Machining Defect Detection Using Torque Curve Anomalies
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Solution Overview
Problem
Existing manufacturing processes face challenges in reliably detecting defective products, particularly inherent material defects like foreign bodies, voids, and hairline cracks, due to limitations in sensor-based measurement methods which are either destructive or non-destructive testing methods that are not extensively applicable in industrial production.
Innovation Solution
A method utilizing edge computing to record and analyze high-frequency machine data, such as torque curves from processing tools, without additional sensors, by comparing current consumption and torque data against reference values to identify anomalies, allowing for continuous and reliable detection of defective workpieces during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If sensor-based measurement methods are used to detect defects, then detection capability is improved, but reliability deteriorates because sensors do not always produce reliable results and cannot be applied during the manufacturing process itself
Solution Approach 1:
The patent replaces sensor-based measurement systems with a method that uses existing machine control data and torque curve analysis. Instead of relying on external sensors that may fail or be inapplicable, the invention utilizes electrical parameters (current consumption) already present in the machining process to detect material defects through torque variations, thereby improving reliability while maintaining detection capability
Solution Approach 2:
The machining process itself generates the detection data through its own electrical consumption patterns. The method uses the machine's own current consumption records during machining to create torque curves that reveal material defects, eliminating the need for separate sensing systems and ensuring continuous monitoring throughout the manufacturing process
2Measurement precision
If destructive testing methods are used to detect inherent material defects, then detection accuracy is improved, but productivity deteriorates because only individual products can be tested
Solution Approach 1:
The patent enables continuous defect detection throughout the entire machining process by monitoring current consumption in real-time. Unlike destructive testing that stops production for individual件 inspection, this method continuously analyzes torque curves generated during normal machining, maintaining full production throughput while providing ongoing quality assurance for every workpiece
Solution Approach 2:
The invention introduces torque curve analysis as an intermediary method between destructive testing and non-invasive sensing. By analyzing variations in torque (derived from current consumption) during machining, the system detects material defects without destroying the workpiece or interrupting production, achieving both high detection accuracy and maintained productivity
3Reliability
If non-destructive testing methods such as acoustic resonance analysis or radiographic testing are used, then product integrity is preserved, but applicability deteriorates because these methods can only be used to a limited extent in an industrial production facility
Solution Approach 1:
The patent creates a universally applicable defect detection method that works across different machining operations (milling, turning, drilling) by analyzing torque curves from standard machine control data. Unlike specialized non-destructive testing methods limited to specific applications, this approach uses the ubiquitous current consumption data already generated by all CNC machines, making it highly versatile for industrial production facilities
Solution Approach 2:
The invention replaces complex non-destructive testing equipment (acoustic sensors, X-ray systems) with analysis of electrical parameters already present in the machining process. By substituting mechanical/physical sensing systems with electrical parameter analysis, the method achieves broad industrial applicability while preserving product integrity
4Measurement precision
If additional sensors are installed in the tool or on the component for measurement, then measurement capability is improved, but device complexity deteriorates
Solution Approach 1:
The machining system serves its own measurement needs by using its own operational data (current consumption) to detect defects. No external sensors or additional measurement devices are required - the machine's own electrical parameters provide the detection information, thereby maintaining simple system architecture while achieving measurement capability
Solution Approach 2:
The machine control system performs dual functions: both controlling the machining process and providing detection data through current consumption records. This multi-functionality eliminates the need for separate sensing systems, reducing overall device complexity while maintaining comprehensive measurement capability
Data Source
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Figure 3a~3b
AI summary
The invention relates to a method for detecting defects during a manufacturing process in production facilities, wherein the production facilities comprise tools for machining workpieces, wherein operating parameters of the tools are continuously recorded during the machining of workpieces and conclusions about defects are drawn from deviations of the operating parameters when machining different workpieces.