Machining Control Logic for Detecting Missed Tool Operations
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Solution Overview
Problem
Industrial machining processes face challenges in detecting machining omissions during operations, leading to potential errors and increased man-hours due to operator errors or process complexity, with existing methods requiring time-consuming video image checks.
Innovation Solution
A control device and system equipped with a program executing unit and counting unit that execute machining instructions and count completion states to detect machining abnormalities, allowing for real-time detection of omissions by comparing start and end instructions within the machining program.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If post-machining inspection methods are used to detect machining omissions, then machining omissions can be detected, but man-hours increase due to the need to discard or remachine defective workpieces
Solution Approach 1:
The system performs preliminary detection of machining omissions during the machining process itself by monitoring completion states of machining instructions, rather than waiting for post-machining inspection. The counting unit continuously tracks whether each machining instruction between start and end positions has been properly executed, enabling early detection before the workpiece leaves the machining line.
2Reliability
If video image checking methods are used to check during machining, then machining omissions can be detected, but man-hours increase due to the need for manual checking
Solution Approach 1:
The machining system performs self-detection of machining omissions through automated monitoring of instruction completion states. The control device automatically counts and verifies whether each machining instruction has been properly executed between start and end positions, eliminating the need for manual video image checking by operators.
Solution Approach 2:
The system replaces manual video image checking with an automated electronic counting mechanism. Instead of operators visually inspecting video images to detect machining omissions, the counting unit electronically tracks and counts the completion states of machining instructions, substituting mechanical human labor with an automated computational system.
3Productivity
If operator intervention is used to handle machining abnormalities, then production line can be restarted, but machining omissions occur due to operator errors or complexity of the machining process
Solution Approach 1:
The system provides automated feedback to operators regarding the accuracy of restart positions. The counting unit monitors whether the number of completed machining instructions matches the expected count, and when a mismatch is detected, the system notifies the operator of the potential machining omission, enabling corrective action before the workpiece is finalized.
Data Source
AI summary
Provided is a control device that is for controlling an industrial machine and that can detect missed machining in a simple manner. This control device for controlling an industrial machine using a machining tool comprises: a program execution unit for causing the industrial machine to execute a program that includes a start command for starting a machining process and an end command for ending the machining process by the machining tool; and a counting unit for counting, during execution of the program, the number of times of a completion state indicating that machining abnormality has not occurred in the machining process including the start command and the end command and that each of the commands has been executed and completed.