Tool Lifespan Search in Machining Systems for Timely Replacement
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Solution Overview
Problem
Managing and efficiently replacing tools in a machining system becomes increasingly difficult as the number of tools grows, especially when tools approach or reach the end of their lifespan, necessitating a technology for searching tool information based on remaining lifespan.
Innovation Solution
A machining system with a display unit and search unit that allows input of search conditions related to tool lifespan, enabling identification and transfer of tools whose remaining lifespan satisfies the conditions, including tools in storage, workstations, and machine tools, with a transfer device for efficient tool replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of tools to manage is increased, then productivity is improved, but tool management difficulty increases
Solution Approach 1:
The patent replaces manual tool management with an automated information processing system. A terminal device automatically acquires tool information from machine tools, calculates remaining lifespan based on usage data, and generates search results without manual intervention. This substitution of mechanical/manual operations with automated information processing resolves the contradiction by maintaining high productivity while reducing management complexity.
Solution Approach 2:
The system enables self-service tool management where the machine tools themselves provide their own usage data, and the terminal device automatically processes this data to determine replacement timing. The system serves itself by automatically acquiring data from connected machine tools and generating actionable search results, reducing the burden on operators while managing large numbers of tools.
2Loss of time
If tool replacement is delayed until end of lifespan, then loss of time is reduced, but reliability deteriorates
Solution Approach 1:
The patent calculates and displays the remaining lifespan of tools before they actually reach the end of their useful life. By showing tools sorted by remaining lifespan in ascending order, the system enables preliminary action - replacing tools proactively before failure occurs. This resolves the contradiction by allowing timely replacement (maintaining reliability) without unnecessary early replacement (minimizing time loss).
Solution Approach 2:
The system continuously monitors tool usage and provides feedback on remaining lifespan through the search results display. This feedback mechanism allows operators to see which tools need replacement soonest and act accordingly, balancing the need for reliability with minimizing unnecessary replacement time.
3Device complexity
If manual tool replacement work is performed, then device complexity is reduced, but loss of time increases
Solution Approach 1:
The patent replaces manual tool management processes with an automated information processing system. The terminal device automatically acquires tool information, calculates remaining lifespan, and generates sorted search results, eliminating manual tracking and assessment time while keeping the physical replacement process simple.
Solution Approach 2:
The terminal device acts as an intermediary between machine tools and operators. It automatically collects usage data from machine tools, processes this information to determine remaining lifespan, and presents actionable search results to operators. This intermediary function eliminates the time-consuming manual assessment process while keeping the overall system relatively simple.
Data Source
AI summary
A machining system that uses a plurality of tools to machine a workpiece includes a display unit capable of displaying a search screen for searching for a tool. The search screen can accept input of a search condition related to the remaining lifespan of a tool. The machining system also includes a search unit for searching for a tool whose remaining lifespan or amount of usage satisfies the search condition, among the plurality of tools, based on the amount of usage of each of the tools from a new state. The search screen displays information regarding a tool that satisfies the search condition as a search result.