Machine Tool Tool Magazine Sequencing for Continuous Machining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing machining methods require frequent manual replacement of machining tools, leading to interruptions in continuous machining, reduced operating efficiency, and prolonged production time due to the need for individual assessment of each tool's accuracy after replacement.
Innovation Solution
A method involving a first and second test-machining step to assess and replace machining tools collectively, allowing continuous machining by ensuring only tools producing acceptable products are used, with automatic replacement by the tool changer, eliminating the need for continuous quality checks during tool changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual replacement of machining tools is performed frequently, then tool accuracy can be maintained, but machining continuity is interrupted and operating efficiency is reduced
Solution Approach 1:
The patent applies preliminary action by performing test machining before full-scale production to pre-assess tool accuracy. Multiple machining tools undergo test machining in advance, and their accuracy is evaluated before they are deployed for continuous production, eliminating the need for interruptions during production for accuracy checks
Solution Approach 2:
The system implements self-service through automatic tool replacement. The tool changer automatically exchanges machining tools based on pre-determined replacement timing, without requiring manual intervention. The control unit manages the entire process of selecting, exchanging, and registering new tools, allowing the system to maintain itself continuously
2Manufacturing precision
If individual accuracy assessment is performed after each tool replacement, then product quality can be ensured, but production time is prolonged
Solution Approach 1:
Accuracy assessment is performed in advance through test machining before tools are used for production. The system conducts test machining with each tool and evaluates accuracy beforehand, so that when tools are replaced during production, no additional accuracy checks are needed and production can continue uninterrupted
Solution Approach 2:
The patent merges the accuracy assessment process with the tool replacement process by implementing batch test machining. Multiple tools are assessed together in test machining operations, and the control unit manages their registration and replacement as a coordinated group, eliminating repeated individual assessments
3Extent of automation
If multiple machining tools of the same type are stored in the tool magazine, then tool replacement can be automated, but the complexity of tool management increases
Solution Approach 1:
The control unit serves multiple functions: it controls test machining operations, evaluates machining accuracy, manages tool replacement timing, operates the tool changer, and registers tool information. This centralized multi-functional control simplifies the overall system architecture despite handling multiple tools
Solution Approach 2:
The system implements feedback through automatic accuracy evaluation. The control unit receives feedback from test machining results, automatically determines when tools need replacement based on accuracy thresholds, and triggers tool replacement only when necessary, simplifying management through data-driven decisions
Data Source
AI summary
A tool magazine of a machine tool holds machining tools of multiple types. The number of stored machining tools of at least one type is more than one. When all the machining tools of the at least one type are unused, a first test-machining step of machining a workpiece using one machining tool of each type is performed. When the machined product is graded as acceptable, a second test-machining step of replacing the machining tool of the at least one type with an unused machining tool in the tool magazine and machining a new workpiece using the one machining tool of each type is performed. The second test-machining step is repeated until all the machining tools are used.