Machining Accuracy Diagnosis for Door-Opening Thermal Displacement
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Solution Overview
Problem
Existing methods to mitigate thermal displacement in machine tools due to temperature changes caused by opening and closing doors or shutters in a plant are either energy-intensive or require significant space, leading to potential degradation of machining accuracy and increased costs.
Innovation Solution
A machining accuracy diagnosing device and management system that predicts the influence of door or shutter opening on machining accuracy by quantitatively estimating temperature changes and thermal displacement, allowing for optimal scheduling of machining starts and shutter operations to minimize accuracy degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If constant temperature management is performed for 24 hours using an air conditioner, then machining accuracy is maintained, but energy consumption and cost burden increase
Solution Approach 1:
The system performs preliminary actions by predicting temperature changes and thermal displacement before machining operations. It calculates the influence amount of temperature changes on machining accuracy in advance, allowing scheduling of machining operations during periods when accuracy requirements are most critical, thereby reducing the need for continuous energy-intensive temperature control.
Solution Approach 2:
The system changes the parameter of temperature control strategy from continuous constant control to predictive intermittent control. By monitoring actual temperature changes and comparing them with predicted values, the system adjusts air conditioner operation to maintain accuracy only when necessary, significantly reducing energy consumption while preserving machining quality.
2Productivity
If door or shutter is opened to carry in and out materials and products, then productivity is improved, but temperature change occurs causing thermal displacement and degradation of machining accuracy
Solution Approach 1:
The system implements feedback by continuously monitoring actual temperature changes in the control room and comparing them with predicted temperature changes. This feedback mechanism allows the system to detect when door or shutter operations cause temperature variations that may affect machining accuracy, and to adjust control strategies accordingly, balancing productivity with precision.
Solution Approach 2:
The system performs preliminary prediction of temperature changes caused by door or shutter operations. By calculating the expected thermal displacement and its influence on machining accuracy before operations occur, the system can schedule material handling activities during periods when machining is not performed or when accuracy requirements are less stringent, thus maintaining both productivity and precision.
3Manufacturing precision
If double shutters with air curtain are installed to reduce temperature change, then machining accuracy is protected, but device complexity and space requirements increase
Solution Approach 1:
The system replaces the mechanical solution of double shutters with air curtain with a predictive control system. By using temperature prediction algorithms and thermal displacement calculations, the system achieves the same goal of protecting machining accuracy through software-based control rather than complex mechanical structures, significantly reducing device complexity and space requirements.
Solution Approach 2:
The system changes the approach from structural modification (adding double shutters) to operational parameter optimization (predictive temperature control). By adjusting air conditioner operation based on predicted temperature changes, the system achieves accuracy protection without increasing physical infrastructure complexity.
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
Enables accurate prediction of machining start times and optimal shutter operations, reducing the negative impact on machining accuracy while minimizing energy consumption and space requirements.
Implementation Method 1
a change in room temperature inside a plant causes a thermal displacement in the machine tool, resulting in degradation of a machining accuracy of a workpiece
Data Source
AI summary
A machining accuracy diagnosing device includes a diagnosing information acquiring, an opening time setting unit, a cutting time setting unit, and a machining accuracy influence amount predicting unit. The diagnosing information acquiring unit acquires at least one of a room temperature inside the plant, a set temperature of a temperature regulating device, an air temperature outside the plant, a wind speed outside the plant, an opening degree of the door or the shutter, and a machine body temperature. The opening time setting unit sets an opening time of the door or the shutter. The machining accuracy influence amount predicting unit predicts an influence amount of opening of the door or the shutter on the machining accuracy based on the acquired information for diagnosis, the set opening time of the door or the shutter, and a set scheduled machining start time and a set scheduled machining end time.