Sensorized Cutting Tool Layout for Sensitivity and Rigidity
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Solution Overview
Problem
Existing cutting tools face challenges in achieving both sensitivity for monitoring and rigidity during machining, as the placement of sensors and batteries can compromise either sensitivity or structural integrity.
Innovation Solution
A cutting tool design with a sensor unit that places sensors closer to the cutting tip and a battery further away, allowing for accurate detection of strain, acceleration, and temperature while maintaining rigidity, using a wireless communication unit to transmit data and minimizing the impact of battery placement on rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor is placed closer to the cutting tip to improve detection sensitivity, then the sensitivity for monitoring is improved, but the structural integrity and rigidity deteriorate
Solution Approach 1:
The cutting tool is divided into functionally distinct segments: a sensor unit containing the sensor and communication components positioned near the cutting tip for high sensitivity, and a battery unit positioned away from the cutting tip to maintain structural integrity. This segmentation allows each component to be optimized for its specific function without compromising the other.
Solution Approach 2:
The patent resolves the spatial conflict by utilizing the longitudinal dimension of the cutting tool. The sensor is positioned at one end (near the cutting tip) while the battery is positioned at the other end (away from the cutting tip), effectively distributing components along the length of the tool to simultaneously achieve sensitivity and structural integrity.
2Ease of manufacture
If the battery is placed closer to the cutting tip to simplify wiring, then the ease of manufacture is improved, but the rigidity and stability during machining deteriorate
Solution Approach 1:
The power supply system is segmented into a battery unit and a sensor unit with distinct positioning. The battery is placed in a location that prioritizes machining stability, while the sensor unit near the cutting tip handles detection and communication functions. This segmentation allows wiring to be managed within each unit separately, maintaining ease of manufacture while ensuring stability.
3Strength
If the sensor unit is placed away from the cutting tip to maintain rigidity, then the structural integrity is improved, but the detection precision and sensitivity deteriorate
Solution Approach 1:
The patent utilizes the longitudinal dimension to resolve the conflict between structural integrity and detection precision. The sensor is positioned at the end near the cutting tip where detection precision is critical, while the battery is positioned at the opposite end to maintain structural integrity. This dimensional distribution allows both requirements to be satisfied simultaneously.
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 design achieves both sensitivity and rigidity, enabling effective monitoring of the cutting tool's state during machining by optimizing sensor placement and battery positioning, thus enhancing detection accuracy and tool stability.
Implementation Method 1
a first sensor arranged on the surface of the body portion to detect a first physical quantity of the body portion
Implementation Method 2
a wireless communication unit mounted on the board and transmitting a signal containing information on the first physical quantity detected by the first sensor to an outside
Data Source
AI summary
A cutting tool includes a body portion having a bar shape extending from a first end, which is an end on a side where a cutting tip for cutting the workpiece is placed, to a second end, which is an end opposite to the first end, and a sensor unit arranged on a surface of the body portion. The sensor unit includes a first sensor arranged on the surface of the body portion to detect a first physical quantity of the body portion, a board arranged on the surface of the body portion and electrically connected to the first sensor, a wireless communication unit mounted on the board and transmitting a signal containing information on the first physical quantity detected by first sensor to the outside, and a battery arranged in body portion and electrically connected to the board. The first sensor is closer to first end than battery.