Tool Wear Detection Using Multi-Band Acoustic Thresholds
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Solution Overview
Problem
Existing tool abnormality detection systems are prone to erroneous determinations due to the inclusion of noise sound waves from ambient sources, which can interfere with the detection of tool wear and breakage.
Innovation Solution
A tool abnormality detection system that utilizes a detector to generate determination signals in both a fundamental frequency band and higher frequency bands, comparing these signals to respective wear and breakage thresholds to accurately determine tool wear and breakage, and optionally incorporates a resonant unit to enhance the detection of wear-indicative sound waves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a detector is used to monitor sound waves for tool abnormality detection, then the detection capability is improved, but noise sound waves from ambient sources cause erroneous determinations
Solution Approach 1:
The sound spectrum is segmented into multiple frequency bands (first frequency band for fundamental frequency, second frequency band for higher frequencies). By dividing the frequency spectrum and analyzing each band separately, the system can distinguish between wear-indicative sounds and noise, reducing erroneous determinations while maintaining detection accuracy.
2Device complexity
If only fundamental frequency band is analyzed, then the detection system is simple, but higher frequency wear-indicative sound waves are missed
Solution Approach 1:
The system extends analysis from a single frequency dimension (fundamental frequency only) to multiple frequency dimensions by incorporating both the first frequency band (fundamental) and the second frequency band (higher frequencies). This multi-dimensional frequency analysis improves wear detection completeness without excessively increasing system complexity, as the same detector is used for both bands.
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
The system effectively reduces erroneous determinations by distinguishing between wear-indicative and noise sound waves, thereby improving the accuracy of tool condition assessment.
Implementation Method 1
a detector configured to detect a sound wave generated in processing a workpiece with a tool and output a detection signal based on the sound wave
Implementation Method 2
optionally incorporates a resonant unit to enhance the detection of wear-indicative sound waves
Data Source
AI summary
A tool abnormality detection system includes a detector configured to detect a sound wave generated in processing a workpiece with a tool and output a detection signal based on the sound wave, and a controller configured to generate, based on the detection signal, determination signals indicating intensities in respective frequency bands: a fundamental frequency band of a wear-indicative sound wave; and a higher frequency band that is higher than the fundamental frequency band, and determine whether the tool is worn by comparing each of the determination signals to its respective wear threshold which is set for the respective frequency bands.