Tool Diameter Measurement for Machine Tool Safety
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Solution Overview
Problem
Machine tools are limited in their ability to efficiently switch between milling, drilling, and grinding operations without intermediate downtimes, as they lack a system to safely and automatically manage and measure tool diameters for different types of tools.
Innovation Solution
A system comprising a tool changing device with a manipulator and a tool diameter measuring device, using optical measurement via a light grid, to automatically measure and manage tool diameters, set safe spindle speeds, and prevent excessive spindle speed, allowing for seamless switching between milling, drilling, and grinding tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a universal machine tool is equipped with both milling tools and grinding tools using the same tool interface, then the versatility and productivity of the machine tool is improved, but the risk of incorrect tool operation and safety hazards increases due to lack of tool identification
Solution Approach 1:
The patent replaces manual tool identification and spindle speed setting with an automated optical measurement system. A light grid camera automatically measures tool diameter and transmits data to the control device, which then automatically sets the maximum spindle speed, eliminating the need for operator intervention and ensuring safety compliance.
Solution Approach 2:
The system enables self-service operation where the tool itself provides measurement information through automatic optical scanning. The light grid camera captures tool diameter data without human assistance, and the control device autonomously processes this data to determine safe operating parameters, making the system self-regulating.
2Reliability
If manual tool diameter measurement and spindle speed setting is performed for each tool change, then safety can be ensured, but time is lost during tool changes reducing productivity
Solution Approach 1:
The system performs preliminary measurement of tool diameter immediately upon tool insertion, before machining begins. The light grid camera automatically captures tool dimensions and the control device pre-calculates the maximum spindle speed, so that safety parameters are ready before the machining operation starts, eliminating post-tool-change setup time.
Solution Approach 2:
Manual measurement and calculation processes are replaced by an automated optical measurement system and control algorithm. The light grid camera and control device work together to automatically determine tool parameters and set spindle speed limits without human intervention, dramatically reducing tool change cycle time while maintaining safety.
3Measurement precision
If optical measurement with light grid camera is implemented for automatic tool diameter measurement, then measurement precision and automation are improved, but device complexity increases
Solution Approach 1:
The patent extracts only the essential measurement function needed for safety - tool diameter measurement - and implements it through a dedicated light grid camera system. By focusing on this single critical parameter rather than comprehensive tool characterization, the system achieves high measurement precision with relatively simple device architecture.
Solution Approach 2:
The light grid camera serves as an intermediary device that bridges the physical tool and the control system. It converts physical tool dimensions into digital measurement data that the control device can process, simplifying the overall system architecture by providing a dedicated sensing interface between the tool and control systems.
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 efficient and safe operation of machine tools by automatically measuring tool diameters and setting appropriate spindle speeds, reducing downtime and ensuring safe operation during tool changes and machining processes.
Implementation Method 1
the tool diameter measuring device has an optical measuring device for optically measuring the tool to be exchanged, in particular comprising a camera and/or a light grid
Data Source
AI summary
The present invention relates to a system for changing and inserting or presenting tools on a machine tool 200, comprising: a tool changing device with a manipulator 120, which is configured to remove a tool 101 to be exchanged from a tool magazine 110 of the machine tool 200 at a removal position in an automatic tool changing process and to transfer it to a work spindle 202 of the machine tool at a tool changing position, and a tool diameter measuring device 140, which is configured to determine a tool diameter or tool radius of the tool 101 to be exchanged, which is removed by the manipulator 120 from the tool magazine 110 of the machine tool 200.