Machining Process Monitoring via Force-Distance Wear Analysis
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Solution Overview
Problem
Existing methods for monitoring machining processes in processing machines lack the ability to ensure uniform quality during machining, particularly for plate-shaped workpieces, as they fail to accurately assess tool wear and material properties in real-time, leading to inconsistencies in cut surface quality.
Innovation Solution
A method that registers time-synchronous process signals from sensors and converts them into force-distance profiles, allowing for the independent evaluation of tool wear and material properties by eliminating signal variances through additional travel component registration and elastic travel component analysis, enabling continuous monitoring and quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If time-synchronous process signals are registered and converted into force-distance profiles, then measurement precision of tool wear and material properties is improved, but device complexity increases due to additional sensors and signal processing requirements
Solution Approach 1:
The monitoring system is segmented into independent functional modules: sensor units for registering process signals, a control device for converting time-based signals to force-distance profiles, and evaluation units for determining tool wear and material properties. This modular segmentation allows each component to perform its specific function with optimized complexity, reducing overall system complexity while maintaining high measurement precision.
Solution Approach 2:
The patent introduces a control device as an intermediary that transforms raw time-synchronous process signals into meaningful force-distance profiles. This intermediary component acts as a mediator between the sensors and the evaluation system, processing complex multi-dimensional signal data into standardized profiles that are easier to analyze for tool wear and material characterization, thereby reducing the complexity burden on downstream evaluation systems.
2Manufacturing precision
If multiple process signals are registered and transformed into characteristic curves, then manufacturing precision of workpiece quality control is improved, but loss of time increases due to extensive signal processing and transformation operations
Solution Approach 1:
The system performs preliminary transformation of time-synchronous process signals into force-distance profiles during the machining process itself, rather than conducting extensive post-processing analysis. By converting signals to characteristic curves in real-time or near-real-time, the system prepares the data for tool wear and material evaluation in advance, reducing the time required for quality assessment while maintaining high manufacturing precision.
Solution Approach 2:
The patent transforms the parameter representation of process signals from the time domain to the force-distance domain. This parameter change converts complex time-varying signals into standardized force-distance profiles that are more directly related to tool wear and material properties. The transformation enables faster evaluation by working with parameters that have more direct physical meaning and require less computational processing for quality determination.
3Reliability
If elastic travel components are analyzed and signal variances are eliminated, then reliability of wear determination is improved, but device complexity increases due to additional travel component registration requirements
Solution Approach 1:
The patent extracts and separately analyzes elastic travel components from the overall process signals. By isolating the elastic deformation effects from the total measured travel, the system can eliminate signal variances caused by machine frame elasticity and other external factors. This extraction approach improves the reliability of tool wear determination by focusing only on the relevant cutting forces, while the separated elastic components can be compensated or discarded without affecting the core measurement.
Data Source
AI summary
A method for monitoring machining processes in a processing machine which machines workpieces using a machining tool that includes an upper tool and a lower tool. Time-synchronous process signals are registered during each machining process by sensors of the processing machine and transmitted to a control device. The process signals determined as a function of time during the machining processes are converted by a transformation into characteristic curves having a force-distance profile, and recorded independently of time in a force-distance diagram. Wear of the machining tool is determined separately from one another and/or the material of the workpiece, which underlies the at least one machining process, from the profile of the characteristic curves in the force-distance diagram.