Rotary Tool Breakage Detection Using Proximity Signal Waveforms
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Solution Overview
Problem
Existing cutting machining apparatuses fail to detect breakage of the cutting edge during machining, leading to reduced machining accuracy when the tip of the cutting edge is damaged, as they rely on conductivity changes that do not account for embedded wire breakages.
Innovation Solution
A cutting machining apparatus equipped with a proximity sensor and a signal acquirer that compares detection signal waveforms before and after machining to determine tool breakage by analyzing intensity changes, allowing for quick detection of tool breakage and improved machining accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductivity monitoring using an embedded enamel wire is used to detect tool breakage, then breakage at the silver soldering joint can be detected, but breakage of the cutting edge tip cannot be detected when the wire is not embedded there
Solution Approach 1:
The patent replaces the electrical conductivity monitoring method with a proximity sensor-based detection system. Instead of relying on electrical signals from embedded wires, the system uses non-contact proximity sensors to detect changes in the tool's physical position and waveform characteristics, enabling detection of cutting edge breakage regardless of wire embedding location
Solution Approach 2:
The patent introduces proximity sensors as an intermediary detection mechanism between the tool and the detection system. The sensors detect waveform changes caused by tool breakage through proximity measurements, serving as a mediator that translates physical tool state changes into detectable signal variations without requiring direct contact or embedded sensors in the tool
2Manufacturing precision
If the cutting edge tip breaks during machining, then machining accuracy deteriorates, but the breakage cannot be detected quickly with existing methods
Solution Approach 1:
The patent performs preliminary detection by acquiring waveform data from proximity sensors before and after machining operations. By establishing baseline waveforms in advance and comparing them with post-machining waveforms, the system can quickly identify tool breakage without requiring real-time complex analysis during the machining process
Solution Approach 2:
The patent implements a feedback mechanism where detection signal waveforms are continuously monitored and compared. The determination unit analyzes waveform differences between pre and post-machining states, providing immediate feedback on tool condition that enables rapid detection of breakage and timely intervention to maintain machining accuracy
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
Enables rapid detection of tool breakage during machining, thereby enhancing the accuracy of workpiece processing and preventing machining defects caused by undetected tool damage.
Implementation Method 1
a first proximity sensor; a signal acquirer obtaining detection signal information indicating an intensity of a detection signal that is output from the first proximity sensor when the rotary spindle is rotated
Data Source
AI summary
A cutting machining apparatus 1 includes: a head 5 including a spindle drive 51 that rotary drives a rotary spindle with a tool 20 secured to a tip of the rotary spindle; a proximity sensor 34; a signal acquirer obtaining a signal waveform of a detection signal that is output from the proximity sensor 34 when the rotary spindle 52 is rotated in a state in which the head 5 is moved so that the proximity sensor 34 faces a lateral side of the tool before and after cutting machining of the workpiece W using the tool; and a determiner determining whether or not the tool 20 is broken based on whether or not there is a difference in signal waveforms obtained before and after the cutting machining.