Hard-Finishing Machine Axis Test Runs During Tool Disengagement

Solution Overview

Problem

Existing hard-finishing machines require periodic reference runs to assess machine condition, which leads to inefficiencies and potential machine downtime due to infrequent checks, and may not detect wear accurately.

Innovation Solution

Implement continuous condition monitoring through test runs on machine axes during idle phases of the machining process, using machine learning to analyze deviations in drive parameters and trigger reference runs only when necessary.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If periodic reference runs are conducted to check machine condition, then machine wear can be detected, but machine capacity is reduced due to non-productive time

Engineering Contradiction:

Improvemachine condition monitoring accuracyVSAvoidmachine capacity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system performs preliminary monitoring actions during idle phases of the machining process. Test runs are conducted on machine axes during non-cutting periods, such as when the tool is not in engagement with the workpiece, allowing condition assessment to be prepared in advance without interrupting productive operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The monitoring system operates continuously during idle phases rather than requiring separate periodic reference runs. By utilizing every available idle moment for test runs and condition assessment, the system maintains continuous monitoring capability without reducing overall machine productivity.

Inventive Principle:

Principle #20Continuity of useful action

2Measurement precision

If reference runs are conducted frequently to improve monitoring accuracy, then wear detection improves, but non-productive time increases

Engineering Contradiction:

Improvewear detection accuracyVSAvoidnon-productive time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system performs preliminary monitoring actions during idle phases of the machining process. Test runs are conducted on machine axes during non-cutting periods, such as when the tool is not in engagement with the workpiece, allowing condition assessment to be prepared in advance without interrupting productive operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of continuous monitoring that would consume excessive time, the system uses periodic test runs during idle phases. This periodic approach balances measurement precision with time efficiency by monitoring at strategically selected moments when the machine is naturally idle.

Inventive Principle:

Principle #19Periodic action

3Reliability

If long reference runs are conducted to assess machine status, then comprehensive wear assessment is achieved, but temperature behavior problems occur

Engineering Contradiction:

Improvemachine status assessment completenessVSAvoidmachine temperature stability

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The monitoring process is segmented into multiple short test runs distributed throughout the machining process rather than one long reference run. Each test run is brief and targeted, assessing specific machine axes during different idle phases, which prevents excessive heat generation while maintaining comprehensive monitoring coverage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system performs preliminary monitoring actions during idle phases of the machining process. Test runs are conducted on machine axes during non-cutting periods, such as when the tool is not in engagement with the workpiece, allowing condition assessment to be prepared in advance without interrupting productive operations.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20260048445A1Method for hard-finishing a workpiece having a gearing or a profile on a hard-finishing machine

Publication Date: 2026.02.19 KAPP NILES GMBH & CO KG

AI summary

A method for hard-finishing a workpiece on a hard-finishing machine, wherein the hard-finishing machine has a number of machine axes. The workpiece is received on a workpiece spindle and is machined by a tool received on a tool spindle. During a temporal segment of the machining phase in which the tool is not in engagement with the workpiece, a test run is carried out on at least one machine axis. The machine axis is driven during the test run. A value is specified for at least one drive parameter for which a nominal value of the movement of the machine axis is expected. The actual value of the movement of the machine axis is detected, a comparison between the nominal value and the actual value is carried out by a monitoring device, and a signal is output by the monitoring device if the difference between the nominal value and the actual value lies outside an admissible range.