Spindle Contact Position Sensing for Precise Tool Reference Setting
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Solution Overview
Problem
Existing processing machines face limitations in accurately acquiring reference positions during processing due to the need for conductive blades and potential errors from using pseudo blades, which can lead to tool and workpiece deterioration.
Innovation Solution
A processing machine equipped with a spindle, holding part, drive part, position sensor, rotation sensor, and control part that moves the spindle and holding part to set a relative position based on detected position changes when the spindle rotates and contacts a reference member, allowing for precise acquisition of the reference position without requiring conductivity or pseudo blades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conductive blade is used to detect contact position, then the reference position can be detected, but the blade material selection is limited and the blade may deteriorate
Solution Approach 1:
A non-conductive blade is used as an intermediary tool that contacts the workpiece, while a separate detection system (capacitance sensor or pseudo-blade) detects the contact position without requiring the blade itself to be conductive. This mediator approach allows standard non-conductive cutting blades to be used while still enabling precise reference position detection.
Solution Approach 2:
A pseudo-blade (conductive copy of the actual blade) is introduced to simulate the blade's position and shape for detection purposes. The pseudo-blade contacts the workpiece or table surface to generate detection signals, while the actual non-conductive blade performs the cutting operation, thus copying the detection function separately from the cutting function.
2Measurement precision
If a pseudo blade is used to simulate the blade for detection, then reference position can be acquired, but errors occur due to differences between the blade and pseudo blade
Solution Approach 1:
The system continuously monitors the position relationship between the blade and workpiece during processing, using detection signals from capacitance sensors or pseudo-blades to provide feedback to the control system. This feedback mechanism allows real-time compensation and adjustment, ensuring that even with a pseudo-blade approximation, the final processing accuracy meets requirements through closed-loop control.
3Measurement precision
If the blade and table contact to detect position, then reference position is acquired, but deterioration of either component may occur
Solution Approach 1:
The direct mechanical contact detection method is replaced with non-contact or indirect contact detection methods. Capacitance sensors detect position changes through electrical field variations without physical contact, or pseudo-blades with different material properties contact the table surface instead of the precious blade, substituting the mechanical detection system to protect the actual cutting blade from deterioration.
4Measurement precision
If high frequency voltage is applied to detect approach, then contact detection is improved, but the blade and table must be conductive
Solution Approach 1:
The detection system is designed to work with both conductive and non-conductive blades through multiple detection modes. The system can switch between capacitance-based detection (for non-conductive blades), pseudo-blade contact detection, or high-frequency voltage detection (for conductive blades), making the processing machine universally applicable to different blade types and workpiece materials without requiring blade conductivity.
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
This configuration enables accurate and precise acquisition of reference positions, reducing the likelihood of tool and workpiece deterioration and eliminating the need for conductive tools or pseudo blades, thereby enhancing processing precision and machine reliability.
Implementation Method 1
a rotation sensor 71 that detects rotation of the spindle 37
Implementation Method 2
a position sensor 69 that detects the position of the movable part in the first direction
Implementation Method 3
the control part 5 acquires as the reference position the position detected by the position sensor 69 when a cessation of rotation of the spindle 37 is detected by the rotation sensor 71 in a situation where the movable part moves in the first direction in a state where the spindle 37 is rotating and the tool 101 and the reference member contact in the first direction
Data Source
AI summary
In a processing machine, a drive part makes a movable part move in a first direction. A position sensor detects the position of the movable part in the first direction. The rotation sensor detects the rotation of the spindle. At the time of processing of a workpiece by a tool in a state where the spindle is rotating, a control part controls the drive part based on the detection value of the position sensor so as to the movable part move in the first direction to a relative position set with respect to a predetermined reference position. Further, the control part acquires, as the reference position, a position detected by the position sensor at the time of detection of cessation of rotation of the spindle by the rotation sensor in a situation where the movable part moves in the first direction in a state where the spindle is rotating, and the tool and the workpiece contact in the first direction.