Non-Contact Affected Layer Detection Sensor for Machine Tool
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Solution Overview
Problem
Existing machine tools with contact affected layer detection sensors face challenges in maintaining precise detection due to sensor wear and require a constant, minimized gap between the sensor and workpiece, while non-contact sensors struggle to achieve precise detection of varying workpiece dimensions and affected layers.
Innovation Solution
A machine tool incorporating a non-contact affected layer detection sensor integrated within a sizing device, where the sensor is positioned in the arm portion, allowing for precise detection of affected layers and workpiece dimensions simultaneously, with a probe maintaining contact and the arm displacing to maintain a constant gap, and utilizing multiple sensors for wide-range detection, along with a balance weight to stabilize the arm portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a contact affected layer detection sensor is used, then the sensor can detect the affected layer, but the distal end of the sensor wears out
Solution Approach 1:
The patent replaces the contact-type mechanical sensor with a non-contact sensor that detects the affected layer through electromagnetic fields or other non-mechanical means. This eliminates physical contact between the sensor and workpiece, preventing wear while maintaining detection capability. The non-contact sensor achieves this by measuring changes in electrical impedance or other physical properties of the workpiece without requiring physical contact.
2Reliability
If a non-contact affected layer detection sensor is used, then the sensor does not wear, but the gap between the sensor and workpiece must be kept constant and minimized
Solution Approach 1:
The patent introduces a probe as an intermediary element that maintains a constant gap between the non-contact sensor and the workpiece. The probe is positioned close to the workpiece surface, and the sensor is mounted on the probe at a fixed distance, ensuring the gap remains constant during measurement. This intermediary structure allows the non-contact sensor to operate at optimal distance without requiring active gap control mechanisms.
3Adaptability or versatility
If the workpiece dimension varies, then the workpiece can be measured, but the gap between the non-contact sensor and workpiece changes
Solution Approach 1:
The patent employs a dynamic positioning system where the probe can move axially to maintain constant contact with the workpiece surface despite dimensional variations. The non-contact sensor is mounted on the probe such that its position relative to the workpiece remains constant through the probe's movement. This dynamic adjustment ensures the measurement gap stays constant even when workpiece dimensions change, maintaining detection precision across varying workpiece sizes.
Data Source
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AI summary
A machine tool including a non-contact affected layer detection sensor capable of detecting an affected layer with high precision is provided. A machine tool (10) includes a non-contact affected layer detection sensor (25), a main body (21), probes (23a) and (23b) that contact the surface of an workpiece (W), arm portions (22a) and (22b) supported by the main body (21), and dimension measurement sensors (24a) and (24b) that output a signal that corresponds to the dimension of the workpiece (W) on the basis of displacement of the arm portions (22a) and (22b) with respect to the main body (21). The affected layer detection sensor (25) is provided in the arm portion (22a), and outputs a signal that corresponds to an affected state of the workpiece (W). The arm portions (22a) and (22b) hold the probes (23a) and (23b), respectively, and are displaceable with respect to the main body (21) in accordance with the dimension of the workpiece (W).