Milling Tool Load Mapping for Cutting Edge Abnormality Detection
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Solution Overview
Problem
Existing techniques for detecting abnormalities in cutting tools are impractical and may not accurately detect issues due to the need for pre-generated two-dimensional data for all cutting tools, and are influenced by positional deviations, leading to potential inaccuracies in detecting cutting edge abnormalities.
Innovation Solution
A system that includes a cutting tool with sensors measuring loads in two directions perpendicular to its rotation axis, generating two-dimensional measurement data, and performing determinations based on both actual and calculated two-dimensional shapes to detect abnormalities and cutting conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-generated two-dimensional data is stored for all cutting tools, then detection coverage is improved, but device complexity and storage requirements increase significantly
Solution Approach 1:
The patent creates a simplified two-dimensional projection copy of the three-dimensional cutting tool geometry. Instead of storing comprehensive 3D models or pre-generated 2D data for all possible cutting tools, the system generates a 2D projection representation that captures the essential geometric features needed for abnormality detection, significantly reducing storage requirements while maintaining detection effectiveness
Solution Approach 2:
The patent replaces the mechanical approach of storing pre-generated 2D data for all cutting tools with a computational method. The system uses sensor measurements during cutting operations to dynamically generate and compare 2D projection data against expected patterns, eliminating the need for extensive pre-stored reference data while improving adaptability to different cutting tool configurations
2Measurement precision
If two-dimensional data is generated from sensor measurements, then detection precision is improved, but positional deviations cause measurement inaccuracies
Solution Approach 1:
The patent acknowledges and utilizes the asymmetric impact of positional deviations on sensor measurements. By analyzing the specific patterns of measurement variations caused by positional offsets and comparing them against expected asymmetric geometric features of cutting tools, the system can distinguish between normal positional variations and actual abnormalities in cutting edges
Solution Approach 2:
The patent introduces an intermediate processing step that accounts for positional deviations before final abnormality determination. The system uses the known geometry of the cutting tool and sensor positions to calculate and compensate for positional effects on the 2D projection data, serving as a mediator between raw sensor measurements and final detection results
Data Source
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.