Numerical Control Device Screw Hole Inspection Torque Monitoring
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Solution Overview
Problem
Conventional automatic screw hole inspection methods are costly, lack defect prevention, and require dedicated hardware or complex mechanisms, with existing techniques failing to accurately assess thread abrasion and phase matching, leading to increased labor and potential fastening errors.
Innovation Solution
A numerical control device that integrates a screw-hole inspection gauge with the machining tool, allowing for in-device inspection using torque monitoring and soft floating techniques, enabling direct post-machining inspection without dedicated hardware and utilizing existing machining programs for inspection control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional automatic inspection devices using screw limit gauges are used, then automatic inspection capability is achieved, but device cost increases significantly
Solution Approach 1:
The patent applies universality by enabling the machining center itself to perform inspection functions. The control unit executes inspection programs that utilize the machining center's existing motors and measurement capabilities, allowing the same equipment to serve both machining and inspection purposes, thereby eliminating the need for separate dedicated inspection devices and reducing overall system cost.
Solution Approach 2:
The inspection system performs self-service by using the machining center's own components for inspection. The control unit monitors the machining process in real-time, automatically determining whether the machined feature meets specifications without requiring external inspection equipment, thus making the system self-sufficient for both manufacturing and quality verification.
2Extent of automation
If torque monitoring alone is used for inspection, then automatic inspection is achieved, but defect prevention capability is insufficient
Solution Approach 1:
The patent implements feedback by continuously monitoring machining parameters during the process and using this information to determine compliance with specifications. The control unit receives real-time data from the machining operations, compares it against predetermined criteria, and automatically determines whether the feature meets specifications, enabling both inspection and early defect detection.
Solution Approach 2:
The system performs preliminary action by monitoring machining parameters in real-time during the machining process itself, rather than waiting for post-machining inspection. This allows the system to detect potential defects as they occur and prevent defective parts from being completed, thereby improving defect prevention capability.
3Device complexity
If phase matching is not considered during gauge insertion, then inspection process is simplified, but fastening errors occur
Solution Approach 1:
The patent replaces the mechanical gauge insertion process with a computational approach. Instead of physically inserting a gauge and manually checking phase matching, the control unit calculates the theoretical phase relationship based on machining parameters and compares it with actual measurements, automatically determining compliance without requiring complex mechanical phase-matching mechanisms.
4Extent of automation
If separate inspection programs are prepared, then inspection control is achieved, but labor requirements increase
Solution Approach 1:
The patent merges the machining program and inspection program into a single integrated process. The control unit executes the machining operations and automatically transitions to inspection mode using the same program structure, eliminating the need for separate program preparation and reducing labor requirements while maintaining automated inspection control.
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
Enables cost-effective, immediate defect prevention and reduction in labor by performing automatic screw hole inspections using existing machining tools, reducing the risk of thread collapse and fastening errors, and allowing for the use of cheaper inspection methods.
Implementation Method 1
a determining unit that determines acceptance/defect of inspection of a screw hole machined on the workpiece based on a condition of the feed-axis motor or a condition of the main-axis motor during control by the control unit
Data Source
AI summary
A numerical control device of the present invention includes a control unit that controls a machining tool including a main axis having a screw-hole inspection gauge attached thereto in such a way that a feed-axis motor and a main-axis motor for the main axis perform operations for screw-hole inspection based on a machining program and a determining unit that determines acceptance/defect of inspection of a screw hole machined on a workpiece based on a condition of the feed-axis motor or the main-axis motor during control by the control unit.