Sensor-Integrated Turning Tool for In-Process Dimensional Measurement
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Solution Overview
Problem
In machining with automatic lathes, measuring dimensions during the process is not efficient, leading to increased machining time and cost due to the need to temporarily separate the tool from the workpiece for measurement, especially for portions that require final finishing.
Innovation Solution
A turning tool equipped with integrated distance sensors that measure dimensions without separating from the workpiece, allowing for on-the-fly measurement of machined surfaces and positions, including outer and inner diameters, roundness, and surface roughness, thereby reducing the time required for measurement steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the tool is sufficiently drawn apart from the workpiece to measure the machined surface, then measurement accuracy is improved, but machining time is lengthened
Solution Approach 1:
The measurement device is integrated directly onto the tool body, merging the cutting function and measurement function into a single tool unit. This allows the tool to measure the machined surface without being drawn apart from the workpiece, thereby maintaining measurement accuracy while eliminating the time loss associated with tool repositioning.
Solution Approach 2:
The patent introduces a measurement device as an intermediary component attached to the tool body that can measure the machined surface through the tool itself. This intermediary measurement system enables contactless or minimal-contact measurement while the tool remains in its machining position, resolving the contradiction between measurement accuracy and machining time.
2Productivity
If the tool is moved close to the workpiece again to carry out additional machining, then productivity is improved, but machining time is lengthened due to repeated positioning
Solution Approach 1:
By integrating the measurement device with the tool body, the patent combines cutting and measurement operations into a single tool unit. This eliminates the need for separate tool repositioning cycles between machining and measurement, thereby improving productivity without incurring additional positioning time penalties.
Solution Approach 2:
The integrated measurement device enables continuous measurement during or immediately after the machining operation without interrupting the workflow. The tool can maintain its position and continuously perform both cutting and measurement functions, eliminating idle positioning time and maintaining continuous productive action.
3Device complexity
If dimensions are not measured during the machining process, then device complexity is reduced, but manufacturing precision deteriorates due to inability to adjust for cutting edge abrasion
Solution Approach 1:
The patent integrates a measurement device directly onto the tool body, combining cutting and measurement functions in one unit. This relatively simple integration enables real-time dimensional measurement during machining, allowing for adjustment of cutting parameters or detection of tool wear, thereby maintaining manufacturing precision without significantly increasing overall system complexity.
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
The solution shortens measurement time, improves dimensional accuracy, and reduces machining costs by integrating sensors that measure dimensions directly on the tool, ensuring precise and efficient machining without additional separation steps.
Implementation Method 1
a measurement device attached to the tool body, and wherein the measurement device measures a distance from the tool body to an object
Data Source
Figure 1
Figure 2
Figure 3~4A
AI summary
A turning tool (1) includes a tool body (10) extending along a tool axis (J) and having a base (18) on a tip of the tool body, a cutting insert (20) detachably attached to the base (18), and a measurement device (3) attached to the tool body (10). The measurement device (3) has a first distance sensor (31) which measures a distance to an object located radially outward of the tool axis (J).