Tool Position Signal Analysis for Workpiece Surface Defect Detection
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Solution Overview
Problem
Current methods for detecting surface quality issues in workpieces, such as scratches and artefacts, require high precision equipment and manual visual assessment, leading to increased time and cost due to the small size of these defects and the need for separate measurement.
Innovation Solution
A method that estimates surface quality by determining a reference signal representing the difference between ideal and real tool positions during a reference phase and a test signal during the finishing process, using statistical features like mean value and standard deviation to identify anomalies, allowing for automated detection without additional measurement equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If separate measurement using high precision equipment or manual visual assessment is used to detect surface artefacts, then measurement precision is improved, but device complexity and loss of time increase
Solution Approach 1:
The patent uses tool position measurement signals as an intermediary to indirectly assess surface quality. Instead of directly measuring the workpiece surface with complex high-precision equipment, the system measures the tool position during machining and uses this data to infer surface quality, thereby avoiding the need for separate complex measurement devices while maintaining detection capability
Solution Approach 2:
The patent replaces direct mechanical/optical surface measurement systems with a signal processing approach based on tool position data. By substituting physical surface contact or optical inspection with electronic signal analysis from the machining process itself, the system achieves surface quality assessment without requiring additional complex measurement equipment
2Measurement precision
If separate measurement using high precision equipment or manual visual assessment is used to detect surface artefacts, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The patent performs surface quality assessment during the machining process itself by continuously monitoring tool position signals. By conducting the quality check preliminarily during manufacturing rather than as a separate post-processing step, the system eliminates additional measurement time while maintaining detection precision through real-time signal analysis
Solution Approach 2:
The system maintains continuous monitoring of tool position signals throughout the machining operation, enabling uninterrupted surface quality assessment. This continuous action allows quality detection to occur simultaneously with manufacturing without requiring separate measurement operations, thereby eliminating time loss while preserving measurement precision
3Ease of operation
If manual visual assessment is used to detect surface artefacts, then ease of operation is improved, but productivity decreases
Solution Approach 1:
The system enables the machining process to self-assess quality by automatically analyzing tool position signals generated during manufacturing. The machining system serves its own quality control function without requiring separate manual inspection operations, thereby maintaining operational simplicity while eliminating productivity loss associated with manual assessment time
4Productivity
If automated detection using tool position signals is used, then productivity is improved, but measurement precision may worsen
Solution Approach 1:
The system employs feedback mechanisms by continuously monitoring tool position signals and comparing them against expected machining patterns. This feedback loop enables automated detection to achieve high precision by identifying deviations that indicate surface artefacts, maintaining measurement accuracy while enabling high-speed automated assessment
Solution Approach 2:
The patent transforms physical surface quality parameters into measurable tool position signal parameters. By changing the measurement parameter from direct surface characteristics to tool position deviations, the system enables automated electronic detection that maintains precision while dramatically improving productivity through rapid signal processing
Data Source
AI summary
A method for checking the quality of a workpiece, a surface section of the workpiece is finished with a manufacturing device. A reference signal representing a time dependent difference between an ideal tool position and a real tool position of a tool of the manufacturing device in a reference phase is determined when finishing the workpiece. A test signal representing a time dependent difference between an ideal tool position and a real tool position of a tool of the manufacturing device in an operation phase is determined when finishing the workpiece. A mean value and a standard deviation value from the reference signal is determined. Data points of the test signal are determined, where the test signal deviates from the mean value more than a defined multiple of the standard deviation value. The surface quality of the workpiece is estimated by using the determined data points.