Non-Contact Tool Setting with Pixel-Segmented Imaging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing non-contact tool setting apparatuses, such as break-beam and video-based systems, face inefficiencies in measuring tool profiles due to slow data processing rates and complex, costly hybrid systems, which hinder high-throughput machining operations.
Innovation Solution
A non-contact tool setting apparatus utilizing a 2D imaging sensor with a subset of pixels to generate a trigger signal, allowing for high-speed light intensity monitoring and image acquisition, providing both accurate positional measurement and detailed tool profile analysis while being compatible with prior art systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If video-based tool setters are used to image larger areas of the tool for tool chip detection and coolant/dirt rejection, then measurement capability is improved, but measurement time increases to around four seconds due to slow data readout and processing
Solution Approach 1:
The imaging sensor is divided into a first subset of pixels (used for high-speed trigger signal generation) and a second subset of pixels (used for detailed tool imaging). This segmentation allows simultaneous high-speed detection and detailed measurement without the trade-off present in conventional systems.
2Adaptability or versatility
If a hybrid tool setting system with beam splitter is used to direct light to both camera and photodiode array, then both imaging and detection capabilities are achieved, but device complexity increases due to multiple elements requiring alignment and calibration
Solution Approach 1:
A single imaging sensor performs both functions: the first subset of pixels generates trigger signals for tool detection, while the second subset captures detailed tool images. This eliminates the need for separate photodiode arrays and beam splitters, reducing system complexity while maintaining dual functionality.
3Speed
If break-beam tool setting apparatus is used for quick tool size measurement, then measurement speed is improved, but capability to obtain detailed tool profile information is limited as it requires multiple beam interruptions
Solution Approach 1:
The imaging sensor is segmented into two functional subsets: the first subset provides high-speed trigger signal generation for quick tool detection, while the second subset captures detailed tool profile images. This enables simultaneous achievement of fast detection and detailed measurement in a single 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
Enables fast and accurate tool detection with similar performance to laser-based systems, reduces measurement time, and offers additional imaging capabilities for tool inspection, while being more compact and cost-effective than hybrid systems.
Implementation Method 1
Light emitted by the transmitter (e.g. a beam of light) is passed through a region of free space to the receiver
Implementation Method 2
The receiver thus receives light from the transmitter and generates a trigger signal by analysing the light
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Anon-contact tool setting apparatus(2), suitable for use with machine tools and the like,is described in which a transmitter(10)emits light (12) that is received by a receiver(14). An analysis unit (16) is provided for analysing the light received by the receiver (14) and generating a trigger signal therefrom. The receiver (14) comprises an imaging sensor(60), such as a CMOS or CCD sensor, having a plurality of pixels.The analysis unit (16) generates the trigger signal by analysing the light intensity measured by a first subset of the plurality of pixels(62). This analysis may involve, for example, determining a resultant received light intensity or performing edge detection. The non-contact tool setting apparatus (2) can thus emulate the operation of a laser based non-contact tool setting apparatus whilst also permitting imaging of cutting tools (32).