Machine Tool Control for Safe Tap Evacuation and Chip Discharge
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Solution Overview
Problem
Current machine tools face challenges in automatically evacuating tools like taps without breakage during machining failures, leading to potential tool breakage and reduced productivity due to the high load caused by chip biting between the cutting edge and the screw surface.
Innovation Solution
A control device for machine tools that includes a parameter preparing unit, an evacuation unit, and a chip discharging unit, which calculates and performs evacuation and chip discharging operations based on predetermined parameters and real-time diagnostics to avoid excessive torque and prevent tool breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automatic evacuation operation is performed using conventional methods, then productivity is improved by eliminating manual intervention, but tool breakage risk increases due to chip biting between cutting edge and screw surface
Solution Approach 1:
The control device performs preliminary diagnosis of chip discharge state before executing evacuation operation. By detecting whether chips are properly discharged in advance, the system prepares appropriate evacuation parameters, preventing tool breakage during automatic evacuation while maintaining productivity.
Solution Approach 2:
The system implements feedback control by monitoring operational torque during evacuation and comparing it against predetermined thresholds. When abnormal torque indicating chip biting is detected, the control device adjusts evacuation parameters or interrupts the operation, preventing tool breakage while enabling safe automatic evacuation.
2Loss of time
If evacuation speed is increased to improve productivity, then machining resume time is reduced, but tool breakage risk increases due to excessive load on the tap
Solution Approach 1:
The control device dynamically adjusts evacuation speed based on real-time chip discharge status and torque feedback. When chip discharge is normal, higher evacuation speeds are used to minimize downtime. When chip biting is detected, the system reduces speed or interrupts evacuation to prevent tool breakage, optimizing both productivity and safety.
Solution Approach 2:
The system changes evacuation parameters (speed, feed rate) based on detected chip discharge conditions. By adjusting these parameters dynamically rather than using fixed high-speed evacuation, the system achieves fast resume times when safe while preventing tool breakage when chip biting occurs.
3Reliability
If manual evacuation operation is performed to avoid tool breakage, then tool safety is improved, but productivity deteriorates due to many man-hours required
Solution Approach 1:
The control device enables the machine tool to perform self-diagnosis and self-control during evacuation operations. By automatically detecting chip discharge status and controlling evacuation parameters without human intervention, the system maintains tool safety while eliminating the productivity loss associated with manual operation.
Solution Approach 2:
The system replaces manual mechanical evacuation operation with automated control based on sensor feedback and algorithmic decision-making. This substitution maintains the safety benefits of careful evacuation while eliminating the time-consuming manual intervention, thereby improving productivity.
Data Source
AI summary
A control device for a machine tool in which a tool used to machine a workpiece is mounted to a main spindle that is relatively movable with respect to the workpiece. The control device includes: a parameter preparing unit that stores a predetermined parameter regarding a control in advance; an evacuation unit that causes the tool to perform an evacuation operation from the workpiece; and a chip discharging unit that causes the tool to perform a chip discharging operation. The evacuation operation of the tool by the evacuation unit and the chip discharging operation by the chip discharging unit are performable at respective predetermined timings.