Integrated Tool Shank Force Sensing for Dynamic Machining Monitoring
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Solution Overview
Problem
Current methods for measuring tool forces in machine tools, such as dynamometers and strain gauges, are either bulky, costly, or lack precision and dynamic resolution, making them unsuitable for high-precision machining and highly dynamic applications.
Innovation Solution
A tool with a force sensor integrated into the tool shank or holder, allowing direct measurement of tool forces with high precision and dynamics, using a compact piezoelectric force sensor that measures forces like compressive, bending, or cutting forces, and can be arranged in a recess or intermediate piece for optimal sensitivity and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If dynamometers are used to measure tool forces, then measurement capability is provided, but device size becomes large and installation flexibility is reduced
Solution Approach 1:
The force sensor is extracted from a separate large dynamometer device and integrated directly into the tool shank structure. This allows the measurement function to be obtained while eliminating the bulk of the measuring device, enabling compact installation in the tool holder without occupying excessive space in the machine room.
Solution Approach 2:
The force sensor is nested within the tool shank structure, with the sensor integrated into the tool shank body itself. This nesting approach allows the measuring device to be contained within the existing tool geometry, minimizing additional volume while maintaining measurement capability.
2Measurement precision
If dynamometers are used to measure tool forces, then measurement capability is provided, but manufacturing and procurement costs become high
Solution Approach 1:
The force sensor functionality is merged with the tool shank structure, combining the measuring device with the tool itself. This integration eliminates the need for separate expensive dynamometer equipment, reducing both manufacturing complexity and procurement costs while maintaining measurement capability.
Solution Approach 2:
The force sensor is implemented as a compact, integrated component within the tool shank that can be manufactured at lower cost compared to traditional dynamometers. The sensor integrates seamlessly with the tool lifecycle, providing economical measurement without requiring expensive separate equipment.
3Measurement precision
If strain gauges are used to measure tool forces, then measurement is possible, but flexibility requirements reduce manufacturing precision
Solution Approach 1:
The strain gauge measurement system is replaced with a force sensor that does not require the same flexibility conditions. The new sensor design eliminates the need for flexible tool structures, allowing rigid, precision-manufactured tools to be used without compromising measurement capability.
4Measurement precision
If torque wrenches are used to measure clamping force, then clamping force measurement is possible, but precision is reduced due to friction coefficients
Solution Approach 1:
The force sensor acts as an intermediary measurement device that directly measures the clamping force between the tool shank and tool holder. This intermediate measurement approach bypasses the friction-dependent torque transmission method, providing direct force measurement that is not influenced by surface friction coefficients.
5Measurement precision
If measuring plates with sensors are used to measure forces, then force measurement is provided, but additional mass reduces dynamic performance
Solution Approach 1:
The force sensor is extracted from a heavy measuring plate structure and integrated directly into the tool shank. This extraction eliminates the additional mass of a separate measuring plate, reducing the overall inertia of the measuring system and improving dynamic response capability for highly dynamic machining applications.
Solution Approach 2:
The mass parameter of the measuring system is significantly reduced by integrating the force sensor into the tool shank rather than using a separate measuring plate. This parameter change from heavy plate to lightweight integrated sensor enables the system to respond dynamically to rapid force changes during high-speed machining operations.
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 precise and dynamic measurement of tool forces, reducing false alarms and improving reaction times in automated production by accurately detecting tool wear or breakage, and allowing real-time monitoring of machining processes.
Implementation Method 1
using a compact piezoelectric force sensor that measures forces like compressive, bending, or cutting forces
Data Source
AI summary
A tool received in a tool holding fixture of a tool holder includes a tool shank defining a recess and a force sensor arranged in the recess. During operation of the tool, the force sensor measures a tool force exerted by the tool shank onto the tool holder. A method for measuring a tool force by using the tool includes the steps of: arranging the force sensor between the tool shank and the tool holding fixture; clamping the force sensor by means of a clamping device of the tool holding fixture; operating the tool; and using the force sensor to measure the tool force exerted by the tool shank onto the tool holder.