Sensor-Equipped Cutting Tool for In-Process Surface Point Measurement
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Solution Overview
Problem
Current machining systems require significant time and resources for inspecting and reworking machined workpieces due to the need for separate measurement tools and processes, which can be inefficient and inaccurate.
Innovation Solution
A method and system where a sensor-equipped cutting tool is used for both machining and measuring, allowing for in-process measurement without a separate probe, utilizing the same tool body to determine the position of a point on a machined surface by monitoring deflection and position, thereby reducing the need for additional measurement steps and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a separate measurement tool is used to inspect the machined workpiece, then measurement can be performed, but inspection time increases and measurement accuracy decreases
Solution Approach 1:
The patent merges the machining function and measurement function into a single integrated tool system. The cutting tool body incorporates sensors (such as capacitive, inductive, or optical sensors) that enable the tool to perform both material removal and dimensional measurement without being replaced or repositioned. This eliminates the time loss associated with tool changes and workpiece repositioning while maintaining high measurement accuracy through the rigid tool body reference.
Solution Approach 2:
The cutting tool is designed with multi-functionality, serving both as a machining tool and a measurement tool. The tool body includes sensors that can detect dimensional parameters of the workpiece during or after the machining operation. This universal design allows the same tool to perform multiple functions (cutting and measuring) without requiring separate dedicated measurement equipment, thereby reducing inspection time while maintaining measurement precision.
2Reliability
If the workpiece is moved to a separate machine for measurement, then dedicated measurement can be performed, but time and resources are consumed
Solution Approach 1:
The patent combines the machining operation and measurement operation into a single stationary setup. The workpiece remains clamped in the machining machine while the cutting tool, equipped with sensors, performs both cutting and measurement functions. This eliminates the need to move the workpiece to a separate measurement machine, thereby maintaining measurement reliability through consistent reference frames while significantly improving manufacturing efficiency by eliminating transport time and enabling in-process measurement.
Solution Approach 2:
The measurement process is made continuous with the machining process. Sensors in the cutting tool can measure dimensional parameters during or immediately after the cutting operation without interrupting the workflow. This continuous measurement approach ensures reliable data capture while maintaining high productivity by eliminating idle time associated with workpiece handling and repositioning to separate measurement equipment.
3Measurement precision
If a conventional measurement probe is used, then measurement can be performed, but the probe is sensitive to vibrations and lacks stiffness
Solution Approach 1:
The patent combines the measurement function with the rigid cutting tool body structure. Instead of using a separate flexible measurement probe, the cutting tool itself serves as the measurement reference. The tool body, being inherently stiff and vibration-resistant due to its design for cutting operations, provides a stable platform for sensors. This merged approach leverages the mechanical strength of the cutting tool to achieve accurate measurements without the vibration sensitivity that plagues conventional probes.
Solution Approach 2:
The cutting tool is designed with local quality differentiation - the cutting edge area is optimized for material removal while the tool body incorporates sensor mounting capabilities and maintains high structural rigidity. The sensor-equipped portion of the tool body provides the necessary measurement precision, while the overall tool structure provides the stiffness needed to resist vibrations during both machining and measurement operations.
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 approach significantly reduces inspection time, increases measurement accuracy, and eliminates the need for separate measurement tools, enabling more efficient and precise machining operations by utilizing the same tool for both cutting and measurement.
Implementation Method 1
measuring a parameter using the sensor
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The present invention relates to a machining system (100) and a method for determining a position of a point on a machined surface of a workpiece (130), wherein the machining system comprises a machine tool (102), a cutting tool (104) comprising a tool body (105) that is arranged at the machine tool and includes at least one sensor (115), and a control system (150) adapted for controlling and monitoring the position of the tool body. The method comprises the steps of: - machining (206) the workpiece using the cutting tool (104); and - measuring the workpiece using a measurement tool (104, 600) comprising the tool body (105) and a first tip, wherein measuring the workpiece comprises: - moving (208) the measurement tool towards the workpiece while measuring a parameter using the sensor (115), and - determining, based on a position of the tool body as monitored by the control system and on values of the parameter as measured by the sensor, a first position of the first tip in which the tip touches the point on the machined surface, thereby indicating the position of the point on the machined surface.