Automatic Monitoring Interval Setting for Machine Tool Torque
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Solution Overview
Problem
Manual setting of monitoring intervals for torque changes in turning machines is prone to errors, such as overlapping or incomplete settings, leading to erroneous determination of tool blade chipping during workpiece processing.
Innovation Solution
An automatic monitoring interval-setting device that includes a control device with a memory section and a calculating section to automatically insert monitoring starting and ending commands into a program, allowing for precise setting of monitoring intervals during specific processing operations, thereby reducing human error.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual setting of monitoring interval is performed, then flexibility in setting is improved, but error rate increases
Solution Approach 1:
The system automatically identifies cutting operations from the NC program and sets monitoring intervals without operator intervention. The control device parses the NC program, detects cutting commands, and autonomously configures the monitoring parameters, eliminating manual errors while maintaining adaptability to different operations
Solution Approach 2:
The system incorporates error detection and correction mechanisms that verify the correctness of automatically set monitoring intervals. By monitoring torque changes and comparing them against expected patterns during cutting operations, the system can identify and correct potential errors in the configured intervals
2Adaptability or versatility
If monitoring interval is manually set, then customization is improved, but overlapping settings occur
Solution Approach 1:
The control device automatically parses the NC program structure, identifies all cutting operations, and calculates appropriate monitoring intervals for each. The system inherently prevents overlapping by sequentially processing operations and setting non-conflicting time windows based on program logic
Solution Approach 2:
The monitoring system divides the workpiece processing into discrete segments corresponding to individual cutting operations. Each monitoring interval is precisely bound to specific NC program lines, ensuring that monitoring windows are separated and do not overlap between different operations
3Reliability
If monitoring is performed during all operations, then comprehensive monitoring is improved, but false alarms increase
Solution Approach 1:
The system extracts and isolates only the cutting operations from the complete NC program, setting monitoring intervals exclusively for these operations. By removing non-cutting operations from monitoring scope, the system maintains comprehensive coverage of relevant operations while eliminating false alarms from operations where torque variations are normal and not indicative of tool damage
Solution Approach 2:
The monitoring system applies different monitoring strategies to different operations based on their characteristics. Cutting operations receive active torque monitoring with specific thresholds, while non-cutting operations are excluded from monitoring or use different parameters, optimizing detection accuracy for each operation type
4Reliability
If automatic monitoring interval setting is implemented, then error reduction is improved, but device complexity increases
Solution Approach 1:
The control device leverages its existing NC program parsing and execution capabilities to perform automatic monitoring interval setting. By reusing existing software modules for program analysis, operation identification, and parameter calculation, the system achieves automatic monitoring configuration without adding significant hardware or software complexity
Solution Approach 2:
The monitoring interval setting function is merged with the NC program execution control. The same control device that manages tool operations also configures monitoring parameters, combining multiple functions into a single integrated system rather than adding separate dedicated hardware
Data Source
AI summary
An automatic monitoring interval-setting device, a machine tool, and an automatic monitoring interval-setting method by which a monitoring interval monitoring a load applied to a tool is able to be automatically set are provided. An automatic monitoring interval-setting device includes a control device including a memory section which stores a program including G1 to G3 for processing a workpiece by using a tool, and a calculating section which is able to edit the program and executes a monitoring interval setting step of respectively inserting starting monitoring of a load applied to the tool into the front of G1 to G3 and ending the monitoring of the load into the rear of G1 to G3 with respect to the program.