Machine Tool Workpiece Position Detection Before Top Cut
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Solution Overview
Problem
The existing machine tools face challenges in maintaining accurate positioning of workpieces during the top-cut process due to supply errors, leading to potential defective products and operational interruptions, especially in unmanned continuous operations.
Innovation Solution
A machine tool system equipped with a spindle, a cutter, and a sensor for abnormality detection, which executes a retry process and sets user-defined retry limits and displacement amounts to ensure the workpiece is correctly positioned before the top-cut process, and includes a cut-off tool breakage detection process to prevent defective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the top-cut process is executed without abnormality detection, then the machining process can proceed continuously, but positioning accuracy of the workpiece end surface deteriorates due to supply errors
Solution Approach 1:
The sensor detects the workpiece position before the top-cut process begins, and the controller determines whether the workpiece is in the correct position in advance. This preliminary detection and determination allow the system to prepare for the cutting operation with confidence in positioning accuracy, resolving the contradiction by ensuring accuracy is verified before production continues.
Solution Approach 2:
The sensor provides feedback about the workpiece position to the controller, which then determines whether the position is appropriate for top-cut. This feedback mechanism enables the system to monitor positioning accuracy in real-time and make necessary adjustments or stop the process if positioning is incorrect, thereby maintaining reliability while allowing continuous operation when conditions are met.
2Reliability
If abnormality detection process is added before top-cut, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The sensor serves multiple functions: it detects the workpiece position before top-cut, monitors during the cutting process, and can detect supply errors. This multi-functionality reduces the need for separate detection systems, thereby improving positioning accuracy without proportionally increasing device complexity.
Solution Approach 2:
The controller performs the abnormality determination process using the sensor data without requiring additional external monitoring systems. The system self-monitors its own positioning accuracy through the integrated sensor-controller determination mechanism, improving reliability while minimizing added complexity.
3Reliability
If retry process is implemented, then positioning accuracy is maintained, but loss of time occurs during abnormality correction
Solution Approach 1:
The retry process dynamically adjusts the workpiece position by moving it in a predetermined direction when positioning abnormalities are detected. This dynamic correction allows the system to quickly restore proper positioning without lengthy manual interventions, maintaining accuracy while minimizing time loss through automated adjustment.
Solution Approach 2:
The system performs abnormality determination before the top-cut process, allowing early detection and immediate retry attempts. By catching positioning errors before they result in defective products, the system can correct issues quickly through predetermined retry movements, maintaining accuracy while reducing overall time loss compared to post-cut detection and correction.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A machine tool capable of preventing production of a defective product. The processing unit 52 determines whether the workpiece exists in the predetermined area. In the event that the workpiece exist in the area, the processing unit 52 execute the top cut process. In the event that the workpiece does not exist in the area, the processing unit 52 determines that the workpiece is in the abnormal position.