Tool Wear Timing from Machining State Time-Series Analysis
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Solution Overview
Problem
Current techniques for determining tool replacement timing in machines are largely subjective and based on experience or intuition, lacking a quantitative approach.
Innovation Solution
A tool replacement timing management system that acquires time series data from machines, calculates machining state variables, and generates tool deterioration state data to predict optimal replacement times using statistical indices and threshold values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If tool replacement timing is determined based on experience or intuition, then the determination can be made simply, but the accuracy and reliability of the determination deteriorates
Solution Approach 1:
The patent replaces the mechanical/manual method of determining tool replacement timing (based on operator experience and intuition) with an automated information processing system. The system acquires machining state data, calculates machining state variables, generates tool deterioration state data, and automatically determines replacement timing, substituting human judgment with computational analysis to improve accuracy while maintaining operational simplicity
Solution Approach 2:
The system enables the machine tool itself to monitor and assess its own tool condition through automated data acquisition and analysis. By having the machine generate and analyze its own machining state data, the system eliminates the need for external manual inspection while providing continuous, objective assessment of tool deterioration
2Productivity
If tool replacement is performed based on fixed intervals or simple criteria, then the operation is simple, but the productivity deteriorates due to premature or delayed replacement
Solution Approach 1:
The patent transitions from static, fixed-interval tool replacement schedules to a dynamic system that continuously monitors machining state variables and adjusts replacement timing based on actual tool deterioration. The system adapts replacement decisions to real-time conditions, allowing optimization of productivity while the automated process maintains operational simplicity
Solution Approach 2:
The system implements continuous feedback by acquiring machining state data, calculating machining state variables, and using this information to determine optimal tool replacement timing. This closed-loop approach ensures tools are replaced based on actual condition rather than fixed schedules, improving productivity while the automated feedback mechanism keeps the process simple to operate
Data Source
AI summary
A tool replacement timing management system includes a data acquisition section configured to acquire time series data indicating a machining state from a machine, a data cutout section configured to cut out specimen data from the time series data according to at least one condition or a combination of conditions selected from among machining, a tool, a workpiece, and a tool speed, a machining state variable calculating section configured to calculate a machining state variable, which is a statistical index, from the specimen data, a tool deterioration state generation section configured to generate tool deterioration state data in which the machining state variable is aligned in a time series, and a tool replacement timing calculating section configured to calculate a tool replacement timing on a basis of the tool deterioration state data.