Tool-Workpiece Contact Measurement for Accurate Machining Setup
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Solution Overview
Problem
Current machining techniques face challenges in achieving high accuracy due to errors in the relative positional relationship between the workpiece and the cutting tool, leading to unmachined portions or excessive tool wear, especially when the workpiece's position or surface shape deviates from the design specifications.
Innovation Solution
A method and apparatus that involve moving the tool relative to the workpiece to detect contact and acquire coordinate values, deriving errors between measured and design coordinates, and outputting this information to enable precise setup and correction, utilizing a control device with a rotation mechanism and feed mechanism to facilitate accurate positional measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor such as a dedicated tool setter is used to measure the relative positional relationship, then measurement can be performed, but it takes time to attach the sensor and measurement accuracy is limited by attachment errors
Solution Approach 1:
The machining apparatus measures its own tool position and workpiece position using built-in detection devices, eliminating the need for external sensors. The control device calculates tool center position and workpiece surface position based on detection values from the apparatus's own sensors, achieving self-measurement without additional attachment time or external equipment.
Solution Approach 2:
The patent extracts the measurement function from external dedicated sensors and integrates it into the machining apparatus itself. By using the apparatus's built-in detection devices and control calculations, the measurement capability is separated from external attachments and embedded within the system, eliminating attachment time and external sensor dependencies.
2Reliability
If setup is performed for a long time to account for position shifts or surface shape deviations, then measurement completeness may improve, but unmachined portions may remain or tool wear increases
Solution Approach 1:
The control device performs preliminary measurement of the workpiece surface position and tool center position before machining begins. By detecting the actual workpiece surface position and calculating the tool center position in advance, the system prepares accurate position information that prevents unmachined portions and excessive tool wear during the actual machining process.
Solution Approach 2:
The control device uses detection values from the machining apparatus to calculate actual tool and workpiece positions, then uses this feedback information to adjust machining parameters and ensure complete machining. The system continuously monitors and adjusts based on measured positions, preventing both unmachined portions and excessive tool wear.
Data Source
AI summary
A control device moves a cutting tool relative to a workpiece to bring the workpiece and the cutting tool into contact with each other, and acquires a coordinate value of a reference point when the workpiece and the cutting tool come into contact with each other. The control device derives an error between the coordinate value thus acquired and a design coordinate value of the reference point at a position where the workpiece and the cutting tool come into contact with each other, and outputs information on the error.