Tool Abnormality Detection via Cycle Load Ratio
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Solution Overview
Problem
Existing tool abnormality determination systems in lathes struggle to accurately detect tool abnormalities due to changes in mechanical efficiency between idle and operational states, leading to false positives or negatives when the monitoring range is set before or after idling.
Innovation Solution
A tool abnormality determination system that corrects the monitoring range for tool load based on data from previous cycles, using a load ratio between early-stage and later-stage data to adapt to changes in mechanical efficiency, ensuring accurate detection regardless of when the monitoring range is set.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the monitoring range is set before idling of the lathe, then the threshold is based on high load conditions, but the load tends to be smaller than the threshold when a workpiece is actually processed after idling, leading to false abnormality detection
Solution Approach 1:
The monitoring range is dynamically adjusted based on the lathe's operational state. The system detects whether the lathe is in an idle or operational state and automatically sets the monitoring threshold range accordingly, making the threshold adaptive rather than fixed. This resolves the contradiction by ensuring the monitoring range matches the actual load conditions during workpiece processing.
Solution Approach 2:
The system changes the monitoring parameter (threshold range) based on the operational state. When the lathe transitions from idle to operational state, the monitoring range is adjusted from a higher threshold (suitable for idle state) to a lower threshold (suitable for operational state), preventing false abnormality detection while maintaining detection sensitivity.
2Productivity
If the monitoring range is set after idling of the lathe, then the threshold is based on low load conditions, but the load tends to be larger than the threshold when the workpiece is actually processed before idling, leading to missed abnormality detection
Solution Approach 1:
The monitoring range dynamically adapts to the lathe's operational state. When processing begins before idling completes, the system detects the high-load condition and adjusts the monitoring threshold upward, ensuring accurate abnormality detection without compromising processing efficiency.
Solution Approach 2:
The system performs preliminary detection of the operational state before setting the monitoring range. By detecting whether the lathe is in idle or operational state before establishing the threshold, the system prepares the appropriate monitoring parameters in advance, ensuring accurate detection regardless of when processing begins.
3Ease of operation
If a fixed monitoring range is used based on test-cutting data, then the system is simple to operate, but it cannot adapt to changes in mechanical efficiency between idle and operational states
Solution Approach 1:
The system automatically detects the operational state and adjusts the monitoring range without requiring manual intervention. The control device self-determines whether the lathe is in idle or operational state and autonomously sets the appropriate threshold, maintaining ease of operation while achieving adaptability.
Solution Approach 2:
The system uses feedback from load detection to automatically adjust the monitoring range. By continuously monitoring the load and comparing it with the operational state, the system feedback-adjusts the threshold to match current conditions, providing both simplicity and adaptability.
Data Source
AI summary
A tool abnormality detection system corrects a monitoring range for a load on a tool in an Mth cycle by using load data of at least one of 1st to (M−1)th cycles (where M is an integer of 2 or more), wherein processing work on a single workpiece corresponds to a single cycle, and the load data is data about the load on the tool in the cycle.