Non-Contact Tool Setting for Small-Tool Beam Occlusion Errors
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Solution Overview
Problem
Non-contact tool setting apparatuses face measurement inaccuracies when measuring tools with diameters less than the beam width, as they only partially occlude the light beam, leading to errors in tool length determination due to the need for tightly focused and complex optical designs.
Innovation Solution
A method for tool length measurement that involves moving the tool through the light beam, generating a trigger signal when the beam intensity crosses a threshold, and applying a tool length correction to account for the nominal tool diameter being less than the beam width, using techniques such as adjusting the trigger threshold or delay to compensate for partial occlusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the beam width is reduced to ensure tools can substantially occlude the beam, then measurement accuracy for small tools is improved, but the optical design becomes more complicated and expensive
Solution Approach 1:
The patent changes the parameter of beam intensity threshold from a fixed value to a dynamically adjustable value based on tool diameter. By adjusting the trigger threshold parameter according to the specific tool being measured, the system can accurately measure tools of varying sizes without requiring a tightly focused narrow beam, thus reducing optical complexity while maintaining measurement precision
Solution Approach 2:
The system transitions from a static fixed threshold trigger to a dynamic adjustable threshold that adapts to different tool diameters. This allows the measurement system to remain accurate across various tool sizes without requiring complex optical focusing mechanisms, resolving the contradiction between measurement precision and device complexity
2Measurement precision
If the beam is tightly focused to improve measurement accuracy, then small tools can be measured accurately, but the system becomes more sensitive to contamination and misalignment
Solution Approach 1:
By changing the trigger threshold parameter based on tool diameter rather than using a tightly focused beam, the system maintains measurement accuracy while using a more robust optical configuration that is less susceptible to contamination and misalignment, thereby improving operational reliability
Solution Approach 2:
The patent uses a wider beam that creates a more robust optical path, effectively copying the measurement capability to work with tools smaller than the beam width by applying correction algorithms, rather than relying on a fragile tightly focused beam that is easily disrupted by environmental factors
3Ease of operation
If a fixed trigger threshold is used, then the system is simple to operate, but measurement errors occur when tool diameter is less than beam width
Solution Approach 1:
The system transitions from a static fixed threshold to a dynamic adjustable threshold that automatically adapts to the specific tool diameter being measured. This maintains ease of operation as the adjustment is automated, while eliminating measurement errors that occur with fixed thresholds when measuring tools smaller than the beam width
Solution Approach 2:
The system incorporates feedback by adjusting the trigger threshold based on the measured tool diameter. The measurement process itself provides information that is used to correct the threshold setting, ensuring accurate measurements across all tool sizes without complicating the user interface or operation
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
This approach allows for accurate tool length measurements using wider, less tightly focused light beams, reducing the need for expensive and high-maintenance optics and improving measurement reliability for small tools.
Implementation Method 1
a transmitter for emitting a light beam having a beam width and a receiver for receiving the light beam
Implementation Method 2
the receiver generating a beam intensity signal describing the intensity of received light
Implementation Method 3
measuring a length of a tool having a nominal tool diameter less than the beam width such that fully inserting the tool into the light beam only partially occludes the light beam
Data Source
AI summary
A method for tool measurement using a non-contact tool setting apparatus mounted to a machine tool, which includes a transmitter for emitting a light beam having a beam width and a receiver for receiving the light beam. The receiver generates a beam intensity signal describing the intensity of received light. The method is for measuring a tool having a nominal tool diameter less than the beam width so fully inserting the tool feature into the light beam would only partially occlude the beam. The method includes moving the tool through the beam thereby causing a change in the intensity signal and generating a trigger signal when the intensity signal crosses a trigger threshold. The tool size is derived using the trigger signal generated. Also, a step of applying a tool length correction that accounts for the nominal tool diameter of the tool being less than the beam width.