Machining Error Diagnosis Using Historical Error Transition Patterns
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Solution Overview
Problem
Existing diagnostic devices for machining errors require collection of machine data during machining, leading to increased costs and complexity, and are difficult for less experienced operators to use effectively.
Innovation Solution
A diagnostic device that records and selects error transition information to identify the causes of machining errors without the need for real-time machine data collection, allowing even less experienced operators to diagnose errors reliably.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If machine data is collected during machining to diagnose causes of machining errors, then diagnostic accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent pre-collects error transition information from historical machining data and organizes it into a database before actual diagnostic use. This preliminary preparation allows the diagnostic device to function with simpler real-time components while maintaining high diagnostic accuracy through pre-processed reference data.
Solution Approach 2:
The patent creates a simplified model by copying essential error transition patterns from complex historical machine data. Instead of collecting and processing all raw machine data in real-time, the system uses pre-extracted error transition information that replicates the diagnostic value of full data collection with much lower complexity.
2Reliability
If comprehensive machine data is collected for error diagnosis, then diagnostic reliability is improved, but ease of operation deteriorates
Solution Approach 1:
The diagnostic device automatically performs the complex task of selecting appropriate error transition information based on the specific machining error being diagnosed. The system self-services by autonomously querying the database and presenting relevant diagnostic data, eliminating the need for operators to manually search through comprehensive machine data.
Solution Approach 2:
The patent introduces an intermediary layer between the operator and the complex machine data. The error transition information database acts as a mediator that translates raw machine data into meaningful diagnostic patterns, making the diagnostic process accessible to operators regardless of their experience level.
3Measurement precision
If real-time machine data collection is implemented for error diagnosis, then measurement precision is improved, but loss of time increases
Solution Approach 1:
Error transition information is pre-calculated and stored in the database during idle periods or alongside normal machining operations. When a diagnostic query is made, the system immediately retrieves pre-processed information rather than collecting and analyzing raw data in real-time, dramatically reducing diagnostic time while maintaining measurement precision.
Data Source
AI summary
A diagnostic device includes an error transition recording unit, an error transition input unit, an error cause recording unit, a cause diagnosis unit, and a display portion. A plurality of types of error transition information with different temporal transitions of the machining error caused by repeating the machining are recorded in the error transition recording unit. The error transition input unit selects one or a plurality of pieces of error transition information from the plurality of types of error transition information. A plurality of types of the causes are each recorded in association with the error transition information in the error cause recording unit. The cause diagnosis unit refers to the error cause recording unit and identifies the causes based on the error transition information selected by the error transition input unit. The display portion displays the causes identified by the cause diagnosis unit.