Wear State Determination for Milling Chisels
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Solution Overview
Problem
Current methods for assessing the wear state of milling chisels and chisel holders in road surface milling and mineral deposit removal are inefficient, relying on visual inspection which is time-consuming, subjective, and disrupts production, failing to optimize the utilization of remaining wear potential.
Innovation Solution
A method that determines the position of key points on the milling tool using measurement methods and compares these position values to reference values stored in a memory device, allowing for quantitative wear evaluation and decision-making on tool replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection by machine driver is used to assess wear state, then no additional equipment is needed, but production must be interrupted and assessment is time-consuming and subjective
Solution Approach 1:
The patent replaces the mechanical/visual inspection system with an optical measurement system. A camera captures images of the milling roller surface, and image processing algorithms automatically analyze wear patterns, replacing the need for manual visual inspection by the machine driver.
Solution Approach 2:
The patent creates a digital copy (image) of the milling roller surface using a camera. This image copy is then processed to extract wear information, allowing assessment without physically touching or interrupting the operational tool.
Solution Approach 3:
The system enables automatic self-assessment of wear state through image capture and processing. The evaluation is performed autonomously by the control unit analyzing the captured images, eliminating the need for operator intervention and subjective judgment.
2Loss of information
If visual inspection is performed by shutting down the machine, then wear state can be assessed, but production efficiency decreases due to interruptions
Solution Approach 1:
The patent enables continuous wear monitoring during machine operation. The camera captures images of the rotating milling roller, and the control unit processes these images in real-time, allowing wear assessment without interrupting the milling process or losing production time.
Solution Approach 2:
The patent introduces an intermediary image capture system between the milling roller and the assessment process. The camera acts as a mediator that can capture wear information from the rotating roller without requiring the machine to stop, bridging the gap between continuous operation and inspection needs.
3Reliability
If early replacement of chisels and holders is performed, then tool reliability is maintained, but costs increase due to premature replacement of expensive wearing parts
Solution Approach 1:
The patent implements a feedback system that continuously monitors wear state and provides quantitative information to the control unit. This feedback enables data-driven replacement decisions based on actual wear progression rather than predetermined schedules, optimizing the balance between reliability and cost.
Solution Approach 2:
The patent transforms the wear assessment from a subjective visual parameter to an objective quantitative parameter through image analysis. By measuring specific features in the captured images, the system provides precise wear metrics that enable optimized replacement timing, preventing both premature and delayed replacement.
4Productivity
If quantitative wear evaluation is implemented, then optimal replacement timing is achieved, but measurement and evaluation complexity increases
Solution Approach 1:
The patent segments the wear assessment task into distinct processing steps: image capture, image preprocessing, feature extraction, and wear calculation. This segmentation allows each step to be handled by specialized algorithms, managing complexity while achieving quantitative evaluation.
Solution Approach 2:
The patent creates a universal image processing framework that can assess wear of different tool components (chisels, holders, milling roller surface) using the same basic methodology. The control unit and image processing algorithms serve multiple functions, reducing overall system complexity despite the comprehensive assessment capability.
Data Source
AI summary
This invention relates to a method for determining a wear state of a chisel, a chisel holder, and/or a chisel holder replacement system equipped with a chisel and chisel holder. For this method to give the user qualitative and quantitative information about the wear, according to one embodiment of this invention, a position of at least one point of the chisel and/or the chisel holder is determined by a contactless measurement method and a corresponding measurement result is compared in a switching unit to a reference value stored in a memory device.