Machine Tool Thermal Displacement Correction Under Sensor Failure
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Solution Overview
Problem
Existing thermal displacement correction methods for machine tools fail to accurately estimate and correct thermal displacement when temperature sensors malfunction, leading to reduced productivity and lower quality products due to the need to stop machine operations for maintenance.
Innovation Solution
A thermal displacement correction device that employs multiple estimating methods to continue accurate thermal displacement correction by selecting an alternative method when a temperature sensor anomaly occurs, using a sensor information acquisition unit, thermal displacement estimating method storage, and a thermal displacement estimating method selection unit to estimate and correct thermal displacement without relying on faulty sensor data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the machine tool operation is stopped to restore the temperature sensor abnormality, then the sensor reliability is improved, but the productivity is reduced
Solution Approach 1:
The system performs preliminary actions by storing multiple thermal displacement estimating methods in advance and preparing alternative estimation approaches. When a sensor abnormality occurs, the system can immediately switch to a pre-prepared alternative method without stopping operation, thus maintaining productivity while ensuring reliable thermal displacement correction
Solution Approach 2:
The system changes the estimation method parameter based on sensor status. When sensor abnormality is detected, the system switches from using actual sensor data to using alternative estimation methods (such as using data from other sensors or predictive models), thereby maintaining continuous operation without compromising correction reliability
2Productivity
If the thermal displacement correction is continued using the abnormal temperature sensor output, then the productivity is maintained, but the manufacturing precision is reduced
Solution Approach 1:
The system continuously monitors sensor output and provides feedback on sensor status. When abnormality is detected through feedback mechanisms, the system automatically switches to alternative estimation methods, ensuring that manufacturing precision is maintained while keeping the machine tool operating continuously
Solution Approach 2:
The control device acts as an intermediary between the temperature sensors and the thermal displacement correction process. When sensor abnormality occurs, the control device mediates by selecting alternative estimation methods from stored methods, thereby preventing direct use of abnormal sensor data while maintaining continuous correction and productivity
3Reliability
If multiple thermal displacement estimating methods are stored and selected based on sensor state, then the reliability is improved during sensor abnormality, but the device complexity is increased
Solution Approach 1:
The control device is designed with multi-functionality to perform both normal thermal displacement correction using sensor data and alternative estimation using stored methods. This universal design allows the same device to handle both normal and abnormal sensor conditions, improving reliability without requiring separate dedicated systems for each scenario
Data Source
AI summary
Provided is a thermal displacement correction device capable of continuing a thermal displacement correction with high accuracy even when some of a plurality of sensors fail. The thermal displacement correction device includes a sensor information acquisition unit that acquires machine tool temperatures detected by the sensor and a state of the sensors, a thermal displacement estimating method storage unit that stores a plurality of thermal displacement estimating methods, a thermal displacement estimating method selection unit that selects a thermal displacement estimating method to be used for estimating the thermal displacement amount of the machine tool based on the state of the sensors, and a thermal displacement estimating unit that estimates the thermal displacement amount of the machine tool based on the machine tool temperature according to the thermal displacement estimating method selected by the thermal displacement estimating method selection unit.