Machining System Force Feedback Control for Tool Wear Compensation
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Solution Overview
Problem
Conventional machining systems fail to maintain high machining quality when the machining tool deteriorates due to the material of the workpiece or machining time, as they do not adjust the rotational speed of the machining tool and the movement speed of the workpiece accordingly.
Innovation Solution
A machining system that includes a robot, a processing machine with a spindle, and a force sensor to detect the force between the workpiece and the machining tool, with a control unit that adjusts the feed speed of the workpiece and the rotational speed of the machining tool to keep the detected force within predetermined thresholds, ensuring optimal machining conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the rotational speed of the machining tool and feed speed of the workpiece are not adjusted according to tool deterioration, then the machining system operates with simple control, but the machining quality deteriorates when the tool wears
Solution Approach 1:
The control unit receives feedback from the force sensor that detects the force between the workpiece and machining tool. Based on this feedback, the control unit automatically adjusts the rotational speed of the machining tool and feed speed of the workpiece to maintain optimal machining conditions even when the tool deteriorates, thereby maintaining machining quality without manual intervention
Solution Approach 2:
The system dynamically changes the operational parameters (rotational speed and feed speed) based on the detected force values. When tool deterioration occurs, the force sensor detects changes in cutting force, and the control unit adjusts the parameters accordingly to compensate for tool wear and maintain consistent machining quality
2Manufacturing precision
If the force sensor is used to detect force between workpiece and machining tool, then the machining quality can be maintained, but the system complexity increases
Solution Approach 1:
The force sensor provides real-time feedback on the cutting force between the workpiece and machining tool. The control unit uses this feedback to automatically adjust operational parameters, creating a closed-loop control system that maintains machining quality while compensating for tool deterioration
Solution Approach 2:
The machining system performs self-adjustment through automatic parameter modification based on force sensor data. The control unit autonomously modifies rotational speed and feed speed without requiring external intervention, allowing the system to self-correct for tool wear and maintain consistent performance
Data Source
AI summary
A machining system of the present invention includes a robot having a hand, a processing machine to rotate a machining tool, a control unit which controls the processing machine and the robot so as to rotate the machining tool and press a workpiece held by the hand against the machining tool to thereby machine the workpiece, and a force sensor which detects force acting between the workpiece and the machining tool when the workpiece is pressed against the machining tool by the robot and is machined by the machining tool. The control unit regulates the workpiece feed speed of the robot and the rotational speed of the machining tool so that the force value detected by the force sensor is between a predetermined upper threshold and a predetermined lower threshold.