Machine Tool Workpiece Discharge at Tool Life Limit
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Solution Overview
Problem
In machine tool systems, when a tool reaches the end of its service life during a machining process, the workpiece remains in the machining device, requiring manual operator intervention to extend the tool's service life and discharge the workpiece, which is time-consuming and inefficient.
Innovation Solution
A machine tool system with a controller that automatically stops loading new workpieces and completes machining on remaining workpieces, then discharges them to the unloading platform when the tool's use state reaches a predetermined value, allowing for seamless tool replacement and efficient operation resumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the tool is used to complete the machining process even after reaching the predetermined use state, then the machining process can be completed without stopping, but the workpiece remains in the machining device requiring manual intervention for discharge
Solution Approach 1:
The system performs self-service by automatically detecting when the tool reaches its use state limit and autonomously executing the discharge sequence without requiring operator intervention. The control device monitors tool condition and triggers automatic workpiece discharge, allowing the system to service itself rather than requiring manual operation.
Solution Approach 2:
The system takes preliminary action by pre-determining the tool's use state limit and preparing the automatic discharge sequence before the tool actually fails. The control device is configured to detect approaching tool limits and initiates the discharge process in advance, preventing workpiece accumulation and ensuring smooth transition to tool replacement.
2Reliability
If the operator manually checks remaining workpieces and extends tool service life, then all workpieces can be discharged to the unloading platform, but this operation takes significant time and effort
Solution Approach 1:
The system replaces the mechanical/manual operation of checking and extending tool service life with an automated control system. The control device electronically monitors tool use state, automatically calculates remaining workpiece counts, and executes discharge commands without physical operator intervention, substituting human mechanical actions with automated electronic control.
Solution Approach 2:
The system implements feedback by continuously monitoring the tool's use state and the number of remaining workpieces in the machining device. The control device receives feedback signals about tool condition and workpiece status, then automatically adjusts the discharge process to ensure complete evacuation of workpieces while minimizing intervention time.
3Productivity
If the loader device continues loading workpieces while the tool is being used beyond its service life, then productivity is maintained, but workpieces accumulate in the machining device requiring manual discharge
Solution Approach 1:
The control device uses feedback to monitor both the tool's use state and the workpiece inventory in the machining device. When the tool approaches its use state limit, the system receives feedback signals and automatically coordinates between the loader device and machining device to stop loading and initiate discharge, preventing workpiece accumulation without requiring complex manual management.
Solution Approach 2:
The control device acts as an intermediary that coordinates between the loader device and the machining device. It receives information about tool condition and workpiece status, then mediates the interaction between loading and discharging operations, automatically managing the transition from continuous loading to discharge mode when tool limits are approached.
Data Source
AI summary
[Problem] To easily discharge a workpiece remaining in a machining device or the like to an unloading platform when a use state of a tool has reached a predetermined value.[Means to Solve Problem] A machine tool system 100 comprises: a processor 20 including a machining device 23 that machines a workpiece W with a tool T; a loading platform 10 on which the workpiece W to be processed in the processor 20 is placed; an unloading platform 30 on which the workpiece W processed in the processor 20 is placed; a loader device 40 that transports the workpiece W between the processor 20, the loading platform 10, and the unloading platform 30; and a controller 50 that controls the processor 20 and the loader device 30. When a use state of the tool T has reached a predetermined value, the controller 50 performs control so as to cause the loader device 40 to stop loading the workpiece W from the loading platform 10 to the processor 20, and cause the machining device 23 to perform machining on the workpiece W remaining in the processor 20 and then the loader device 40 to discharge the workpiece W to the unloading platform 30.