Thread Turning Error Diagnosis Using Spindle and Feed Speed Curves
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Thread pitch errors during thread turning on machine tool equipment are difficult to diagnose and adjust quickly, leading to suboptimal thread quality.
Innovation Solution
An automatic diagnosis method and system that acquires main shaft and feed shaft speeds, computes thread errors, and analyzes error curves to identify and correct faults, allowing for automatic implementation of solutions to achieve ideal thread cutting quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If manual diagnosis and adjustment methods are used for thread turning, then the diagnostic process can be performed with existing equipment, but the diagnostic time is excessive and thread quality cannot be optimized quickly
Solution Approach 1:
The system enables automatic self-diagnosis by having the machine tool system itself collect operational data, compute thread errors, and identify fault causes without external intervention. The control unit automatically processes main shaft and feed shaft speed data to generate thread error curves and diagnose issues, eliminating the need for manual measurement and analysis while achieving both rapid diagnosis and high thread quality
Solution Approach 2:
The patent replaces manual mechanical measurement methods with automated computational analysis. Instead of physically measuring thread pitch errors with calibration tools, the system uses the existing encoder signals from the main shaft and feed shaft to computationally calculate thread errors and generate diagnostic information, significantly reducing diagnostic time while maintaining accuracy
2Measurement precision
If automatic diagnosis system is implemented, then diagnostic speed and accuracy are improved, but system complexity increases
Solution Approach 1:
The control unit performs multiple functions: it controls the main shaft and feed shaft operation, collects speed data from encoders, computes thread errors, generates error curves, and diagnoses fault causes. By making the control unit multi-functional, the system achieves high diagnosis precision without adding separate dedicated hardware, thus avoiding increased system complexity
Solution Approach 2:
The patent uses the existing encoder signals as intermediaries to obtain main shaft and feed shaft speeds. These encoder signals already exist in the machine tool system and are used to compute thread errors through mathematical relationships, avoiding the need for additional sensors or measurement devices while achieving precise diagnosis
3Manufacturing precision
If thread error computation is performed continuously, then thread quality is improved through accurate error detection, but computational load and processing time increase
Solution Approach 1:
The system continuously computes thread errors during the entire thread turning operation by continuously collecting main shaft and feed shaft speed data from encoders. This continuous computation ensures accurate thread quality monitoring throughout the machining process while utilizing the already-present encoder signals, avoiding the need for additional energy-intensive measurement systems
Data Source
AI summary
A turning thread automatic diagnosing method includes collecting a spindle actual speed and a feeding shaft actual speed of a lathe; based upon the spindle actual speed and the feeding shaft actual speed, continuously calculating thread errors to obtain a thread error curve; and analyzing an error cause according to the thread error curve. In addition, a turning thread automatic diagnosing system is disclosed, using the method. A data processing system and a storage medium are also disclosed. The technology of the embodiments can automatically identify the problem causing a thread error and provide a corresponding solution.