Robot Machining Load Control Based on Tool Wear Feedback
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Solution Overview
Problem
In machining processes performed by robots, the inability to automatically control tool wear leads to increased machining loads, resulting in higher defective rates and reduced stability due to manual checks using imaging devices or the naked eye.
Innovation Solution
A robot system coupled with a machining unit, a support, and sensors that measure current and operation force to derive machining load values, controlling movement speeds when loads exceed reference values, thereby maintaining stability and reducing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual checking of tool wear is performed using imaging devices or naked eye, then the system complexity is reduced, but the machining load increases and defective rate increases
Solution Approach 1:
The machining unit performs self-diagnosis by measuring its own machining load through current sensors and force sensors, eliminating the need for external manual inspection systems. The unit automatically detects tool wear conditions through its own operational parameters
Solution Approach 2:
The controller receives feedback signals from sensors measuring current and operation force, continuously monitors machining load conditions, and automatically adjusts movement speed based on the detected tool wear state, creating a closed-loop control system
2Device complexity
If manual checking of tool wear is performed using imaging devices or naked eye, then the measurement system is simpler, but the machining load increases and stability decreases
Solution Approach 1:
The machining unit autonomously monitors its own operational state through integrated sensors, eliminating dependence on external measurement systems and maintaining continuous stability assessment
Solution Approach 2:
Real-time feedback from current and force sensors enables continuous monitoring of machining load, allowing the controller to maintain stable operation by adjusting movement parameters based on actual tool condition
3Productivity
If movement speed is maintained at high level regardless of tool wear, then productivity is improved, but machining load increases and defects increase
Solution Approach 1:
The movement speed is made dynamic rather than fixed, automatically adjusting based on real-time machining load conditions. When tool wear is detected through sensor feedback, the speed is reduced to maintain quality; when tool condition is good, higher speeds are maintained for productivity
Solution Approach 2:
The controller changes the movement speed parameter in response to changes in machining load conditions, creating a variable speed machining process that adapts to tool wear progression to balance productivity and quality
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
The system effectively maintains machining load values within reference limits, lowering defective rates and improving robot stability by automatically adjusting movement speeds based on real-time tool wear measurements.
Implementation Method 1
a sensor unit that is provided on the machining unit and measures an amount of current supplied to a machining motor which operates the tool
Implementation Method 2
measures an amount of current supplied to a machining motor which operates the tool or an operation force of the tool
Data Source
AI summary
A robot system for adjusting a machining load depending on tool wear includes a robot that is coupled to a machining unit, moves the machining unit to change a position of a tool with respect to a machining target, and has a plurality of joints. The robot system further includes a support that supports the machining target and moves the machining target to change a position of the machining target with respect to the tool, a sensor unit that is provided on the machining unit and measures an amount of current supplied to a machining motor which operates the tool or an operation force of the tool, and a controller that receives a measurement signal from the sensor unit and transmits a control signal to the robot and the support.