Sensorized Rotating Tool for Precise Machining State Detection
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Solution Overview
Problem
Existing cutting tools lack accurate measurement capabilities to assess the state of machining, which is crucial for optimizing cutting processes and identifying issues such as vibration and tool wear.
Innovation Solution
A rotating tool equipped with acceleration sensors and strain sensors attached to the shaft portion, allowing for real-time measurement of displacement, rotary cutting resistance, and deformation, enabling accurate monitoring of machining conditions and reducing signal attenuation by placing sensors closer to the cutting edge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are attached to the shaft portion of the rotating tool, then measurement precision of machining state is improved, but device complexity increases
Solution Approach 1:
The patent embeds multiple sensors (acceleration sensor and strain sensor) within the shaft portion of the rotating tool, creating a nested structure where sensing elements are integrated into the tool's internal architecture. This nesting approach enables precise measurement of machining states while minimizing the increase in overall device complexity by utilizing the existing tool structure.
Solution Approach 2:
The shaft portion serves as an intermediary structure that hosts the sensors and transmits measurement data from the cutting edge to the measurement system. By placing sensors on the shaft portion, the patent creates an intermediate measurement point that accurately reflects the machining state without requiring direct attachment to the cutting edge, thus balancing measurement precision with device complexity.
2Measurement precision
If sensors are placed closer to the cutting edge, then measurement precision is improved, but signal attenuation is reduced
Solution Approach 1:
The patent places sensors on the shaft portion in advance, positioned as close as possible to the cutting edge before the actual cutting operation begins. This preliminary positioning ensures that the sensors are optimally located to capture machining state data with minimal signal attenuation from the outset, improving both measurement precision and signal quality.
Solution Approach 2:
The patent applies local quality by concentrating sensor placement at the specific location on the shaft portion that is closest to the cutting edge. This localized sensor positioning ensures that the measurement point is optimally situated to capture the machining state with minimal signal loss, enhancing both measurement precision and signal strength without requiring sensors throughout the entire tool structure.
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 provides precise measurement of machining states, enhancing the accuracy of cutting processes, facilitating early detection of abnormalities like vibration and wear, and allowing for improved tool performance and maintenance.
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
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.