Tool Holder Redistribution in Machine Tools for Continuous Machining
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Solution Overview
Problem
Machine tools face challenges in continuing machining operations when tools become unusable, especially when tools of the same type are unevenly distributed across holders, leading to interruptions in inner and outer diameter machining processes.
Innovation Solution
A machine tool system with a tool rest, machining control unit, tool changing unit, and tool management unit that identifies unused tools and performs either external or internal tool changes to maintain continuous machining by redistributing tools between holders, ensuring that machining can continue even when tools become unusable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If tools of the same type are unevenly distributed across holders, then the tool rest can hold more tools for continuous machining, but when a tool becomes unusable, machining operations are interrupted because no replacement is available
Solution Approach 1:
The system performs preliminary identification of unused tools and proactively redistributes them from majority-side holders to minority-side holders before a tool failure occurs. The tool management unit monitors tool usage status and automatically executes redistribution when conditions are met, ensuring replacement tools are ready in advance.
Solution Approach 2:
The system dynamically adjusts tool distribution based on real-time holder configuration and tool usage status. The tool changing unit automatically repositions tools between holders during operation, transforming a static tool arrangement into a dynamic system that adapts to maintain machining continuity.
2Productivity
If tools are redistributed between holders to maintain machining continuity, then productivity is improved, but the complexity of the tool management system increases
Solution Approach 1:
The tool management unit automatically monitors tool status, identifies unused tools, determines appropriate target holders, and executes redistribution without external intervention. The system serves itself by autonomously managing tool allocation based on pre-set criteria, reducing the need for complex external control mechanisms.
Solution Approach 2:
The system continuously monitors tool usage status and holder configuration, using this feedback to automatically trigger redistribution operations. The tool management unit receives status information, processes it according to redistribution criteria, and executes appropriate actions, creating a closed-loop control system that maintains optimal tool distribution.
Data Source
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AI summary
A machine tool (100) includes a tool rest (102, 164) including first holders (168A) each configured to hold a tool for an inner-diameter side and second holders (168B) each configured to hold a tool for an outer-diameter side, a machining control unit (116) configured to control the tool rest (102, 164) to machine the workpiece, a tool changing unit (114), and a tool management unit (130) configured to identify an unused tool. In a case where a plurality of tools of the same type are held by both the first and second holders (168), when the number of the first holders (168A) is larger than the number of the second holders (168B), and one of the tools held by the second holders (168B) is identified as the unused tool, the tool changing unit (114) changes the unused tool in the second holder (168B) with the tool in the first holder (168A).