Tool Magazine Origin Detection Using Radial Distance Sensing

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Solution Overview

Problem

Conventional machine tools require manual operation for detecting the origin point of a rotary tool magazine, which is complex and prone to inaccuracies.

Innovation Solution

A machine tool system featuring a rotary unit with a measured portion and a distance sensor outside the rotary unit, controlled by a processor to automatically detect the origin point by measuring distance changes, allowing for precise and automated detection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual operation is used for detecting the origin point, then the detection process is simple in terms of device complexity, but the detection precision and reliability are poor and prone to inaccuracies

Engineering Contradiction:

Improveorigin point detection precisionVSAvoiddetection system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces manual mechanical detection operations with an automated optical detection system. A sensor detects a measured portion (such as a reflective marker or geometric feature) on the rotary unit to automatically determine the origin point position, eliminating manual operation errors while maintaining manageable system complexity through standardized sensor components

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The detection system is designed to automatically detect and identify the origin point without requiring external manual intervention. The sensor continuously monitors the position of the measured portion on the rotary unit, and the control unit automatically processes this data to establish the origin point, enabling the system to self-calibrate and operate autonomously

Inventive Principle:

Principle #25Self-service

2Productivity

If manual operation is used for detecting the origin point, then the device structure is simple, but the productivity and efficiency are reduced due to complex manual procedures

Engineering Contradiction:

Improvetool exchange operation efficiencyVSAvoiddetection system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Manual detection operations are replaced with an automated sensor-based detection system that continuously monitors the rotary unit position. The control unit automatically processes sensor data to identify the origin point, enabling rapid and accurate tool exchange operations without manual intervention, thereby significantly improving productivity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The detection system operates continuously during rotary unit rotation, constantly monitoring the position of the measured portion. This continuous detection eliminates interruptions and delays associated with manual detection, maintaining uninterrupted tool exchange operations and maximizing equipment utilization

Inventive Principle:

Principle #20Continuity of useful action

3Reliability

If manual operation is used for detecting the origin point, then the system is simple to operate, but the reliability is poor due to human errors

Engineering Contradiction:

Improveorigin point detection reliabilityVSAvoiddetection operation ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Manual detection operations are replaced with automated sensor detection that objectively measures the position of the measured portion on the rotary unit. This eliminates human errors in judgment and measurement, significantly improving detection reliability. The system requires minimal operation input, maintaining ease of use through automatic origin point identification

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The sensor provides continuous feedback about the rotary unit position to the control unit, which processes this information to accurately determine the origin point. This closed-loop feedback mechanism ensures reliable detection by continuously verifying position data and automatically adjusting for any deviations, eliminating reliance on human judgment

Inventive Principle:

Principle #23Feedback

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables accurate and automated detection of the origin point, improving efficiency and reducing manual errors in tool exchange operations.

Implementation Method 1

a sensor disposed outside of the rotary unit in a radial direction that is perpendicular to the rotary axis, and configured to detect the measured portion

Methodology Applied

Scientific EffectDistance measurement:

Data Source

PatentUS11396075B2Method of detecting origin point of machine tool and tool magazine

Publication Date: 2022.07.26 FANUC LTD

AI summary

A machine tool includes a tool magazine configured to hold a plurality of tools, the tool magazine having a rotary unit rotatable around a predetermined rotary axis and a measured portion provided in the rotary unit, a sensor disposed outside of the rotary unit in a radial direction that is perpendicular to the rotary axis, and configured to detect the measured portion, and a controller configured to detect a position of an origin point of the rotary unit based on a result of the detection by the sensor.