Motor Current Monitoring for Thread Forming Fault Detection
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Solution Overview
Problem
Existing methods for monitoring and ensuring reliable thread formation in machining processes are complex, costly, and often fail to detect manufacturing errors or tool faults in a timely manner, leading to defective parts and high reworking costs.
Innovation Solution
A method using torque monitoring based on current consumption of electric motors, where a software-implemented solution records and analyzes torque data to establish permissible limits, triggering a stop if deviations exceed predefined thresholds, and integrating this with existing control components to detect and prevent faults.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex monitoring systems are installed to detect manufacturing errors and tool faults, then detection capability is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent extracts the monitoring function from complex mechanical monitoring systems and implements it through software-based torque analysis. By taking out the essential monitoring capability and implementing it through current consumption analysis of the electric motor, the system achieves reliable fault detection without the complexity of additional mechanical sensors and monitoring hardware.
Solution Approach 2:
The patent replaces mechanical monitoring systems with an electrical/software-based solution. Instead of using mechanical sensors and complex monitoring hardware to detect tool faults and manufacturing errors, the system uses electric motor current consumption data to infer torque variations and detect abnormalities through software analysis.
2Reliability
If existing complex monitoring systems are used, then fault detection is possible, but adjustment and programming effort and cost increase
Solution Approach 1:
The monitoring system uses the electric motor's own current consumption data as the monitoring signal. By analyzing the motor's inherent electrical parameters during operation, the system achieves fault detection without requiring external sensors or complex programming, making the system easy to implement and adjust.
Solution Approach 2:
The patent makes the electric motor serve multiple functions: it provides both the driving torque for the thread-forming tool and simultaneously serves as the monitoring sensor through its current consumption characteristics. This multi-functionality eliminates the need for separate monitoring hardware and reduces programming complexity.
3Reliability
If traditional monitoring approaches are used, then some faults may be detected, but detection timing is delayed leading to defective parts and reworking costs
Solution Approach 1:
The system continuously monitors electric motor current consumption throughout the entire machining process. This continuous electrical measurement provides real-time torque information, enabling immediate detection of abnormalities such as tool breakage or manufacturing errors without the detection delays associated with periodic mechanical monitoring.
Solution Approach 2:
The system establishes a feedback loop where electric motor current consumption is continuously measured and analyzed to detect torque variations. This real-time feedback mechanism enables immediate identification of faults and timely intervention, preventing the production of defective parts and reducing reworking costs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances process reliability and cost-effectiveness by accurately detecting torque deviations, preventing tool damage, and ensuring consistent thread formation, thereby reducing reworking costs and improving part quality.
Implementation Method 1
a rotatingly drivable machining unit (20) which can be driven by an electric motor (10), in particular a servo motor
Implementation Method 2
a controller (100) with a detection module (30) which detects the current consumption (Iactual) (actual values) of the electric motor (10), which corresponds to torque generation
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a method for process monitoring of a rotating machining unit (20) driven by an electric motor (10) comprising the following steps: detecting the current consumption (IIst) corresponding to torque generation (actual values) of the electric motor (10) by means of at least one detection module (30); comparing the detected actual value (IIst) with stored target values (Imin, Imax) of a target value range (Isoll); determining whether the actual value (IIst) of the current consumption is a permissible value from the target value range (Isoll); and outputting a signal (S) when a deviation of the actual value (IIst) is detected in order to thereby detect a torque deviation of the rotating machining tool (20).