Tool Holder Sensor System for Machining Parameter Optimization
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Solution Overview
Problem
Current methods for setting up and monitoring operating parameters of workpiece processing machines, particularly those with rotating tool holders, are imprecise, leading to suboptimal machining results, tool wear, and potential economic losses due to inefficient tool usage and detection of anomalies.
Innovation Solution
A method that records and evaluates measured variables such as axial force, torque, and bending moments using sensors like strain gauges and SAW sensors, plotting these values in a coordinate diagram to analyze tool stress and optimize machining parameters for extended tool life and consistent machining quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If operating parameters are set up based on machine operator experience and general information, then setup can be performed without complex measurement systems, but machining precision and optimal parameter selection are compromised
Solution Approach 1:
The patent replaces complex mechanical measurement systems with a sensor-based electrical measurement system. Strain gauges and SAW sensors convert mechanical stresses (axial force, bending moments, torque) into electrical signals that can be processed electronically, providing precise machining parameter data without requiring complex mechanical measurement apparatus.
Solution Approach 2:
The measurement system utilizes the tool holder's own structure as the measurement platform. The strain gauges and SAW sensors are integrated directly onto the tool holder, allowing it to self-measure the forces and moments it experiences during machining, eliminating the need for separate external measurement devices.
2Measurement precision
If tool wear is monitored only through periodic optical assessment after processing specified workpieces, then monitoring equipment remains simple, but tool wear detection precision and timely intervention capability are reduced
Solution Approach 1:
The measurement system enables continuous monitoring of tool condition throughout the machining process rather than periodic checks. The strain gauges and SAW sensors continuously measure axial forces, bending moments, and torque, providing real-time data on tool wear and anomalies, allowing for timely intervention before catastrophic failure occurs.
Solution Approach 2:
The patent replaces optical assessment methods with electrical sensing. Instead of periodically stopping the machine to visually inspect the tool under a microscope, the system uses strain gauges and SAW sensors to continuously detect mechanical changes indicating tool wear through electrical measurements during operation.
3Measurement precision
If motor current is monitored to detect tool wear and anomalies, then monitoring can be performed without additional sensors, but measurement precision for small tools and low machining forces is insufficient
Solution Approach 1:
The measurement system applies local quality sensing by placing strain gauges and SAW sensors directly on the tool holder where forces are applied. This localized measurement approach provides precise data about the actual mechanical loads on small tools and cutting edges, rather than inferring from general motor current at the machine level.
Solution Approach 2:
The patent replaces indirect electrical current monitoring with direct mechanical stress measurement using strain gauges and SAW sensors. These sensors directly measure the mechanical forces and moments acting on the tool holder, providing accurate detection of small forces and low machining conditions that current monitoring cannot detect.
4Productivity
If bending moments and directional loads are not measured, then the measurement system remains simple, but analysis of tool stress and optimization of machining parameters is limited
Solution Approach 1:
The measurement system adds dimensional measurement capability by detecting bending moments in multiple directions (lateral and longitudinal) in addition to axial forces and torque. This multi-dimensional measurement approach provides comprehensive spatial information about tool stresses, enabling detailed analysis of complex loading conditions and optimization of machining parameters from multiple perspectives.
Solution Approach 2:
The measurement system segments the total tool stress into distinct components: axial forces, lateral bending moments, longitudinal bending moments, and torque. By measuring each component separately with appropriate sensors, the system enables detailed analysis of specific stress sources and their individual impacts on tool wear and machining quality.
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 approach provides precise analysis and monitoring of machining processes, enabling optimal setup and operation of workpiece processing machines, reducing tool wear, and detecting anomalies, thus improving machining efficiency and reducing economic losses.
Implementation Method 1
values for at least one of the following measured variables which occur on the tool during interaction with the workpiece and are transmitted to the tool holder are recorded on the tool holder: a. an axial force acting in a direction parallel to the first axis, b. a torque applied with respect to the first axis or an axis parallel to the first axis, c. bending moments or bending moment components according to direction and magnitude
Implementation Method 2
A method that records and evaluates measured variables such as axial force, torque, and bending moments using sensors like strain gauges and SAW sensors
Data Source
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AI summary
The invention discloses a method for setting up and/or monitoring operating parameters of a workpiece machining machine, which has a tool holder and means for moving a workpiece and the tool holder relative to each other at least along a first axis. The method according to the invention is characterized in that, during machining operation of the tool holder equipped with a tool and when the tool engages a workpiece, values for at least one of the following measured quantities occurring at the tool during interaction between the tool and the workpiece and transmitted to the tool holder are detected at the tool holder and recorded for the machining process: a. an axial force acting in a direction parallel to the first axis, b. a torque acting with respect to the first axis or an axis parallel thereto, c.Bending moments or bending moment components according to direction and magnitude, wherein the determined values for the at least one measured quantity are used to set up the operating parameters in a manner that is coordinated with regard to an extended service life of the tool used while simultaneously keeping the machining time below a maximum machining time and/or to monitor the machining process with regard to its reproducibility and/or tool wear and/or machine failure of the workpiece machining machine.