Optical Tool Measurement for Safe Machine Tool Exchange
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Solution Overview
Problem
Existing tool changers require manual input of tool lengths, which can lead to errors and potential damage during the tool changing process due to incorrect measurements.
Innovation Solution
A method utilizing an image capturing device to determine the tool's dimensions automatically, allowing the changing arm and shutter to optimize their operation for safe and efficient tool exchange by calculating the tool's length, diameter, mass, and center of gravity, thereby minimizing the time required for tool changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual input of tool lengths is used, then the system can obtain tool dimension data, but errors occur and potential damage results during tool changing due to incorrect measurements
Solution Approach 1:
The patent replaces the manual measurement system with an optical imaging system. A camera captures images of tools, and image processing algorithms automatically calculate tool lengths, diameters, and other dimensions. This substitution eliminates human error in manual input and provides precise, consistent measurements, directly resolving the contradiction between measurement accuracy and tool changing safety.
Solution Approach 2:
The system enables tools to self-measure through automatic image capture and processing. When a tool is placed in the tool holder, the camera automatically captures its image, and the control unit automatically calculates its dimensions without requiring manual intervention. This self-service approach ensures accurate data entry and prevents errors that could lead to tool damage during changing operations.
2Reliability
If automatic image-based measurement is implemented, then measurement accuracy and tool changing safety improve, but device complexity increases due to addition of image capturing device and processing system
Solution Approach 1:
The camera system serves multiple functions: it captures tool images for dimension measurement, verifies tool presence in holders, and potentially monitors tool conditions. This multi-functionality justifies the added complexity by providing comprehensive tool management capabilities beyond simple measurement, improving overall system reliability while sharing hardware resources.
Solution Approach 2:
The patent introduces an image processing algorithm as an intermediary between the physical tool and the control system. This software mediator automatically extracts dimensional data from images, translating visual information into actionable measurement data without requiring direct mechanical contact or complex sensor arrays, thus managing system complexity while maintaining high reliability.
3Productivity
If traditional manual measurement methods are used, then device complexity remains low, but time required for tool changing increases due to manual input operations
Solution Approach 1:
The system performs preliminary measurement of tool dimensions automatically when tools are loaded into holders, before tool changing operations begin. The camera captures images and the control unit calculates dimensions in advance, storing this data for rapid retrieval during tool changing. This preliminary action eliminates the need for manual measurement input during actual tool changes, significantly improving productivity while the initial measurement complexity is amortized over multiple tool changes.
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
Significantly reduces the time needed for tool changes by ensuring accurate and automatic measurement of tool dimensions, preventing interference and damage, and optimizing the operation of the changing arm and shutter.
Implementation Method 1
an image of the tool is captured by an image capturing device
Data Source
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AI summary
This tool exchange device (40) for a machine tool uses an exchange arm (43) to exchange tools (5) between a processing area (61) and a tool accommodation area (62) which are partitioned by a partition wall (51) provided with an opening (51a) and a shutter (52) capable of opening and closing the opening (51a). In the tool exchange device, an imaging device (24) is used to capture an image of a tool in the tool accommodation area (62), the length (L) of the tool (5) is calculated from the captured image of the tool, the opening width of the shutter (52) is determined in accordance with the length (L) of the tool (5), and the shutter (52) is opened to the determined opening width.