Non-Contact Tool Setting with Segmented Imaging Sensor Triggering
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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 complexity in 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 analysis and image capture, providing both accurate positional detection and detailed tool profile analysis while maintaining compatibility with prior art systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If video/camera 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 of pixel data from the image sensor
Solution Approach 1:
The imaging sensor array is segmented into multiple regions, with specific regions (first subset of pixels) dedicated to high-speed trigger signal generation and other regions (second subset of pixels) dedicated to detailed tool imaging and profile analysis. This segmentation allows simultaneous high-speed detection and detailed measurement without time conflict.
Solution Approach 2:
Only a first subset of pixels (partial action) is used for generating the trigger signal at high speed, while the remaining pixels are used for detailed imaging. This partial use of the sensor array for the critical timing function enables high-speed operation without requiring the entire array to operate at the same speed.
2Adaptability or versatility
If hybrid tool setting systems with beam splitter are 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:
The imaging sensor array performs multiple functions: it serves as both the detection element for trigger signal generation and as the imaging element for tool profile capture. This multi-functionality eliminates the need for separate photodiode arrays and beam splitters, significantly reducing system complexity while maintaining both detection and imaging capabilities.
Solution Approach 2:
The functions of the camera sensor and photodiode array are merged into a single imaging sensor array. The sensor array simultaneously provides pixel data for both trigger signal generation (through the first subset of pixels) and detailed tool imaging (through the second subset of pixels), eliminating the need for separate optical paths and components.
3Speed
If break-beam tool setting devices with laser source and photo-detector are used for quick tool size measurement, then measurement speed is improved, but measurement capability is limited and cannot obtain detailed tool profile information without moving the tool through the beam multiple times
Solution Approach 1:
The system transitions from one-dimensional break-beam detection to two-dimensional imaging sensor detection. The imaging sensor array provides spatial resolution across the tool profile, enabling detailed measurement of tool features in a single pass rather than requiring multiple passes through a simple break-beam setup.
Solution Approach 2:
The imaging sensor array serves dual purposes: it generates high-speed trigger signals for tool detection and simultaneously captures detailed tool profile images. This multi-functionality allows the system to achieve both the speed of break-beam devices and the measurement detail of video-based systems without the slow processing times of the latter.
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 and measurement with improved throughput, reducing measurement time and operational complexity compared to existing systems, while offering additional imaging capabilities for tool inspection.
Implementation Method 1
a transmitter for emitting light, a receiver for receiving light emitted by the transmitter, and an analysis unit for analysing the light received by the receiver
Data Source
AI summary
A non-contact tool setting apparatus, suitable for use with machine tools and the like, is described in which a transmitter emits light that is received by a receiver. An analysis unit is provided for analysing the light received by the receiver and generating a trigger signal therefrom. The receiver includes an imaging sensor, such as a CMOS or CCD sensor, having a plurality of pixels. The analysis unit generates the trigger signal by analysing the light intensity measured by a first subset of the plurality of pixels. This analysis may involve, for example, determining a resultant received light intensity or performing edge detection. The non-contact tool setting apparatus can thus emulate the operation of a laser based non-contact tool setting apparatus whilst also permitting imaging of cutting tools.