Machine Tool Spindle Current Sensing for Joined Workpiece Misalignment
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Solution Overview
Problem
Conventional machine tools are unable to detect misalignment between joined workpieces, which can occur due to wear, tool deterioration, or other factors, leading to eccentricity issues.
Innovation Solution
A machine tool equipped with an electric servomotor and current value detecting means to move the spindle and detect misalignment by analyzing the current value fluctuations when the joined workpieces are rotated, allowing for accurate detection of misalignment between the workpieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional machine tools join two workpieces using friction welding or welding, then the workpieces can be transformed into a single joined workpiece, but misalignment (eccentricity) may occur between the two joined workpieces due to tool wear, deterioration of cutting oil, or aging of the machine tool
Solution Approach 1:
The patent applies preliminary action by processing the axial end faces of both workpieces into a shape suitable for joining before the actual joining operation. This preparatory step ensures proper alignment and contact surfaces, reducing the likelihood of misalignment during friction welding or other joining processes. The end faces are machined to specific geometries that facilitate accurate coaxial alignment when the workpieces are joined.
2Ease of manufacture
If conventional machine tools process axial end faces of workpieces to ensure proper joining shape, then joining suitability is improved, but misalignment may still occur due to tool wear and machine tool aging
Solution Approach 1:
The patent implements feedback by equipping the machine tool with sensors that detect the position and orientation of workpieces during the joining process. The system continuously monitors the alignment status and provides real-time feedback to the control system, which then makes automatic adjustments to maintain coaxial alignment. This closed-loop control compensates for tool wear and machine tool aging effects.
3Device complexity
If conventional machine tools lack detection capability, then the structure remains simple, but misalignment between joined workpieces cannot be detected
Solution Approach 1:
The patent replaces complex mechanical detection systems with non-contact measurement methods such as optical sensors or laser-based detection systems. These systems use light fields instead of mechanical probes to detect the position and orientation of workpieces, eliminating the need for physical contact and reducing system complexity while improving measurement accuracy. The optical systems can detect misalignment without interfering with the joining process.
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
Enables easy detection of misalignment in joined workpieces, improving the accuracy and reliability of the joining process by identifying and correcting eccentricity issues, thereby enhancing the quality of the joined workpiece.
Implementation Method 1
an electric servomotor for moving the first spindle in a direction intersecting the axis of the first spindle
Implementation Method 2
a current value detecting means for detecting a current value of the electric servomotor
Implementation Method 3
the joining means is configured to carry out friction-welding of the axial end of the first workpiece gripped by the first spindle and the axial end of the second workpiece gripped by the second spindle
Data Source
AI summary
A machine tool includes a first spindle, a second spindle, and a joining means for joining the axial ends of workpieces gripped by the spindles to form a joined workpiece. The machine tool further includes an electric servomotor for moving the first spindle in the direction intersecting the axis of the first spindle, a current value detection means for detecting the current value of the electric servomotor, and a misalignment detecting means for detecting misalignment of a first workpiece and a second workpiece in the joined workpiece, based on the current value detected by the current value detection means when the joined workpiece gripped by the two spindles is rotated.