Tool Holder Slip Detection Using Periodic Process Signals
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Solution Overview
Problem
During machining of difficult-to-machine materials, axial and rotational slips in tool-tool holder connections lead to tool pull-out, resulting in quality loss and potential tool breakage, with existing solutions either enhancing friction or using additional locking mechanisms, both of which are costly and complicate predictive modeling.
Innovation Solution
A method to detect and prevent rotational slip by analyzing periodic process signals, such as spindle current, to identify changes in phase and period length, allowing for real-time compensation and prevention of tool pull-out without additional design or locking measures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional locking mechanisms or form-locking elements are added to prevent tool pullout, then tool holder reliability improves, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent replaces mechanical locking mechanisms with a sensor-based detection system that monitors tool position and provides feedback to the control unit, enabling electronic compensation instead of mechanical reinforcement
Solution Approach 2:
The patent implements a feedback loop where sensors detect tool position deviations and transmit signals to the control unit, which then adjusts the drive system to compensate for the deviation, creating a closed-loop control system
2Reliability
If laser-induced roughening or surface treatment is applied to increase frictional engagement, then tool holder reliability improves, but manufacturing costs and processing time increase
Solution Approach 1:
The patent replaces physical surface modifications with an electronic monitoring and control system that detects and compensates for slippage through sensor feedback, avoiding additional manufacturing steps
3Measurement precision
If sensors and additional measurement devices are added to detect tool position, then measurement precision improves, but device complexity and costs increase
Solution Approach 1:
The patent utilizes existing machine tool sensors and control systems to perform the detection function, allowing the system to monitor its own state without adding external measurement devices
Solution Approach 2:
The patent employs multi-functional sensors that serve both as position detectors and as triggers for the compensation mechanism, reducing the need for separate dedicated components
Data Source
Figure 1a~2
Figure 3
AI summary
The invention relates to a method and a device for determining the rotational slip of a tool 6 frictionally held in a tool holder 4. By evaluating a phase and/or a period length of a periodic process signal of the tool 6, a rotational slip of a tool 6 frictionally held in the tool holder 4 is determined.