In-Tool Distance Sensing for Wear-Accurate Cutting Measurement
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Solution Overview
Problem
The cutting tool's cutting edge gradually abrades over time, affecting the accuracy of dimension measurements taken by the attached distance sensor, as the sensor's readings are influenced by the cutting edge's position and attachment accuracy.
Innovation Solution
A cutting method that sets both the cutting edge and sensor coordinates independently, allowing for accurate measurement of the machined surface without separating the tool from the workpiece, using multiple sensors with different measurement directions and an eddy current sensor for precise calibration, and includes a contact sensor for reliable coordinate setting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the cutting edge is used as reference for coordinate setting, then machining accuracy is maintained, but measurement accuracy deteriorates as the cutting edge abrades
Solution Approach 1:
The patent separates the reference coordinate system into two independent parts: one based on the cutting edge for machining operations, and another based on the distance sensor for measurements. This segmentation allows each coordinate system to serve its specific function without interference from the other's degradation or errors.
Solution Approach 2:
The distance sensor acts as an intermediary measurement tool that does not depend on the cutting edge position. By introducing this independent sensor-based reference system, the patent eliminates the direct dependency between cutting edge condition and measurement accuracy.
2Measurement precision
If the tool is separated from the workpiece for measurement, then measurement accuracy is improved, but productivity deteriorates due to additional time required
Solution Approach 1:
The distance sensor mounted on the tool body enables the tool to perform self-measurement of the workpiece dimensions during the machining process. This eliminates the need for separate measurement operations with external measuring instruments, thereby maintaining measurement accuracy while improving productivity.
Solution Approach 2:
The patent enables continuous measurement during the machining process by mounting the distance sensor on the tool. The measurement action occurs continuously alongside the machining action without interruption, eliminating idle time between machining and measurement operations.
3Adaptability or versatility
If multiple distance sensors are attached to the tool body, then measurement capability is improved, but device complexity increases
Solution Approach 1:
The patent employs multiple distance sensors with different measurement directions (e.g., radial and axial directions) to enable comprehensive measurement of various workpiece features. Each sensor is strategically positioned and oriented to measure specific dimensions, creating a universal measurement system that handles multiple measurement tasks simultaneously.
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 enhances measurement accuracy and reduces measurement time by eliminating the need for separate calibration steps and jig usage, ensuring precise dimension measurement even with abraded cutting edges and varying materials.
Implementation Method 1
an eddy current sensor for precise calibration
Data Source
AI summary
This method is a machining method using a tool body (10, 110) to which a distance sensor (31, 32) is attached, the method including a coordinate setting step of setting each of a cutting edge coordinate with a point of a cutting edge (22, 122) provided at the tool body (10, 110) as reference and a sensor coordinate with a reference point of the distance sensor (31, 32) as reference, a machining step of forming a machined surface using the cutting edge coordinate, and a measurement step of measuring a dimension of the machined surface using the sensor coordinate.