Wireless Cutting Tool State Monitoring via Optical Sensing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing techniques for monitoring the state of cutting tools during machining lack real-time high-resolution measurement capabilities and fail to display detection information in real time, particularly for rotating cutting tools with multiple blade portions.
Innovation Solution
A state measuring device with measurement units attached to the cutting tool, featuring distortion sensors, temperature sensors, AD converters, and digital wireless communication, which transmits data to a monitor device for real-time display and storage, allowing for high-resolution monitoring of blade portion states during cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a thermocouple is attached to the cutting edge to detect temperature, then the machining state can be detected, but the measurement resolution is only macro level (order of seconds) and high-resolution measurement cannot be performed
Solution Approach 1:
The patent replaces the mechanical/thermal measurement system (thermocouple) with an optical measurement system (light source and light receiver). The optical system measures the state of the cutting tool blade by detecting light reflection or transmission, enabling high-resolution measurements with rapid response times without the thermal inertia limitations of thermocouples.
Solution Approach 2:
The patent introduces light as an intermediary medium to measure the cutting tool state. Instead of directly measuring temperature with a thermocouple, the system uses light interaction (reflection, transmission, or scattering) with the cutting tool blade to infer its state, achieving both high resolution and fast response.
2Loss of information
If detection information is wirelessly transmitted to a management device, then real-time monitoring is enabled, but the system only categorizes and stores data without real-time display
Solution Approach 1:
The patent implements a feedback mechanism where the light receiver detects changes in the cutting tool state and this information is immediately processed and displayed. The system continuously monitors and provides real-time feedback about the cutting tool condition, enabling operators to take immediate action when abnormalities are detected.
Solution Approach 2:
The system performs automatic real-time display and analysis of cutting tool state without requiring manual intervention for data categorization or retrieval. The management device automatically processes the transmitted wireless data and presents it in real-time format, making the monitoring capability readily available.
3Measurement precision
If multiple blade portions are monitored with individual measurement sections, then comprehensive state measurement is achieved, but the device complexity increases
Solution Approach 1:
The patent employs a universal measurement approach where a single type of optical measurement system (light source and light receiver combination) is used for all blade portions. This multi-functional system can measure different blade portions by adjusting the position of the light source or receiver, eliminating the need for multiple specialized measurement sections and reducing overall system complexity.
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
Enables real-time display and storage of cutting tool state measurements, facilitating immediate recognition of tool conditions and potential abnormalities, thereby improving machining efficiency and preventing defects.
Implementation Method 1
one or more measurement sections attached to the blade portion or to a vicinity of the blade portion to measure a state of the blade portion
Implementation Method 2
an AD converter attached to the cutting tool to acquire a measurement value measured by each of the measurement sections at a predetermined sampling rate and perform AD conversion on the measurement value
Implementation Method 3
a transmission section which transmits, on each acquisition of the measurement value from the AD converter, the acquired measurement value using digital wireless communication
Data Source
AI summary
The state measuring device includes a measurement section attached to the blade portion or to a vicinity of the blade portion to measure a state of the blade portion, an AD converter attached to the cutting tool to acquire a measurement value measured by the measurement section at a predetermined sampling rate and perform AD conversion on the measurement value, a transmission section which transmits, on each acquisition of the measurement value from the AD converter, the acquired measurement value using digital wireless communication, and a monitor device provided outside the cutting tool. The monitor device includes a reception section which receives the measurement value transmitted by the transmission section, and a data management section which causes a display section to display the measurement value and causes a storage section to store the measurement value on each reception of the measurement value by the reception section.