by comparing simulated workpiece geometry with nominal geometry. This eliminates the need for user experience-based wear specification while maintaining operational simplicity through automated self-assessment.
3Ease of operation
If tool correction is performed by machine tool controller, then ease of operation is improved, but manufacturing precision deteriorates due to inability to modify milling paths
Solution Approach 1:
The patent adds a simulation dimension to the traditional tool correction approach. By creating a virtual model that can simulate the effects of tool wear on workpiece geometry, the system enables comprehensive wear assessment that goes beyond simple tool correction, allowing modification of milling paths to compensate for wear effects that would otherwise cause geometry deviations.
Solution Approach 2:
The simulation computer acts as an intermediary between the machine tool controller and the actual machining process. It provides detailed wear state information and recommendations that enhance the basic tool correction capability, enabling more precise control over workpiece geometry by simulating and analyzing wear effects before actual machining.
Data Source
AI summary
The invention relates to a system for determining the wear state of a machine tool. It has a machine tool with a controller, a production control computer and the tool database via a respective data connection. A simulation computer, by way of a simulation process, while taking into account actual machine, production and tool data of the machine tool, is provided for determining data describing the wear state of the machine tool and for feeding said data to a display unit or a further process via a data connection.