Sensor-Mounted Rotating Tool Shaft for Accurate Machining State Sensing
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Solution Overview
Problem
Existing rotating tools lack an effective method to accurately measure the state of machining, which is crucial for optimizing cutting processes and identifying potential issues.
Innovation Solution
A rotating tool configuration that includes a shaft portion with an acceleration sensor and a strain sensor attached, allowing for the measurement of displacement, rotary cutting resistance, and deformation, even if the tool holder and spindle of the machine tool change.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are attached to the tool holder or spindle, then measurement coverage is improved, but signal attenuation increases and measurement sensitivity decreases
Solution Approach 1:
The patent introduces the rotating tool shaft as an intermediary carrier for sensors. Instead of attaching sensors directly to the tool holder or spindle (which causes signal attenuation), the sensors are mounted on the rotating tool shaft itself, serving as a mediator that transmits vibration signals directly from the cutting edge to the sensors with minimal attenuation.
Solution Approach 2:
The patent shifts the sensor mounting location from the stationary tool holder/spindle system to the rotating tool shaft dimension. This dimensional change allows sensors to be positioned closer to the cutting action while rotating with the tool, thereby reducing signal attenuation and improving measurement sensitivity.
2Measurement precision
If multiple sensors are attached to the rotating tool, then measurement accuracy is improved, but device complexity increases
Solution Approach 1:
The rotating tool shaft serves multiple functions: it is both the cutting tool carrier and the sensor mounting platform. By making the shaft universal for both cutting operations and sensor attachment, the patent avoids adding separate complex sensor mounting mechanisms, thereby improving measurement accuracy without proportionally increasing device complexity.
3Adaptability or versatility
If the cutting tool is attached to different machine tools, then adaptability is improved, but consistent measurement becomes difficult
Solution Approach 1:
The rotating tool shaft with attached sensors serves itself as a portable measurement system that can be transferred between different machine tools. The shaft inherently provides the measurement capability without requiring external measurement systems, enabling consistent measurements across different machine tools through self-contained sensing.
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 accurate measurement of machining states, allowing for improved process optimization and issue identification, while maintaining sensitivity and reducing signal attenuation.
Implementation Method 1
a plurality of sensors attached to the shaft portion, wherein the plurality of sensors include an acceleration sensor and a strain sensor
Implementation Method 2
a plurality of sensors attached to the shaft portion, wherein the plurality of sensors include an acceleration sensor and a strain sensor
Data Source
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AI summary
A rotating tool according to an aspect of the present disclosure is a rotating tool used in a state held by a tool holder, and the rotating tool includes a shaft portion having an end attached to the tool holder, a blade attaching portion or a blade portion provided at an end of the shaft portion opposite to the end, and a plurality of sensors attached to the shaft portion, and the plurality of sensors include an acceleration sensor and a strain sensor.