Tool Taper Glossiness Detection for Early Deterioration Control
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Solution Overview
Problem
Machine tools lack effective methods to detect tool deterioration, particularly in the tapered outer surfaces of tools, which can lead to reduced machining accuracy and tool failure due to chip attachment and vibrations during machining.
Innovation Solution
Incorporating a glossiness measurement unit and deterioration determination unit in the machine tool to assess the condition of the tapered outer surfaces by measuring glossiness and comparing it to a predetermined threshold, with a notification system to alert operators of any deterioration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional inspection methods (image comparison, length measurement) are used, then tool breakage and attachment issues can be detected, but tool surface deterioration cannot be detected early
Solution Approach 1:
The patent replaces traditional mechanical inspection methods (image comparison, physical measurement) with optical measurement technology. A glossiness measurement unit uses light reflection principles to detect surface deterioration of tool tapers, enabling non-contact, high-precision detection of surface condition changes that mechanical methods cannot capture.
Solution Approach 2:
The system performs glossiness measurement of tool tapers before they are mounted on the spindle, during the tool change process. This preliminary detection allows identification of surface deterioration early, preventing deterioration from affecting machining accuracy before it occurs.
2Productivity
If tools are used until failure, then productivity is maintained, but machining accuracy deteriorates and tool failure causes damage
Solution Approach 1:
The system establishes a feedback mechanism where glossiness measurement results are fed back to determine tool condition. When surface deterioration is detected (glossiness below threshold), the system notifies operators to replace tools, creating a closed-loop control that maintains machining accuracy while optimizing tool usage.
Solution Approach 2:
The system enables precise determination of tool service life based on surface condition rather than fixed usage cycles. Tools are replaced based on actual surface deterioration state detected by glossiness measurement, optimizing the balance between tool utilization and machining quality requirements.
3Device complexity
If no surface deterioration detection is implemented, then device complexity is low, but tool and spindle damage occurs due to undetected deterioration
Solution Approach 1:
The patent introduces glossiness measurement as an intermediary parameter to indirectly assess tool surface condition. Instead of directly detecting complex surface deterioration mechanisms (chip attachment, micro-cracks), the system uses light reflection characteristics as a mediator to evaluate overall surface state, simplifying the detection system while maintaining effectiveness.
4Manufacturing precision
If tools are replaced frequently, then machining accuracy is maintained, but productivity decreases due to tool change interruptions
Solution Approach 1:
The system measures tool taper glossiness in advance during the tool change process before tools are mounted on the spindle. This preliminary detection identifies deteriorated tools early, allowing operators to replace only necessary tools and avoid unnecessary tool changes, thereby maintaining productivity while ensuring machining accuracy.
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
Early detection of tool surface deterioration prevents further damage to the tool and spindle, maintaining machining accuracy and extending tool life by allowing for timely replacement of deteriorated tools.
Implementation Method 1
a glossiness measurement unit that measures glossiness of a tapered outer surface of a taper shank of each of the plurality of tools
Data Source
AI summary
A machine tool includes: a tool magazine that stores a plurality of tools; a spindle that holds one of the plurality of tools stored in the tool magazine; a glossiness measurement unit that measures glossiness of a tapered outer surface of a taper shank of each of the plurality of tools; a deterioration determination unit that determines whether or not the tapered outer surface is deteriorated on the basis of the glossiness measured by the glossiness measurement unit; and a notification unit that notifies an operator of deterioration of the tapered outer surface if it is determined by the deterioration determination unit that the tapered outer surface is deteriorated.