Rotary Tool Vibration Sensing for Real-Time Frequency Analysis
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Solution Overview
Problem
Existing vibration measurement devices for rotary tools in machining devices lack real-time evaluation of vibrational acceleration, relying on RMS calculation which loses frequency information and limits detailed analysis, hindering high-speed and high-precision machining.
Innovation Solution
A vibration measurement device with acceleration sensors attached symmetrically to the rotary tool's horizontal plane, transmitting high-resolution waveform signals at a high sampling rate without averaging, allowing for real-time analysis and detection of machining phenomena using FFT and autocorrelation processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If RMS calculation is used to average acceleration outputs, then the sampling rate limit is avoided and transmission is feasible, but frequency information is lost
Solution Approach 1:
The patent segments the vibration signal processing into two distinct paths: one for effective value calculation (RMS) and another for high-resolution waveform acquisition. By dividing the signal processing functions, the system preserves frequency information in the high-resolution path while still providing averaged data for comparison, thus resolving the contradiction between sampling rate limitations and information preservation.
Solution Approach 2:
The patent changes the processing parameter from simple RMS averaging to a dual-mode system that includes both effective value calculation and high-resolution waveform capture. By introducing a new parameter dimension (high-resolution sampling), the system maintains frequency information while still addressing transmission constraints through selective processing.
2Loss of information
If high-resolution waveform signals are transmitted without averaging, then frequency information is preserved, but transmission data volume increases
Solution Approach 1:
The patent applies partial action by transmitting high-resolution waveform data selectively rather than continuously. The system processes signals through both RMS averaging and high-resolution capture, transmitting the detailed waveform data only when necessary for frequency analysis, thus preserving frequency information while controlling data transmission volume.
3Measurement precision
If acceleration sensors are attached symmetrically to the rotary tool, then vibration measurement accuracy is improved, but device complexity increases
Solution Approach 1:
The patent uses symmetric arrangement of acceleration sensors on the rotary tool, which is the opposite of asymmetry. This symmetric configuration allows for differential measurement that cancels out common-mode vibrations and improves measurement accuracy. The symmetry principle enables precise vibration detection while maintaining a relatively simple sensor layout.
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 advanced real-time analysis of machining states, detecting specific machining phenomena and abnormalities like chattering, improving machining accuracy and efficiency by preserving frequency information and removing unwanted noise.
Implementation Method 1
a pair of acceleration sensors attached to a horizontal plane with respect to a rotary axis of a rotary tool
Data Source
AI summary
Provided a vibration measurement device for a rotary tool held by a tool holder that is coupled with a spindle and axially rotates in cooperation with the spindle. The vibration measurement device includes: a pair of acceleration sensors attached to a horizontal plane with respect to a rotary axis of a rotary tool in a manner symmetric to the rotary axis; an amplifier circuit that matches impedance of acceleration information from the acceleration sensors and amplifies voltage; a low-pass filter that removes predetermined high frequencies from an output signal of the amplifier circuit; and a subtraction circuit and an addition circuit that output a parallel vibration signal in an XY direction and a vibration signal in a rotational direction, respectively, from the output signal of the low pass filter.