Spindle Load Segmentation for Accurate Tool Damage Detection
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Solution Overview
Problem
Conventional damage detection methods for tools in machine tools are inaccurate due to load data including variations from acceleration/deceleration torque and non-cutting phases, leading to potential misidentification of tool damage.
Innovation Solution
A tool damage detection device that acquires and analyzes load and rotational speed data specifically in the cutting feed section, extracting evaluation data to reliably detect tool damage using reference load data and evaluation data comparison.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If load data is acquired from the start to the end of the machining cycle, then the data coverage is comprehensive, but the accuracy of tool damage detection deteriorates due to inclusion of acceleration/deceleration torque and non-cutting phase data
Solution Approach 1:
The machining cycle is segmented into multiple phases (acceleration phase, cutting feed section, deceleration phase, non-cutting phase). The patent extracts load data specifically from the cutting feed section by identifying start and end points based on rotational speed thresholds, thereby separating useful cutting data from irrelevant acceleration/deceleration data and achieving both sufficient coverage and high accuracy
Solution Approach 2:
The patent extracts only the relevant portion of load data corresponding to the cutting feed section by using rotational speed data as a reference. When rotational speed exceeds a predetermined threshold, the system identifies the start of cutting; when it falls below the threshold, the end is identified. This extraction process removes unwanted data from acceleration/deceleration phases while retaining essential cutting data
2Ease of operation
If load data including acceleration/deceleration torque is used, then the data acquisition process is simple, but the reliability of damage detection deteriorates
Solution Approach 1:
Rotational speed data serves as an intermediary to identify the boundaries of the cutting feed section. By using rotational speed as a mediator, the system automatically determines when cutting starts and ends without complex manual intervention, maintaining ease of operation while ensuring only reliable cutting phase data is used for damage detection
Solution Approach 2:
The system uses the rotational speed data itself to automatically mark the start and end points of the cutting feed section. This self-service approach eliminates the need for external intervention or complex configuration, allowing the system to autonomously extract reliable data while keeping the operation simple
Data Source
AI summary
A tool damage detection device includes: a data acquisition unit that acquires load data indicating a load of a spindle and rotational speed data indicating a rotational speed of the spindle in a cutting feed section; an extraction unit that extracts, from the load data, evaluation data to be used for evaluation of occurrence of damage to a tool based on the rotational speed data; a detection unit that detects occurrence of damage to the tool using the evaluation data; and an output unit that outputs data indicating occurrence of damage to the tool when the detection unit detects the damage to the tool.