Tool Holder Slippage Detection Using Periodic Process Signals
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Solution Overview
Problem
Existing methods for preventing tool slippage and pull-out in machining processes, such as those involving difficult-to-machine materials like titanium alloys, are either costly or lead to over-determined connections that are difficult to predict mechanically, and do not effectively detect or prevent axial and rotational slippage.
Innovation Solution
A method that measures and evaluates the phase and period length of periodic process signals, such as spindle current or vibration signals, to detect rotational slippage, which is correlated with axial slippage and tool pull-out, allowing for real-time compensation and prevention without additional sensors or costly constructional measures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional form fit support (locking elements) is used to prevent tool slippage, then tool pull-out prevention is improved, but device complexity increases and mathematical prediction of mechanical behavior becomes impossible
Solution Approach 1:
The patent replaces complex mechanical locking elements with a sensor-based detection system that uses acoustic emission sensors and signal processing to monitor tool slippage. This substitution maintains tool pull-out prevention capability while eliminating the need for additional form fit support structures, thereby reducing device complexity and enabling mathematical modeling of the tool-tool holder system.
Solution Approach 2:
The patent introduces acoustic emission signals as an intermediary parameter to detect tool slippage. Instead of directly preventing slippage through mechanical means, the system uses acoustic emissions as a mediator to indirectly detect and monitor slippage conditions, allowing for early warning and corrective action without modifying the mechanical connection structure.
2Reliability
If laser-induced roughening is applied to improve frictional connection, then slippage reduction is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces mechanical/physical surface modification methods (laser-induced roughening) with a sensor-based detection system. Instead of permanently altering the tool surface to improve friction, the system uses acoustic emission sensors to detect slippage in real-time, maintaining manufacturing simplicity while achieving reliable slippage monitoring and prevention.
3Device complexity
If frictional connection is used to hold tool in tool holder, then device simplicity is maintained, but axial and rotational slippage occurs under load
Solution Approach 1:
The patent implements a feedback-based monitoring system using acoustic emission sensors that continuously detect tool slippage conditions. The system processes the acoustic signals in real-time and provides feedback about the tool-tool holder connection status, enabling early detection of slippage and allowing for corrective action before tool pull-out occurs, thereby maintaining connection stability without increasing structural complexity.
Solution Approach 2:
The patent uses acoustic emission signals as an intermediary to detect the state of the frictional connection. Instead of directly measuring mechanical slippage, the system captures acoustic emissions generated during slippage events, providing an indirect but reliable method to monitor connection stability while maintaining the simplicity of the frictional connection structure.
Data Source
AI summary
A method and a device for determining a rotational slippage of a tool that is frictionally held in a tool holder. The rotational slippage of the tool is determined by evaluating a phase and/or a period length of a periodic process signal from the tool.