Virtual Tool Holder Force Sensing From Machine Energy Data
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Solution Overview
Problem
Existing tool machines face challenges in measuring and controlling radial forces on tool holders, which can lead to damage due to laborious and cost-intensive direct force measurement processes.
Innovation Solution
A virtual sensor process that records time-dependent data of workpieces, tools, tool holders, and drive axes to calculate radial forces as the difference between real and virtual total energy intake, eliminating the need for additional sensors and allowing for real-time force measurement during machine program execution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional sensors are used to measure forces acting on the tool holder, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent creates a virtual copy of the force measurement function through simulation. Instead of using physical sensors to directly measure forces, the system creates a virtual model that replicates the mechanical behavior and calculates forces through simulation, eliminating the need for additional physical sensing components
Solution Approach 2:
The patent replaces the mechanical sensor-based force measurement system with a computational approach. The physical measurement mechanism (sensors) is substituted by a virtual simulation system that uses mathematical models and existing operational data to calculate forces, transforming a mechanical measurement problem into an information processing problem
2Reliability
If direct force measurement is implemented, then reliability of force data is improved, but ease of manufacture deteriorates
Solution Approach 1:
The virtual simulation creates a digital replica of the force measurement function, allowing reliable force data to be obtained without adding physical measurement components to the manufactured machine
Solution Approach 2:
The system uses its own existing operational data and built-in simulation capabilities to generate force measurements, making the machine self-sufficient for force monitoring without requiring external sensor additions
3Device complexity
If virtual sensor simulation is used, then device complexity is reduced, but measurement precision may deteriorate
Solution Approach 1:
The virtual simulation system incorporates feedback loops where simulation results are continuously compared with actual operational data, and the model parameters are adjusted to improve accuracy. This iterative refinement process ensures that the virtual measurements converge toward true force values
Solution Approach 2:
The system performs preliminary calibration and validation of the virtual simulation model before actual force measurements are taken. By pre-establishing the accuracy of the simulation model through controlled testing and parameter optimization, the system ensures measurement precision is maintained even without additional physical sensors
Data Source
AI summary
A process for operating a virtual sensor for determining the condition of a tool holder on a tool machine, such as a spindle, and the condition of a tool machine which has at least one tool holder and at least one tool, attached or attachable to the tool holder, which allows a workpiece to be processed by running a machine program, and which has at least one control unit comprising at least one sensor.