Magnetic Multi-Groove Gauge Block for Machine Tool Gap Sensor Calibration
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Solution Overview
Problem
The calibration of gap sensors in machine tools often requires multiple workers due to the need for manual holding of gauge blocks, increasing costs and time, and involves creating multiple gauge blocks for different tolerance specifications, which is inefficient.
Innovation Solution
A magnetized gauge block with multiple gauge grooves of varying depths is used, allowing a single worker to perform calibration by attaching the block to the machine tool using magnetic attraction, enabling the same block to provide multiple calibration settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple gauge blocks are used for different tolerance specifications, then calibration accuracy is improved, but device complexity and inventory requirements increase
Solution Approach 1:
The gauge block is designed with multiple grooves of different depths on its surface, allowing a single gauge block to provide multiple calibration settings for different tolerance specifications. Each groove depth corresponds to a specific calibration value, enabling one gauge block to replace multiple separate gauge blocks while maintaining calibration accuracy across different measurement requirements
2Measurement precision
If manual holding of gauge blocks is required during calibration, then measurement precision is maintained, but productivity decreases and labor costs increase
Solution Approach 1:
The patent replaces the manual mechanical holding of gauge blocks with a magnetic field-based attachment system. The gauge block contains embedded magnets that magnetically attract to the machine tool surface, automatically securing the gauge block in position during calibration. This eliminates the need for operators to manually hold and stabilize the gauge block, allowing faster calibration while maintaining measurement precision through consistent positioning
3Measurement precision
If multiple workers are involved in calibration, then measurement precision is ensured through verification, but loss of time increases
Solution Approach 1:
The magnetic attachment system provides self-positioning and self-holding functionality, where the gauge block automatically secures itself to the machine tool surface through magnetic attraction. This self-service mechanism ensures consistent positioning and stable contact during calibration, allowing a single worker to perform the calibration task with the same reliability that previously required multiple workers for verification and stabilization, thereby reducing calibration time while maintaining precision
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution allows for a single worker to perform calibration efficiently and cost-effectively, reducing manpower and time required for the process while enabling the use of a single gauge block for various calibration settings.
Implementation Method 1
attaching the magnetized calibration device to a rest pad of the machine tool using a magnetic attraction of the magnetized calibration device to the rest pad
Implementation Method 2
applying air to the rest pad and the one of the first groove and second groove
Data Source
AI summary
An apparatus for calibrating an air gap sensor of a machine tool can include a gauge block and a plurality of magnets. The gauge block can have a plurality of gauge grooves. Each of the gauge grooves can have a unique gauge depth that corresponds to a respective one of a plurality of predetermined calibration values for the air gap sensor. Each of the magnets can be embedded in the gauge block. A method of using the apparatus for calibrating an air gap sensor can include attaching the apparatus to a machine tool using only magnetic force to keep the apparatus in place.