Numerical Control Device Swarf Estimation and Correction
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Solution Overview
Problem
Existing numerical control devices for machine tools face challenges in efficiently removing swarf, particularly in limited installation areas, as they require large chip conveyors or robots, and manual checks are inefficient, leading to potential tool damage and accuracy degradation due to swarf overflow.
Innovation Solution
A numerical control device that estimates swarf accumulation based on machining conditions and motor current values, with a correction unit accounting for swarf shape, to assist operators in timely removal without additional hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a chip conveyor or robot is used for swarf removal, then swarf can be automatically removed, but the device size becomes large requiring more installation area
Solution Approach 1:
The invention extracts the swarf removal function from traditional large-scale chip conveyors and robots, implementing it through a compact imaging device that captures images of the swarf container. This extraction allows automation without requiring large installation space, as the imaging device can be integrated into the existing machine tool structure.
Solution Approach 2:
The invention uses image copying technology to create visual representations of the swarf container and its contents. By capturing images with an imaging device and processing them to detect swarf accumulation levels, the system achieves automated monitoring without physical contact with the swarf, eliminating the need for large mechanical removal devices.
2Device complexity
If manual checking of swarf accumulation is performed, then no additional removal device is needed, but the operator cannot timely detect when swarf removal is needed
Solution Approach 1:
The system enables self-service monitoring where the machine tool automatically captures images of the swarf container and processes them to detect accumulation levels. This eliminates the need for operator intervention in detection, while still providing timely alerts when swarf removal is needed, combining simplicity with effectiveness.
Solution Approach 2:
The invention implements a feedback mechanism where images of the swarf container are continuously captured, processed to detect accumulation levels, and used to generate alerts when thresholds are exceeded. This closed-loop feedback system ensures timely detection and response without requiring manual checking or complex removal devices.
3Productivity
If swarf is not removed in time, then no additional removal action is needed, but cutting accuracy degrades and tool damage occurs
Solution Approach 1:
The system performs preliminary detection of swarf accumulation levels by capturing images and processing them to identify when removal is needed. By detecting accumulation trends and issuing alerts before critical thresholds are reached, the system enables proactive swarf management that prevents accuracy degradation and tool damage while maintaining production continuity.
Data Source
AI summary
A numerical control device includes: an estimation unit to estimate an accumulation amount of swarf to be produced when a tool mounted on a machine tool cuts a workpiece on the basis of a machining condition in cutting the workpiece by the tool and a value of current to be applied to a motor for moving a shaft of the machine tool when the tool cuts the workpiece. The numerical control device further includes a correction unit to correct the accumulation amount of swarf estimated by the estimation unit on the basis of a machining mode specifying a shape of swarf to be produced when the tool cuts the workpiece.