NC Machine Tool Diagnosis via Host Computer Centralization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional NC machine tools require an operator for each unit to diagnose and maintain, leading to labor inefficiencies in large factories with multiple machines, as existing technologies do not provide a comprehensive solution for remote monitoring and management.
Innovation Solution
A system comprising one or more NC machine tools, a host computer device, and a communication unit that allows for remote monitoring and diagnosis, enabling the upload of numerical control information for centralized management and parameter adjustments, eliminating the need for on-site operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an operator is disposed to each NC machine tool for diagnosis and maintenance, then the machine tool can be properly monitored and maintained, but labor costs and operational complexity increase significantly in large factories with multiple machines
Solution Approach 1:
Multiple NC machine tools are merged into a single networked system where one host computer device manages diagnosis and maintenance for all connected machines. The numerical controllers of individual machine tools upload numerical control information to the host computer, which centrally processes diagnosis and maintains parameter databases, eliminating the need for separate operators at each machine while ensuring proper monitoring and maintenance.
Solution Approach 2:
A host computer device acts as an intermediary between multiple NC machine tools and operators. It receives numerical control information from machine tools via communication units, performs centralized diagnosis by comparing uploaded information against stored parameters, and manages maintenance activities. This intermediary consolidates multiple operator roles into a single centralized management point.
2Ease of operation
If an operator is disposed to each NC machine tool, then immediate diagnosis and maintenance can be performed, but labor costs and time consumption increase
Solution Approach 1:
The NC machine tools perform self-diagnosis by automatically uploading their numerical control information to the host computer device, which compares the uploaded data against stored parameters to identify abnormalities. This automated self-service mechanism eliminates the need for operators to manually inspect each machine, providing immediate diagnosis capability while significantly reducing labor time and costs.
Solution Approach 2:
The system implements continuous feedback loops where numerical controllers monitor their own operation parameters, upload this information to the host computer, which then compares it against standard parameters and provides diagnostic feedback. This automated feedback mechanism ensures immediate detection of issues without requiring operator intervention, maintaining ease of operation while reducing time loss.
3Productivity
If numerical control parameters are automatically rewritten based on diagnosis results, then machine tool performance is optimized, but the risk of incorrect parameter changes increases
Solution Approach 1:
The host computer device stores pre-established standard parameters for each NC machine tool in its parameter database before operation begins. When diagnosis is performed, the system compares uploaded numerical control information against these pre-stored standards and only rewrites parameters when abnormalities are detected, ensuring that parameter changes are based on verified deviations rather than arbitrary modifications. This preliminary preparation of standard parameters ensures accuracy while enabling automated optimization.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A host computer device downloads a monitor management program to a numerical controller of an NC machine tool in step S10, collects numerical control information input/output between the numerical controller and a servomotor in step S30, analyzes numerical control information monitored in step S40, and diagnoses the NC machine tool in steps S50 to S110.