Optical Residue Detection for Automated Machining Tool Maintenance
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Solution Overview
Problem
Current methods for determining cleaning, maintenance, and repair information for motor-driven machining tools require direct inspection and dismantling, which is time-consuming and costly, and do not allow for timely identification of necessary maintenance or repairs.
Innovation Solution
A method and system for automated detection and classification of residues on motor-driven machining tools using optical detection, image recognition, and electronic databases, enabling the determination and output of specific cleaning, maintenance, and repair information without disassembling the tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct inspection and dismantling methods are used to determine cleaning, maintenance and repair information, then accurate maintenance information can be obtained, but the process becomes time-consuming and costly
Solution Approach 1:
The patent creates an optical copy (image) of the residue on the machining tool and processes this copy to determine maintenance information. Instead of physically dismantling the tool for inspection, the system captures an image of the residue and uses image processing algorithms to analyze it, thereby obtaining accurate maintenance information without time-consuming physical inspection.
Solution Approach 2:
The patent replaces the mechanical dismantling and physical inspection process with an optical detection and image processing system. The mechanical system of taking apart the tool is substituted by an optical system that captures images and uses automated algorithms to extract maintenance information, significantly reducing inspection time while maintaining accuracy.
2Reliability
If direct inspection and dismantling methods are used to determine cleaning, maintenance and repair information, then comprehensive tool status can be assessed, but the cost of maintenance increases
Solution Approach 1:
The system creates optical copies of the residue for analysis, eliminating the need for expensive and time-consuming physical disassembly and inspection procedures. The image-based approach provides comprehensive tool status assessment at a lower cost by using automated image processing instead of manual expert inspection.
Solution Approach 2:
The system enables the machining tool to essentially inspect itself by capturing images of its own residue and processing them through automated algorithms. This self-diagnostic capability reduces the need for expensive external maintenance services and expert inspection, thereby lowering overall maintenance costs while maintaining comprehensive assessment.
3Productivity
If manual inspection methods are used, then maintenance information can be determined, but timely identification of maintenance needs is not possible
Solution Approach 1:
The system enables continuous or frequent optical inspection of the machining tool by capturing images of the residue at different time points. The automated image processing allows for rapid analysis, enabling timely identification of maintenance needs before they become critical, thus maintaining both high productivity and reliability.
Solution Approach 2:
The replacement of manual inspection with automated optical detection and image processing dramatically increases the speed of maintenance determination. The system can rapidly analyze multiple images and provide timely maintenance alerts, ensuring that maintenance needs are identified promptly without the delays inherent in manual inspection processes.
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 quick and cost-effective determination and execution of cleaning, maintenance, and repair tasks by allowing users to identify necessary actions without disassembly, promoting timely maintenance and reducing downtime.
Implementation Method 1
optical detection device (11) designed to optically detect the residue (RS)
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a method for automatically determining cleaning, maintenance and/or repair information (Info) for a motor-driven machining tool (2), wherein the machining tool (2) causes a residue (RS) during operation that can be optically detected from the outside, and wherein the method comprises the steps: a) optical detection of the residue (RS), b) classification of the detected residue (RS) according to a type (AT) of residue (RS), c) determination of the cleaning, maintenance and/or repair information (Info) based on the classification, and d) output of the determined cleaning, maintenance and/or repair information (Info).