Optical Tool Setting for Single-Pass Tool Profile Measurement
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Solution Overview
Problem
Existing non-contact tool setting apparatuses for coordinate positioning systems are time-consuming and impractical for measuring the profile of tools, as they require repeated movement of the tool into and out of the light beam to measure multiple points along the tool edge.
Innovation Solution
A method and apparatus that use a light beam and receiver to collect beam intensity data by moving the tool along a tool inspection path tangential to its periphery, allowing for the analysis of beam intensity data to assess the tool profile, including shape, position, and dimensions, thereby reducing the need for multiple point measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the tool is moved into and out of the light beam multiple times to measure multiple points along the tool edge, then the tool profile measurement is achieved, but the measurement time increases significantly making the process impractical
Solution Approach 1:
The patent implements continuous tool profile measurement by moving the tool continuously through the light beam along a measurement path that traverses the entire tool profile in a single pass. The beam intensity signal is continuously recorded during this single continuous movement, eliminating the need to repeatedly move the tool into and out of the beam for different measurement points. This continuous measurement approach maintains high measurement precision while dramatically reducing measurement time.
Solution Approach 2:
The patent transforms the measurement approach from one-dimensional (moving tool in and out of beam repeatedly) to two-dimensional (moving tool continuously along a path that spans the entire profile). By introducing a spatial dimension along the tool profile and using a wide light beam that covers the entire profile height, the system captures all profile information in a single continuous pass, resolving the time-precision contradiction.
2Productivity
If a single point on the tool edge is measured quickly using trigger signals, then measurement speed is improved, but complete tool profile assessment becomes impractical
Solution Approach 1:
The patent makes the measurement system multi-functional by using a single continuous measurement pass to achieve multiple objectives: determining tool length, measuring tool diameter, and assessing the complete tool profile. The wide light beam and continuous movement approach allow all these measurements to be performed simultaneously during one tool pass, eliminating the need for separate measurement operations and preserving complete profile information while maintaining high productivity.
Solution Approach 2:
The system performs continuous data collection throughout the entire tool profile in a single unbroken measurement sequence. The beam intensity signal is recorded continuously as the tool moves through the beam, capturing all profile information without interruption. This continuous action ensures no profile information is lost while maintaining the speed advantage of single-pass measurement.
3Productivity
If the light beam width is increased to cover the entire tool profile, then single-pass measurement becomes possible, but the device complexity increases
Solution Approach 1:
The patent merges the light beam dimensions to create a wide beam that spans the entire tool profile height while maintaining appropriate width. This merged beam configuration allows the optical system to capture the complete tool profile in a single pass without requiring multiple beams or complex scanning mechanisms. The combination of beam width and beam height is optimized to cover the full profile, achieving high productivity without excessive device complexity.
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
This approach enables quick and detailed measurement of the tool profile by tracing the light beam around the tool's periphery, improving efficiency and accuracy while detecting deviations from nominal profiles, allowing for real-time assessment of tool tolerances and adjustments.
Implementation Method 1
a transmitter for emitting a light beam and a receiver for receiving the light beam
Implementation Method 2
the receiver generating a beam intensity signal describing the intensity of received light
Data Source
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AI summary
A method is described for assessing the profile of a tool (50; 80; 170) using a non-contact tool setting apparatus (150) that comprises a transmitter (10) for emitting a light beam (12; 152) and a receiver (14) for receiving the light beam. The receiver (14) generates a beam intensity signal describing the intensity of received light. The non-contact tool setting apparatus (150) is mounted to a coordinate positioning apparatus, such as a machine tool, that allows the tool (50; 80; 170) to be moved relative to the non-contact tool setting apparatus (150). The method comprises comparing the beam intensity data to previously acquired beam intensity data, the comparison providing an indication of whether the profile of the tool has changed. A corresponding device is also described.