Stone Cutting Tool Offset Control for Precise Profile Machining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The processing of stone materials using diamond wheel sets is hindered by the need for precise offset calculation, leading to excessive tool wear, potential breakage, and slow, costly manufacturing due to incorrect offset determinations.
Innovation Solution
A device and procedure that automatically calculates the offset for each tool based on its removal thickness and current cutting profile, using a control unit and acquisition system to determine the optimal position and trajectory for processing, allowing for precise and efficient material removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual offset calculation is used by the operator, then the processing can be performed with simple equipment, but the processing time increases and manufacturing precision decreases due to incorrect offset determination
Solution Approach 1:
The patent replaces the manual mechanical offset calculation method with an automated computer-based system. The control unit automatically calculates the offset values based on the tool profile data and workpiece geometry, eliminating the need for manual operator calculation and significantly improving both precision and speed of offset determination.
Solution Approach 2:
The system enables self-service by allowing the control unit to autonomously determine offset values without operator intervention. The automated calculation process uses pre-stored tool profiles and workpiece data to compute optimal offset values, reducing dependency on operator expertise and minimizing calculation time.
2Manufacturing precision
If manual offset calculation is performed with numerous tests, then manufacturing precision can be maintained, but the productivity decreases and loss of time increases
Solution Approach 1:
The patent applies preliminary action by pre-storing accurate tool profile data in the control unit before processing begins. The system calculates and stores offset values in advance based on the known tool geometry and workpiece requirements, eliminating the need for time-consuming trial-and-error tests during actual production.
Solution Approach 2:
The automated computer-based offset calculation system replaces manual trial-and-error testing with precise mathematical computation. The control unit rapidly calculates optimal offset values using stored tool profiles and workpiece geometry, achieving high manufacturing precision without the time loss associated with manual testing and adjustment.
3Productivity
If incorrect offset is used, then the manufacturing process is faster, but tool wear increases and tool reliability decreases
Solution Approach 1:
The system incorporates feedback by continuously monitoring tool position and depth of cut during processing. The control unit uses this feedback to maintain the calculated offset values, ensuring that the tool removes the precise amount of material intended without excessive wear or breakage, thereby preserving both productivity and tool reliability.
4Manufacturing precision
If complex offset calculations are performed manually, then manufacturing precision can be improved, but the device complexity increases and ease of operation decreases
Solution Approach 1:
The patent replaces complex manual offset calculation with an automated control unit that performs all computational tasks electronically. The operator simply loads tool profiles and workpiece data, and the system automatically computes precise offset values, maintaining high manufacturing precision while dramatically improving ease of operation.
Solution Approach 2:
The system uses digital copies of tool profiles stored in memory rather than requiring physical measurement and manual calculation. The control unit reads these digital representations and automatically computes offset values, eliminating the need for operators to perform complex manual calculations while maintaining high precision.
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 approach ensures precise and high-quality processing, reduces tool wear, and significantly decreases processing time and costs by automating offset calculations and optimizing tool usage.
Implementation Method 1
an acquisition system configured to capture the current cutting profile of the tool
Data Source
Figure 1~2
Figure 3
AI summary
It is provided a processing procedure (100) of an object (1a) in stone material and defining final profile (1c), the process (100) comprises: a work station of said object (1a); tools (2) configured to process the object (1a) and defining a removal thickness (2b); a block for reciprocal movement between object (1a) and tool (2); a drive block control unit; an acquisition step (20) wherein the acquisition system acquires the current cutting profile (2c) of each tool (2); an evaluation step (30) wherein for each tool (2) an offset is determined between object (1a) and tool (2) as a function of the final profile (1c), removal thickness (2b) and current cutting profile (2c); and at least one processing step wherein the movement block reciprocally moves object (1a) and tool (2) defining said offset.