Intelligent Tool Holder Vibration Monitoring with Resultant Axis Signals
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Solution Overview
Problem
Existing methods for monitoring the operating behavior of tool holders, such as those used in milling operations, provide inadequate and low-informative data due to the use of uniaxial acceleration sensors, making it difficult to interpret and model the operation effectively, leading to unreliable identification of instabilities and tool conditions.
Innovation Solution
A method utilizing a tool holder with a measuring apparatus featuring at least two measurement axes oriented radially with respect to the tool holder axis of rotation, allowing for the calculation of a resultant measurement axis signal, which enhances data informativeness and enables more reliable analysis of operating states, instabilities, and tool conditions by combining signals from multiple axes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a uniaxial acceleration sensor with a single measurement axis is used, then the device complexity is reduced, but the measurement precision and informativeness of the monitoring data deteriorate
Solution Approach 1:
The patent transitions from a uniaxial acceleration sensor to a biaxial or triaxial acceleration sensor, adding measurement dimensions. This dimensional expansion enables comprehensive capture of vibration signals in multiple directions (radial and axial), significantly improving the informativeness and precision of monitoring data while maintaining reasonable device complexity
2Device complexity
If a uniaxial acceleration sensor is used, then the device complexity is reduced, but the reliability of instability identification deteriorates
Solution Approach 1:
By adding measurement axes from uniaxial to biaxial/triaxial configuration, the patent enables more reliable detection of instabilities such as chatter. The multiple measurement dimensions provide more comprehensive vibration information, allowing for more accurate identification of abnormal operating states and tool conditions
3Measurement precision
If multiple measurement axes are used, then the measurement precision and monitoring capability are improved, but the device complexity increases
Solution Approach 1:
The patent employs a multi-functional acceleration sensor that integrates multiple measurement axes (biaxial or triaxial) within a single device. This universal sensor configuration simultaneously captures vibrations in radial and axial directions, providing comprehensive monitoring capability while avoiding the complexity of multiple separate uniaxial sensors
Solution Approach 2:
The patent combines multiple measurement functions into a single acceleration sensor unit. By merging the measurement capabilities of multiple uniaxial sensors into one biaxial or triaxial sensor, the system achieves improved monitoring precision without proportionally increasing device complexity
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
The use of a biaxial or triaxial acceleration sensor with multiple measurement axes improves the modeling and monitoring of tool holder operations, allowing for more accurate identification of abnormal states, instabilities, and tool wear, and enables automatic adaptation of machine tool parameters for improved process control.
Implementation Method 1
The measuring apparatus is a sensor with at least two measurement axes that are oriented substantially radially with respect to the tool holder axis of rotation
Data Source
AI summary
In a method for monitoring an operating behavior of a tool holder, a resultant measurement axis signal is calculated using at least two measurement axis signals of at least two radially oriented measurement axes of a sensor provided in the tool holder. The monitoring is performed using the resultant measurement axis signal or the resultant.