Tool Changer Verification in Machine Tools for Mismatch Prevention
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Solution Overview
Problem
Existing machine tools with tool changers fail to detect mismatches between the tools envisioned in machining programs and those actually loaded, leading to potential tool damage, defective products, and machine tool shutdowns, especially when nondesignated tools are mistakenly loaded or cutting edges become damaged.
Innovation Solution
A machine tool system that includes an input unit for machining programs, a storage unit for tool data, a tool measuring device to measure tool dimensions, and a judging unit that compares measured dimensions with stored data to detect mismatches, issue warnings, and automatically switch to spare tools if necessary, preventing improper or damaged tool usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If tool matching is not detected, then machining can proceed without interruption, but machine tool damage and defective products occur
Solution Approach 1:
The system performs preliminary measurement of tool dimensions and generates a tool information table before machining begins. This advance preparation allows the judging unit to compare actual tools with programmed tools beforehand, detecting mismatches before they cause damage or defects, thus maintaining both productivity and reliability
Solution Approach 2:
The measuring device continuously measures tool dimensions and feeds this information back to the control device. The judging unit compares this feedback with programmed tool data and can interrupt machining when mismatches are detected, creating a closed-loop system that maintains reliability without sacrificing productivity
2Reliability
If tool measurement and judgment is implemented, then tool mismatches can be detected, but system complexity increases
Solution Approach 1:
The control device performs multiple functions: it stores machining programs, controls the tool changer, manages the tool information table, and executes judgment logic. By making the control device multi-functional rather than adding separate dedicated systems, the patent achieves reliable tool mismatch detection without proportionally increasing system complexity
Solution Approach 2:
The measuring device automatically measures tool dimensions and the control device automatically compares measurements with programmed data and makes judgment calls. This self-service approach eliminates the need for manual tool verification by operators, achieving reliable detection while keeping the automation system relatively simple
3Reliability
If manual tool verification is performed, then tool accuracy can be checked, but machining time is wasted
Solution Approach 1:
The patent replaces manual mechanical verification with an automated optical or electromagnetic measuring device that quickly captures tool dimensions. This substitution maintains high verification accuracy while dramatically reducing the time required, as the automated measurement and judgment occur rapidly without interrupting the machining flow
Data Source
AI summary
This machine tool has a tool changing device, and sequentially changes tools to machine a workpiece. The machine tool comprises: an input unit which receives a machining program output from a CAM system and tool basic data; a storage unit which stores the tool basic data received from the input unit for each tool number; a tool measuring device which measures the size of a tool loaded into a tool magazine of the tool changing device; and a determination unit which compares the tool basic data stored in the storage unit and the actual data measured by the measuring device, and determines that the measured tool is different from a desired tool if the difference between the two tool sizes is beyond a preset allowable range.