Spectral Confocal Tool Alignment for Micron-Precision Machining

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Solution Overview

Problem

Current methods for tool alignment in servo valve machining are inefficient and prone to errors due to manual processes, requiring high operational skill and resulting in low precision and high rejection rates.

Innovation Solution

An automatic tool aligning system utilizing a spectral confocal displacement sensor with a three-dimensional moving platform and control module, which automates the tool alignment process, reducing the need for manual intervention and enhancing precision.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual tool arrangement method is used, then operational flexibility is maintained, but manufacturing precision deteriorates due to high requirement for operating technology and continuous debugging

Engineering Contradiction:

Improvetool alignment precisionVSAvoidoperating skill requirement

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The patent replaces the manual mechanical tool arrangement process with an automatic tool aligning system that uses a spectral confocal displacement sensor to detect tool positions and a control module to automatically adjust the three-dimensional moving platform, eliminating the need for manual debugging and high operating skills while achieving micron-level precision

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-alignment through the spectral confocal displacement sensor that automatically detects tool positions and feeds back to the control module, which then autonomously adjusts the platform position without requiring external manual intervention or continuous debugging

Inventive Principle:

Principle #25Self-service

2Productivity

If manual tool arrangement method is used, then system complexity is low, but productivity deteriorates due to complicated procedure and low efficiency

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidsystem structural complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces the simple manual arrangement process with an automated system comprising a spectral confocal displacement sensor, control module, and three-dimensional moving platform, which significantly improves productivity by eliminating complicated manual procedures and continuous debugging requirements

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The control module acts as an intermediary that receives detection data from the spectral confocal displacement sensor and automatically generates control instructions for the three-dimensional moving platform, streamlining the tool alignment process and eliminating the need for manual intervention

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If manual tool arrangement method is used, then equipment cost is low, but manufacturing precision deteriorates with alignment errors causing feed errors and workpiece scrap

Engineering Contradiction:

Improvecutting edge alignment accuracyVSAvoidworkpiece scrap rate

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent replaces manual tool arrangement with an automated alignment system that uses spectral confocal displacement sensing to achieve micron-level precision in cutting edge, cylindrical generatrix, and axis alignment, eliminating feed errors that cause workpiece scrap while maintaining cost-effectiveness through reduced rejection rates

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 system significantly reduces manufacturing auxiliary time and costs while improving precision, allowing for rapid and accurate tool alignment, even with less skilled operators, and increasing efficiency by 12 times with precision improved by 10 times.

Implementation Method 1

spectral confocal displacement sensor

Methodology Applied

Scientific EffectSpectral confocal displacement sensing: Interference

Implementation Method 2

spectral confocal displacement sensor

Methodology Applied

Scientific EffectOptical interference: Interference

Implementation Method 3

linear motor

Methodology Applied

Scientific EffectElectromagnetic force: Lorentz Force

Implementation Method 4

grating ruler

Methodology Applied

Scientific EffectLight diffraction: Diffraction

Data Source

PatentUS12011795B2Automatic tool setting system and method based on spectral confocal displacement sensor

Publication Date: 2024.06.18 SHANGHAI JIAOTONG UNIV

AI summary

The invention discloses an automatic tool aligning system based on a spectral confocal displacement sensor. The system comprises three-dimensional mobile platform, tool aligning component based on the spectral confocal displacement sensor, clamping device, machine tool and the control module. The three-dimensional mobile platform is fixed on the outer side of the machine tool, the tool aligning component is connected with the three-dimensional mobile platform, the clamping device used to clamp the workpiece is fixed on the center of the machine tool through mechanical connection, and the spectral confocal displacement sensor is connected with the control module. After judging the collected working condition data, the control module outputs a control instruction to the three-dimensional mobile platform.