Integrated Tool Holder Sensor Module for Real-Time State Detection
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Solution Overview
Problem
Existing sensor systems for machine tools require significant equipment and manufacturing expenditures, are application-specific, and can only detect steady-state conditions, lacking flexibility and real-time monitoring capabilities.
Innovation Solution
A modular sensor module integrated into tool elements and machine tools, using additive manufacturing for complex geometries, allowing real-time detection of system states with reduced equipment costs and flexibility to adapt to different applications by positioning sensors like vibration sensors in rotating parts and diverting coolant flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are specifically inserted in separated design into different channels/pockets of the tool holder, then sensor detection capability is improved, but device complexity and manufacturing expenditures increase
Solution Approach 1:
The patent combines multiple separated sensor systems into a single integrated sensor module that can be inserted into one pocket of the tool holder. This module integrates sensors for measuring different physical quantities (force, acceleration, temperature) that were previously distributed across multiple separate channels, thereby reducing device complexity while maintaining detection capability
Solution Approach 2:
The sensor module is designed as a universal component that can detect multiple types of physical quantities simultaneously using a single integrated unit. This multi-functional module replaces the need for application-specific separate sensor designs, reducing both device complexity and manufacturing expenditures while maintaining comprehensive detection capability
2Reliability
If tool holder is adapted with special design for sensor integration, then sensor system functionality is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent segments the sensor system into a separate, standalone module that can be manufactured independently using standard processes. This modular sensor module is then inserted into a conventional tool holder pocket, eliminating the need to adapt the tool holder itself. This approach maintains reliable sensor functionality while preserving the ease of manufacture of standard tool holders
3Measurement precision
If application-specific design of measuring technology is used, then measurement accuracy for specific task is improved, but adaptability to different applications deteriorates
Solution Approach 1:
The sensor module is designed as a dynamic, reconfigurable system that can be adapted to different applications by changing the specific sensor configuration within the module rather than redesigning the entire measurement system. The module maintains accurate measurement capability across different machining tasks through its flexible internal architecture
Solution Approach 2:
The integrated sensor module provides universal measurement capability across multiple applications by combining multiple sensor types in a single unit. This allows the same module design to serve different machining tasks (milling, drilling, turning) with appropriate sensor activation, maintaining measurement accuracy while providing adaptability to different applications
4Stability of the object's composition
If steady-state detection is used, then system stability is improved, but real-time monitoring capability deteriorates
Solution Approach 1:
The sensor module enables continuous real-time monitoring of machining processes by continuously capturing transient transitions and system states. This continuous detection capability provides both real-time monitoring speed and system stability through uninterrupted measurement data streams that capture both steady-state and transient conditions
Data Source
AI summary
The invention relates to: sensor modules for e.g. a tool holder, wherein the sensor unit is integrated as a structural entity; tool or machine elements designed with such sensor modules; and a machining/machine tool comprising such a sensor module. The sensor modules have a sensor system for detecting system states or operating states which occur during the machining of a workpiece.