Machine Tool Automation via Wireless Actuators and Sensors
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Solution Overview
Problem
Existing machine tool automation systems require proprietary interfaces and additional hardware, limiting integration of third-party automation components and increasing retrofit costs, especially for machine tools without suitable interfaces or rotary feed-throughs.
Innovation Solution
A system that uses external devices with suitable actuators and sensors to automate machine tool operations wirelessly, eliminating the need for additional interfaces or hardware, and allowing for the integration of machine tools without existing automation solutions, by controlling machine tool functions via a control unit that communicates with a higher-level control unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If proprietary interfaces and additional hardware are used for automation, then automation capability is improved, but device complexity and cost increase
Solution Approach 1:
The machine tool uses its own existing control unit and human-machine interface to automate operations, eliminating the need for separate automation interfaces. The control unit directly controls actuators and processes sensor signals without requiring external automation hardware or proprietary interfaces.
Solution Approach 2:
The existing control unit and HMI are made multi-functional by enabling them to perform both traditional control functions and automation functions. The HMI serves both as an operator interface and as an interface for automation components, eliminating the need for dedicated automation interfaces.
2Extent of automation
If proprietary interfaces are used, then machine tool control is improved, but adaptability to third-party components deteriorates
Solution Approach 1:
The control unit and HMI are designed to serve multiple functions including control of third-party automation components. Standard communication protocols and the existing HMI enable universal integration without proprietary interfaces, allowing both machine tool control and third-party component compatibility.
Solution Approach 2:
The existing control unit acts as an intermediary between the machine tool and third-party automation components. It provides a universal communication interface that mediates between different protocols and systems, enabling integration without requiring proprietary interfaces.
3Extent of automation
If rotary feed-throughs and additional hardware are installed, then automation functionality is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The automation functionality is extracted from dedicated hardware components and integrated into the existing control unit and HMI. This eliminates the need for rotary feed-throughs and additional automation hardware, reducing manufacturing costs and simplifying retrofitting.
Solution Approach 2:
The machine tool uses its own existing control unit and HMI to provide automation functionality, eliminating the need for external automation hardware. The control unit directly controls actuators and processes sensor signals without requiring additional feed-throughs or specialized components.
4Extent of automation
If complex interfaces are required, then control precision is improved, but ease of operation deteriorates
Solution Approach 1:
The HMI serves multiple functions including operator interface and automation component interface. It provides precise control capabilities while maintaining ease of operation through its existing user-friendly design, eliminating the need for complex proprietary interfaces.
Solution Approach 2:
The control unit acts as an intermediary that translates between the simple HMI interface and the precise control requirements of automation components. It maintains control precision while preserving the ease of operation of the existing HMI.
Data Source
AI summary
A system for automating a machine tool, that is associated with an external device for feeding workpieces and/or tools to and/or removing workpieces and/or tools from the machine tool. The system includes at least one actuator for actuating a component of the machine tool. Alternatively or additionally to the at least one actuator, the system includes at least one sensor for detecting at least one signal of a display component or of a state of the machine tool or of the external device. A control unit is also included which is configured to trigger at least one function of the machine tool or of the external device by actuating the at least one actuator and/or to trigger at least one function of the external device as a function of a signal from the at least one sensor.