Milling Tool Load Mapping for Abnormality Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing techniques for monitoring and managing the state of cutting tools lack the capability to provide detailed and accurate analysis of cutting conditions and tool abnormalities, limiting their effectiveness in optimizing cutting processes.
Innovation Solution
A system comprising a cutting tool equipped with multiple sensors that measure loads in two directions perpendicular to the rotation axis, generating two-dimensional measurement data, and a processing unit that performs determinations based on this data to analyze cutting conditions and detect abnormalities, allowing for precise monitoring and condition estimation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors are used to measure loads in two directions, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The cutting tool is divided into multiple sensor units, each measuring load in specific directions. Multiple sensors are strategically positioned to capture two-dimensional load data, breaking down the complex measurement task into manageable segments that collectively provide comprehensive measurement precision
Solution Approach 2:
The system transitions from one-dimensional load measurement to two-dimensional load measurement by adding sensors that measure loads in perpendicular directions. This dimensional expansion enables comprehensive analysis of cutting conditions while maintaining manageable device complexity through systematic sensor arrangement
2Manufacturing precision
If two-dimensional measurement data is generated and analyzed, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
Two-dimensional measurement data is generated and analyzed in real-time during the cutting process rather than after completion. The system continuously monitors load variations and performs preliminary analysis to detect abnormalities early, enabling immediate corrective actions that maintain manufacturing precision without significant time loss
Solution Approach 2:
The system implements continuous feedback loops where two-dimensional measurement data is constantly analyzed and used to adjust cutting parameters in real-time. This closed-loop control enables the system to maintain high manufacturing precision by responding dynamically to measured conditions, preventing defects before they occur rather than requiring rework later
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A processing system includes a cutting tool for milling, a plurality of sensors, and a processing unit. The plurality of sensors each is configured to measure a physical quantity that indicates a state related to loads on the cutting tool during cutting. The processing unit is configured to generate, based on measurement results from the respective sensors at a plurality of measurement time points, measurement data that is related to the loads in two directions on a plane perpendicular to a rotation axis of the cutting tool and that includes two-dimensional data at each of the measurement time points, and to perform a determination process concerning cutting in which the cutting tool is used, based on a two-dimensional shape indicated by the generated measurement data.