Machining Shape Model Comparison for Abnormal Surface Diagnosis
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Solution Overview
Problem
Existing machining shape model comparison technologies do not effectively allow users to identify and quantify the factors causing abnormalities in machined surfaces, especially when multiple processes are involved, as they lack the ability to easily assess and display differences between multiple machining shape models.
Innovation Solution
A machining-shape-model comparison device that stores and selects multiple machining shape models generated from different machining processes, calculates differences between their surfaces, and provides a quantitative evaluation of these differences to determine which process caused the abnormality, using a difference calculation unit and a difference-evaluation-value calculation unit to display and assess the results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple machining shape models are stored and compared to identify abnormality causes, then the ability to diagnose machining issues is improved, but the device complexity increases
Solution Approach 1:
The comparison process is segmented into distinct functional units: a storage unit for maintaining multiple machining shape models, a selection unit for choosing specific models to compare, and a difference calculation unit for computing variations. This segmentation allows the complex task of multi-model comparison to be broken down into manageable, modular operations that can be implemented systematically.
Solution Approach 2:
The patent introduces an intermediary processing layer that automatically calculates difference values between machining shape models and compares them against reference data. This intermediary unit acts as a mediator between the raw machining data and the final diagnosis, reducing the complexity burden on the user while maintaining high measurement precision for abnormality identification.
2Measurement precision
If quantitative difference values are calculated between machining surfaces, then the assessment capability is improved, but the computational complexity increases
Solution Approach 1:
The patent replaces complex manual measurement and comparison methods with automated computational algorithms. The difference calculation unit employs mathematical operations to compute quantitative difference values between machining surfaces, substituting what would otherwise require complex manual measurement systems with efficient computational processes.
Solution Approach 2:
The system transforms the comparison task from a qualitative visual assessment to a quantitative parameter-based analysis. By calculating specific difference values (parameters) between machining surfaces and comparing them against reference thresholds, the system achieves precise measurement accuracy while maintaining manageable computational complexity through standardized parameter calculations.
3Loss of information
If multiple sets of difference values are determined from serial processes, then the ability to identify specific problematic processes is improved, but the data processing complexity increases
Solution Approach 1:
The patent segments the machining process data into distinct serial process stages, with each process having its own machining shape model and difference value set. This segmentation allows information from each process stage to be preserved and analyzed independently, preventing information loss while keeping the processing of each segment manageable rather than overwhelming.
Solution Approach 2:
The system adds a temporal/process-stage dimension to the data structure, organizing difference values not just by spatial coordinates but also by their association with specific serial processes. This dimensional organization allows comprehensive process information retention while enabling systematic processing through the added structure.
Data Source
AI summary
The present invention enables the simple determination of the cause of an abnormality of a machined surface of a machined workpiece regardless of the proficiency of a user.The present invention comprises: a machining shape model storage unit that stores at least a first, second, and third machining shape model which are generated on the basis of three machining position data items of at least three steps in series of machining an object with a machine tool; a machining shape model selection unit that selects the first and second machining shape models, and the second and third machining shape models; a machining shape model acquisition unit that acquires the first and second machining shape models and also acquires the second and third machining shape models; and a difference calculation unit that finds a set of the distances between the machined surface of the first machining shape model and the machined surface of the second machining shape model as a first difference set, and finds a set of the distances between the machined surface of the second machining shape model and the machining surface of the third machining shape model as a second difference set.