Rotary-Axis Measuring System for Fast In-Process Tool Machining
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Solution Overview
Problem
Existing machining devices face challenges in performing high-precision, repeatable, and fast in-process measurements without damaging sensitive workpieces, while being robust against thermal effects and contamination, and requiring a compact, non-intrusive integration with the machining operation.
Innovation Solution
A machining device with a measuring system positioned at the center of a rotary machine axis, utilizing a force-controlled touch probe or contactless sensor, and a control unit to perform measurements along multiple axes, minimizing thermal and contamination effects, and allowing for precise, repeatable, and fast measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a touch trigger probe is used for in-process measurement, then measurement capability is provided, but measurement precision and speed are degraded due to time delay and thermal effects
Solution Approach 1:
The patent replaces the mechanical touch trigger probe with a laser-based optical measurement system. The laser beam measures workpiece dimensions optically without physical contact, eliminating mechanical time delays and thermal effects associated with contact probes. The laser beam can rapidly scan and measure multiple points simultaneously, providing both high precision and fast measurement speed.
Solution Approach 2:
The patent introduces a laser beam as an intermediary measurement medium between the measurement system and the workpiece. This optical intermediary allows non-contact measurement, avoiding the thermal conduction and mechanical inertia problems of direct contact probes while maintaining measurement accuracy through optical detection.
2Measurement precision
If a touch probe is used for measurement, then contact measurement is achieved, but workpiece damage risk increases due to contact force
Solution Approach 1:
The patent substitutes the mechanical contact probe with a laser-based optical measurement system. The laser beam provides non-contact measurement capability, completely eliminating the mechanical contact force that could damage sensitive or brittle workpieces. The optical system detects workpiece dimensions through light reflection and interference patterns without applying any physical stress to the measured surface.
3Adaptability or versatility
If multiple machine axes are used for machining, then machining capability is improved, but measurement system integration complexity increases
Solution Approach 1:
The patent merges the measurement system with the existing multi-axis machine tool structure by integrating the laser measurement装置 into the machine's coordinate system. The measurement system shares the machine's motion control and coordinate transformation capabilities, allowing measurements to be performed in the same reference frame as machining operations without requiring separate measurement equipment or complex additional control systems.
Solution Approach 2:
The patent creates a universal measurement system that can accurately measure workpieces across all axes of the multi-axis machine tool. The laser measurement system is designed to work with the machine's existing degrees of freedom, providing a unified measurement and machining platform that eliminates the need for separate measurement equipment for each axis or configuration.
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 high-precision, repeatable, and fast in-process measurements with minimal interference to the machining operation, reducing thermal and contamination impacts, and ensuring accurate data for closed-loop control of the machining process.
Implementation Method 1
a laser system with an optical system for generating, directing and/or moving a laser beam along an optical axis
Implementation Method 2
The sensing end is deflected, the deflection is determined by corresponding means and in the instant of contact, the touch trigger probe generates a trigger signal
Data Source
AI summary
A machining device is provided with multiple translational and/or rotary machine axes for laser processing, grinding or electrical discharge machining of a workpiece into a tool. The machining device includes a machining unit comprising either a laser system with an optical system for generating, directing and/or moving a laser beam along an optical axis, a grinding tool rotatable around a tool axis, or an electrode tool for generating electrical discharge. The machining device also includes a workpiece support on which the workpiece is attached. The workpiece support is arranged movable about a second rotary machine axis, which is movable relative to a first rotary machine axis, perpendicular to the second rotary machine axis. A measuring system is positioned in a center of the first rotary machine axis and orientated towards a machine zero point defined by an intersection of the first rotary machine axis and the second rotary machine axis. The measurement system is configured to perform measurements along a first measurement axis and/or a second measurement axis to determine measurement data. A control unit is configured to control the machining unit and/or the measuring system.