Tool Beam Scanning for Fast, Precise Cutting-Edge Measurement
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Solution Overview
Problem
Existing methods for measuring cutting-edge lengths of tools in machine tools are time-consuming and lack precision, unable to simultaneously determine all cutting-edge lengths in a single measuring process, and are susceptible to disturbances from coolants and swarf, which affect measurement accuracy.
Innovation Solution
A method using a measuring device with a light emitter and receiver to scan the tool, rotating it until all cutting edges shade the measuring beam, allowing for precise determination of cutting-edge lengths by moving the tool at a constant feed rate, expanding the usable measurement range, and processing shadow signals to generate a switching point for accurate measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional measuring methods are used to determine cutting-edge lengths, then measurement accuracy can be maintained, but measurement time is significantly increased
Solution Approach 1:
The measurement process is segmented into distinct phases: positioning phase where the tool is moved to the measuring beam, measurement phase where cutting-edge lengths are determined, and separation phase where the tool is moved away. This segmentation allows optimization of each phase independently, reducing total measurement time while maintaining accuracy
Solution Approach 2:
The tool is pre-positioned in the measuring beam at a starting position where all cutting edges are within the measurement range before measurement begins. This preliminary positioning ensures that the measurement can proceed immediately without delays during the actual measurement process
2Adaptability or versatility
If the tool is moved at variable speed during measurement, then measurement range can be adjusted, but measurement precision deteriorates due to feed rate variations
Solution Approach 1:
The system dynamically adjusts the feed rate during the measurement process based on the position of the tool and the measurement range requirements. The feed rate is optimized for each phase: slower during positioning for precision, and faster during separation to reduce measurement time, while maintaining overall measurement accuracy
3Productivity
If measurement is performed under harsh conditions with coolants and swarf, then productivity is maintained, but measurement accuracy is affected by disturbances
Solution Approach 1:
The system converts the potentially harmful effects of coolants and swarf into beneficial filtering opportunities. The measuring beam's detection system identifies and filters out disturbances caused by these contaminants, effectively converting measurement errors into identifiable and correctable signals, allowing accurate measurement even in harsh machining conditions
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 method significantly reduces measurement time while maintaining high accuracy, allowing for the precise determination of all cutting-edge lengths in a single process, and effectively filters out disturbances, enabling reliable measurement under harsh conditions.
Implementation Method 1
a light emitter (LS), which is designed to emit a measuring beam (MS) for contactless scanning of the tool (WZG)
Implementation Method 2
a light beam receiver (LE), which is designed to receive the measuring beam (MS) and to output a shadow signal representative of a degree of shading of the measuring beam (MS) by the tool (WZG)
Data Source
AI summary
A method for checking a tool uses a device with a light emitter for beam emission for tool scanning and with a beam receiver for beam reception and for outputting a shadow signal; and an evaluation unit for processing the shadow signal; rotation of the tool; moving the tool until it reaches a starting position in which the blade dips into the beam and shades this such that a threshold of a range of the evaluation unit is reached or undershot; moving the tool, starting from the starting position, out of the beam and registering the shadow signal; ascertaining that the shadow signal for a cutting edge does not fall below the lower switching threshold or exceed the upper switching threshold such that a shadow signal lies above the lower and below the upper switching threshold; wherein the feed is determined in proportion to a measurement range.