Non-Contact Measurement of Rotating Burr Tools Without Defect Errors
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Solution Overview
Problem
Existing non-contact tool measurement systems, such as the NC4 system, are not optimal for measuring non-toothed tools like grinding tools and burr tools due to protrusions from defects like contaminants or blisters, which introduce significant measurement errors by including these protrusions in the measured dimensions.
Innovation Solution
A method that involves rotating the non-toothed tool relative to a light beam while analyzing variations in the received intensity signal, determining when the signal crosses a threshold for a defined duration less than one complete tool rotation, to exclude the effects of protrusions and provide accurate measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If prior art tool measurement techniques are used, then the measurement process is simple, but measurement precision deteriorates due to protrusions from defects being included in the measured dimensions
Solution Approach 1:
The patent applies dynamics by rotating the tool during measurement and using a time-varying threshold crossing criterion (defined duration less than one rotation) rather than a static single-point measurement. This dynamic approach allows the system to distinguish between transient protrusions (defects) and the stable tool geometry, improving measurement precision without requiring complex additional hardware.
Solution Approach 2:
The patent utilizes periodic action by rotating the tool at a consistent speed and analyzing light intensity variations over multiple rotation cycles. The measurement triggers when the light intensity signal crosses a threshold for a defined duration that is less than one complete rotation, creating a periodic measurement pattern that filters out transient defects while capturing the true tool dimensions.
2Reliability
If the light-to-dark measurement mode is used, then the measurement process is straightforward, but reliability deteriorates because protrusions from defects are included in the measured dimensions
Solution Approach 1:
The patent implements feedback by continuously monitoring the light intensity signal during tool rotation and using this feedback to determine when the threshold has been crossed for the required defined duration. This feedback mechanism allows the system to reliably distinguish between transient protrusions and the actual tool geometry, improving measurement reliability while maintaining ease of operation through automated signal analysis.
Solution Approach 2:
The patent applies parameter changes by modifying the measurement criterion from a simple single-point threshold crossing to a time-integrated criterion (threshold crossed for a defined duration less than one rotation). This parameter change in the measurement methodology improves reliability by filtering out transient defects while keeping the system easy to operate through automated processing.
3Productivity
If the dark-to-light measurement mode with one rotation duration threshold is used, then transient protrusions can be excluded, but productivity deteriorates due to the extended measurement time
Solution Approach 1:
The patent applies partial action by requiring the threshold to be crossed for a defined duration that is less than one complete rotation, rather than requiring a full rotation. This partial duration criterion is sufficient to filter out transient protrusions while significantly reducing measurement time compared to full-rotation methods, thereby improving productivity without sacrificing measurement precision.
Solution Approach 2:
The patent implements skipping by allowing the measurement to trigger as soon as the threshold crossing criterion is met within the defined duration, rather than waiting for a complete rotation cycle. This rushing through the measurement process reduces measurement time and improves productivity while maintaining precision through the defined duration filter that excludes transient defects.
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 method allows for more robust and reliable measurement of non-toothed tools by excluding transient protrusions, ensuring that the measured dimensions reflect the actual tool geometry rather than protruding defects.
Implementation Method 1
a transmitter and a receiver, the transmitter generating a beam of light that is directed towards the receiver
Implementation Method 2
the receiver producing a received intensity signal related to the intensity of received light
Data Source
Figure 1
Figure 2a~4
Figure 5~6
AI summary
An improved method is described for measuring a dimension (e.g. diameter) of a non-toothed tool, for example a grinding tool such as a diamond coated burr. The method may be implemented on a machine tool, such as a lathe, machining centre or the like. The method comprises passing a beam of light from a transmitter (10) to a receiver (14). The receiver (14) produces a received intensity signal related to the intensity of received light. Analysis of variations in the received intensity signal is performed when a rotating tool (40; 88) is moved relative to the light beam (12) to enable a dimension of the tool (40; 88) to be measured. In particular, it may be determined when the received intensity signal has crossed a threshold for at least a defined duration (Tq), the defined duration being less than the time taken for one complete rotation of the tool (Tr).