Friction Welding Spindle Misalignment Detection by Servo Current
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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 for moving the spindle intersecting the axis, a current value detecting means to monitor the servomotor's current, and a misalignment detecting means that uses the current value and rotation angle to identify misalignment between workpieces during the friction-welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional machine tools join two workpieces using friction welding or other joining means, then the workpieces are transformed into a single joined workpiece, but misalignment (eccentricity) occurs between the two joined workpieces due to wear, tool deterioration, or aging
Solution Approach 1:
The patent applies preliminary action by detecting misalignment between workpieces before the joining process is completed. The detection means measures the position relationship between the first and second workpieces in advance, allowing the system to identify and correct misalignment issues before they result in defective joined products. This proactive detection prevents the worsening of alignment precision that would otherwise occur during the joining process.
2Manufacturing precision
If conventional machine tools process axial end faces of workpieces to ensure coaxial alignment, then joining accuracy is improved, but unexpected misalignment still occurs due to wear, tool deterioration, or aging
Solution Approach 1:
The patent implements feedback by continuously monitoring the position relationship between workpieces during the joining process. The detection means provides real-time information about misalignment, which is fed back to the control system. This feedback loop enables dynamic adjustment and correction, maintaining consistent alignment despite wear, tool deterioration, or aging that would otherwise cause reliability to deteriorate over time.
Solution Approach 2:
The machine tool applies self-service by using its own detection means to monitor and identify misalignment issues during the joining process. The system automatically detects problems without requiring external inspection, enabling self-correction and maintaining consistent alignment performance throughout operation despite deteriorating conditions.
3Productivity
If conventional machine tools lack detection capability, then the joining process continues without interruption, but misalignment between joined workpieces cannot be detected
Solution Approach 1:
The patent introduces an intermediary detection means that acts as a mediator between the joining process and the control system. This detection device continuously monitors the position relationship between workpieces without interrupting the joining process, thereby maintaining productivity while preventing loss of information about misalignment. The intermediary detector enables continuous operation with simultaneous quality monitoring.
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, allowing for timely correction and improving the accuracy and reliability of the joining process.
Implementation Method 1
an electric servomotor for moving the first spindle in a direction intersecting the axis of the first spindle
Implementation Method 2
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
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AI summary
A machine tool (1) includes a first spindle (10), a second spindle (20), and a joining means (51) for joining the axial ends of workpieces (W1, W2) gripped by the spindles (10, 20) to form a joined workpiece (W3). The machine tool (1) further includes an electric servomotor (33) for moving the first spindle (10) in the direction intersecting the axis of the first spindle (10), a current value detection means (53) for detecting the current value of the electric servomotor (33), and a misalignment detecting means (52) for detecting misalignment of a first workpiece (W1) and a second workpiece (W2) in the joined workpiece (W3), based on the current value detected by the current value detection means (53) when the joined workpiece (W3) gripped by the two spindles (10, 20) is rotated.