Milling Cutter Load Mapping for Blade Abnormality Detection
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Solution Overview
Problem
Existing cutting tool systems struggle to accurately detect abnormalities in cutting blades during the milling process due to interference from other blades' cutting forces and require a number of sensors equal to the number of blades, leading to increased costs and potential inaccuracies in abnormality detection.
Innovation Solution
A cutting system that uses a plurality of sensors to measure load states during the milling process, generating two-dimensional data and classifying it into unit regions equal to or greater than the number of cutting blades, allowing for the detection of abnormalities based on distinct changes within these regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a number of sensors equal to the number of cutting blades is used to detect blade abnormalities, then detection coverage is improved, but system cost and complexity increase
Solution Approach 1:
The patent segments the cutting tool's rotational cycle into multiple measurement timings corresponding to different blade positions. By dividing the measurement process into discrete time segments rather than using multiple physical sensors, the system achieves comprehensive monitoring of all blades using fewer sensors. The processing unit analyzes load variations at each segment to detect abnormalities in specific blades.
Solution Approach 2:
The patent transitions from a spatial arrangement of sensors (one per blade) to a temporal arrangement of measurements (multiple measurement timings). By adding the time dimension to the measurement process, the system captures load data from all blades sequentially, achieving the same detection capability with fewer physical components.
2Measurement precision
If multiple sensors are used to measure load states of each cutting blade individually, then detection accuracy is improved, but the system becomes more complex and expensive
Solution Approach 1:
The patent makes a single sensor system perform multiple measurement functions by capturing load data at different rotational timings. The same sensor setup measures load states for all cutting blades sequentially, making the measurement system universal rather than requiring dedicated sensors for each blade.
Solution Approach 2:
The patent creates temporal copies of measurement data at different rotation phases. Instead of having physical copies (sensors) for each blade, the system captures load information at multiple time points that represent different blade positions, then processes these temporal copies to identify blade-specific abnormalities.
3Device complexity
If sensors measure overall cutting load, then system simplicity is maintained, but the ability to detect specific blade abnormalities is reduced
Solution Approach 1:
The patent employs periodic measurements synchronized with the rotational period of the cutting tool. By taking load measurements at regular intervals corresponding to different blade positions during rotation, the system extracts blade-specific information from overall load data, maintaining simple hardware while achieving precise blade-level detection.
Data Source
AI summary
A cutting system includes a cutting tool for milling, a plurality of sensors, and a processor, wherein the cutting tool performs a cutting process using two or more cutting blades, the plurality of sensors measure a physical quantity indicating a state regarding a load of the cutting tool at a time of the cutting process, and the processor generates, based on measurement results of the sensors at a plurality of measurement timings, two-dimensional data for each measurement timing, the two-dimensional data regarding the load in two directions on a plane perpendicular to a rotation axis of the cutting tool, classifies pieces of the generated two-dimensional data into any of a plurality of unit regions, a number of which is equal to or greater than a number of the cutting blades on the plane, and detects, based on the two-dimensional data for each unit region, an abnormality of the cutting blade.