Machine Tool Tool-Holder Response During Simultaneous Cutting Faults
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Solution Overview
Problem
During simultaneous processing in machine tools with multiple tool holders, detecting an abnormality in one cutting-tool can lead to unnecessary shutdowns and increased risk of tool breakage or workpiece deformation, as existing methods fail to differentiate between the impact of the abnormal tool and other tools, resulting in inefficient recovery and potential loss of workpieces.
Innovation Solution
An operational control method that determines the occurrence of an abnormality and whether simultaneous processing is occurring, allowing the tool holder with the abnormality to take an avoidance operation while other tool holders continue processing or adjust their response based on the impact assessment, thereby minimizing disruptions and maintaining efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If all cutting-tools are retreated when an abnormality is detected in one tool during simultaneous processing, then the workpiece is protected from damage, but processing efficiency deteriorates and unnecessary tool breakage occurs
Solution Approach 1:
The patent segments the response to abnormality detection by tool holder position. Instead of uniformly retreating all tool holders, the control unit selectively retreats only those tool holders positioned before the abnormal tool in the processing sequence, while allowing subsequent tool holders to continue processing. This segmentation resolves the contradiction by protecting the workpiece from the abnormal tool's effects while maintaining productivity through continued processing by unaffected tools.
Solution Approach 2:
The patent applies local quality by differentiating the response based on the spatial relationship between tool holders. Tool holders before the abnormal tool receive the retreat action (local protection), while tool holders after the abnormal tool maintain their processing action (local continuity). This localized differentiation resolves the contradiction between comprehensive protection and maintained productivity.
2Strength
If the cutting-tool is retreated in the cutting load direction when an abnormality is detected, then the cutting-tool is protected from breakage, but other tool holders may cause workpiece deformation due to loss of balancing force
Solution Approach 1:
The patent applies dynamics by making the tool holder retreat decision conditional on the processing sequence and position relative to the abnormal tool. The control unit dynamically determines which tool holders to retreat based on whether they are positioned before or after the abnormal tool in the processing flow. This dynamic approach resolves the contradiction by protecting the abnormal tool while maintaining the balancing effect on the workpiece through selective continuation of subsequent tool holders.
3Reliability
If all tool holders are stopped and retreated during simultaneous processing abnormality, then complete workpiece protection is achieved, but recovery time and labor increase significantly
Solution Approach 1:
The patent maintains continuity of useful action by allowing tool holders positioned after the abnormal tool to continue their processing without retreat. This selective continuation preserves productivity while the tool holders before the abnormal tool are retreated for protection. The contradiction is resolved by maintaining continuous processing where safe while protecting where necessary, thereby minimizing recovery time and labor.
Data Source
AI summary
An operational control method is provided for a machine tool that includes a plurality of tool holders with a cutting-tool. The machine tool relatively moves the tool holders with respect to a workpiece to process the workpiece. The operational control method includes determining whether an abnormality has occurred in the cutting-tool during a processing or not, determining whether a simultaneous processing in which at least two or more of the tool holders perform the processings to an identical workpiece is being performed or not and whether the cutting-tool having the detected abnormality is the cutting-tool that is performing the simultaneous processing or not when the abnormality is detected, and causing the tool holder with the cutting-tool having the detected abnormality to take an abnormality avoidance operation and another of the tool holders to take a response operation based on a determination result at the determining of the simultaneous processing.