Motor Current Feedback for Tool Breakage Detection in Metal Processing
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Solution Overview
Problem
Tools often break during processing, leading to loss of contact with the workpiece over a large area, making it difficult to process the workpiece and resulting in defective products.
Innovation Solution
A processing system that includes a tool, a motor, a measurement unit, and a control unit that changes the rotational speed of the motor based on the difference between electrical quantities measured before and during processing, allowing for detection of tool breakage and prevention of defective product production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a tool is used to process a workpiece, then the workpiece can be manufactured, but the tool may break during processing causing defective products
Solution Approach 1:
The system performs preliminary action by measuring the electrical quantity of the motor before processing begins (first electrical quantity), establishing a baseline for comparison. This allows the system to detect tool breakage during processing by comparing the current electrical quantity against the pre-established baseline, enabling timely intervention before defective products are produced.
Solution Approach 2:
The system implements feedback by continuously monitoring the electrical quantity of the motor during processing (second electrical quantity) and comparing it with the first electrical quantity obtained before processing. The control unit uses this feedback information to detect tool breakage and adjust the processing parameters or stop the operation, preventing production of defective products.
2Manufacturing precision
If the tool loses contact with the workpiece due to breakage, then processing cannot continue, but additional detection checks increase system complexity
Solution Approach 1:
The system applies self-service by using the motor's own electrical quantity as the detection parameter. The motor inherently provides this information during operation, and the measurement unit simply monitors this existing electrical signal. This eliminates the need for separate, complex tool presence detection systems, as the motor's electrical characteristics naturally reveal whether the tool is properly engaged with the workpiece.
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
The system effectively detects tool breakage and prevents the production of defective products by adjusting the motor speed, thereby improving productivity and reducing the need for additional breakage detection checks.
Implementation Method 1
a measurement unit that obtains an electrical quantity of the motor
Implementation Method 2
the control unit changes a rotational speed of the motor based on a difference between a first electrical quantity and a second electrical quantity
Data Source
AI summary
A processing system comprises a tool that processes a workpiece composed of a metal member, a motor that rotates the workpiece or the tool, a control unit that controls the motor, and a measurement unit that obtains an electrical quantity of the motor, wherein the control unit changes a rotational speed of the motor based on a difference between a first electrical quantity and a second electrical quantity, the first electrical quantity is an electrical quantity obtained by the measurement unit while the motor rotates before the workpiece is processed, and the second electrical quantity is an electrical quantity obtained by the measurement unit while the workpiece is processed.