Servo Data Compression for Machine Tool Life Estimation
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Solution Overview
Problem
Conventional methods for estimating and detecting tool life in machine tools require a large amount of data, leading to significant data band occupation in communication lines, which can hinder efficient monitoring and management.
Innovation Solution
The method involves squaring and integrating torque values from motor current data to compress the data, allowing for high-speed sampling and efficient transmission, enabling accurate tool life estimation and detection while reducing data volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If continuous monitoring of tool life is performed by transmitting a large amount of servo data to upper-level controllers, then measurement precision and reliability of tool life estimation is improved, but the data band occupation in communication lines increases significantly
Solution Approach 1:
The patent extracts only the essential information needed for tool life estimation from the servo data, rather than transmitting the complete raw data set. By identifying and transmitting only the critical parameters that correlate with tool wear and failure, the system achieves accurate tool life monitoring while minimizing communication bandwidth consumption.
Solution Approach 2:
The system performs preliminary processing of servo data at the machine tool level before transmission. By pre-calculating and pre-processing the data to extract only the necessary features for tool life estimation, the system reduces the data volume that needs to be transmitted while maintaining the accuracy required for reliable tool life prediction.
2Measurement precision
If high-speed sampling of torque data is performed to accurately grasp subtle load changes, then measurement precision is improved, but the data amount increases making transmission difficult
Solution Approach 1:
The patent extracts only the essential information needed for tool life estimation from the servo data, rather than transmitting the complete raw data set. By identifying and transmitting only the critical parameters that correlate with tool wear and failure, the system achieves accurate tool life monitoring while minimizing communication bandwidth consumption.
Solution Approach 2:
The system performs preliminary processing of servo data at the machine tool level before transmission. By pre-calculating and pre-processing the data to extract only the necessary features for tool life estimation, the system reduces the data volume that needs to be transmitted while maintaining the accuracy required for reliable tool life prediction.
Data Source
AI summary
To efficiently estimate and detect a tool life of a machine tool while lowering an occupation ratio in a data band of a communication line between a machine tool and an upper-level controller, a management apparatus or the like. A machine tool to be managed by a production management apparatus includes a motor for moving one of a workpiece to be machined and a tool for performing a machining operation, an amplifier for driving the motor, a servo controller for controlling the motor via the amplifier based on a notification of a predetermined machining operation, and an NC device for notifying the servo controller of the predetermined machining operation. The servo controller obtains servo data representing a load on the amplifier, performs a first processing for compressing the servo data, and transmits the compressed data to the NC device.