Patent Application
20120243952
The present disclosure relates to an on-line vibration detected and intelligent control apparatus for cutting process, designed to be integrated with an input/output (I/O) module of a machine tool, and the method thereof, by which the vibration of the machine tool during a machining process can be detected and used as base for updating and thus changing either the spindle speed or the feed rate of the machine tool so as to eliminate the vibration of the machine tool during the machining process, resulting that not only the wear and tear of the cutting tools used in the machining process can be reduced, but also the spindle accuracy of the machine tool can be maintained for achieving a better machining accuracy.
A machine tool is a powered mechanical device, typically used to fabricate metal components of machines by machining, which is the selective removal of metal.
Generally, machine tools can be divided into turning machines, drilling machines, milling machines and grinding machines, but no matter which type a machine tool is, it is primarily comprises: a frame; a workbench, mounted on the frame; at least one spindle, each disposed at a position above the workbench or proximate to the same while being configured with one blade holder that is provided for at least one cutting tool to mounted thereat; wherein the at least one cutting tool can be a milling cutter, a drilling bit, a reamer, or a boring cutter, that can be bring along to rotate in high speed or to move in a reciprocating manner for performing a machining process upon a workpiece.
Most times being unintended and undesirable that can result in imprecise processing and deteriorated surface qualities, machining vibration during the machining of any machine tool can be the most troubling problem that the machine tool industry tries to avoid. Vibration can result from a number of conditions, acting alone or in combination, such as inproper configuration in cutting parameters, dynamic unbalance in cutting tool assembly, chattering correspond to the relative movement between the workpiece and the cutting tool that can result in waves on the machined surface, thickness variation in workpiece that is to be machined, and resonance, etc. Since the effect of machining vibration can severe that, for instance, it can accelerate rates of wear in cutting tools, can cause the surface quality of a workpiece to deteriorate, and even cause deterioration in spindle accuracy, it is important for a machining center to be capable of preventing any machining vibration in an automatic manner during machining without inducing any adverse affect upon its machining efficiency.
Therefore, it is in need of an apparatus for preventing machining vibration of a machine tool.
The present disclosure relates to an on-line vibration detected and intelligent control apparatus for cutting process, designed to be integrated with an input/output (IO) module of a machine tool, and the method thereof, by which the vibration of the machine tool during a machining process can be detected and used as base for updating and thus changing either the spindle speed or the feed rate of the machine tool so as to eliminate the vibration of the machine tool during the machining process, resulting that not only the wear and tear of the cutting tools used in the machining process can be reduced, but also the spindle accuracy of the machine tool can be maintained for achieving a better machining accuracy.
In a exemplary embodiment, the present invention provides an on-line vibration detected and intelligent control apparatus for cutting process, designed to be integrated with an input/output (I/O) module of a machine tool as the machine tool is comprised of: a workbench; a spindle, disposed at a position proximate to the workbench; and a controller, configured with an I/O module, the apparatus comprising: at least one vibration sensor, each disposed at a position selected from the group consisting of: the spindle and the workbench; a vibration signal processing unit, configured with a microcomputer processor and being electrically connected to the at least one vibration sensor and the I/O module.
In another exemplary embodiment, the present invention provides an intelligent control method for an on-line vibration detection apparatus that is integrated with an input/output (I/O) module of a machine tool, the method comprising the steps of:
In further another exemplary embodiment, the present invention provides an intelligent control method for an on-line vibration detection apparatus that is integrated with an input/output (I/O) module of a machine tool, the method comprising the steps of:
By the aforesaid on-line vibration detected and intelligent control apparatus for cutting process, designed to be integrated with an input/output (I/O) module of a machine tool, and the method thereof, a vibration of a machine tool that is induced during a machining process will be detected by vibration sensors, and then the vibration sensors will send a vibration signal relating to the vibration to a microcomputer processor to be used as basis for calculating a gain of spindle speed or a gain of feed rate, and thus, based upon the gain, either the spindle speed or the feed rate of the machine tool is changed so as to eliminate the vibration of the machine tool during the machining process, resulting that not only the wear and tear of the cutting tools used in the machining process can be reduced, but also the spindle accuracy of the machine tool can be maintained for achieving a better machining accuracy.
Further scope of applicability of the present application will become more apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating exemplary embodiments of the disclosure, are given by way of illustration only, since various changes and modifications within the spirit and scope of the disclosure will become apparent to those skilled in the art from this detailed description.
The present disclosure will become more fully understood from the detailed description given herein below and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present disclosure and wherein:
For your esteemed members of reviewing committee to further understand and recognize the fulfilled functions and structural characteristics of the disclosure, several exemplary embodiments cooperating with detailed description are presented as the follows.
Please refer to
In this embodiment, the on-line vibration detected and intelligent control apparatus comprises: at least one vibration sensor 20 and a vibration signal processing unit 21, in which each vibration sensor can be an MEMS sensor or an accelerometer, whereas the accelerometer is made of a quartz material.
In addition, the vibration signal processing unit 21 is further configured with an electronic I/O module 210, a microcomputer processor 211 and a band-pass filter 212 in a manner that the electronic I/O module 210, the microcomputer processor 211 and the band-pass filter 212 are electrically connected to each other. Moreover, the electronic I/O module 210 can be a solid-state electronic I/O module, the vibration signal processing unit 21 can be selectively mounted on the spindle 10, and the electronic I/O module 210 is electrically connected to the I/O module 120.
As shown in
Please refer to
ES=KP*(EK−EK1)+KI*EK;
KP=(KPmax−KPmin)*((10−abs(EK))/(10−STDAYV))+(KPmax−KPmin)*((8−abs(EK−EK1))/8);
KI=(KImax−KImin)*((abs(EK)−STDAYYV)/(10−STDAYV))+(KImax−KImin)*((abs(EK−EK1)−0)/8);
wherein,
Please refer to
In this embodiment, the on-line vibration detected and intelligent control apparatus comprises: at least one vibration sensor 50 and a vibration signal processing unit 51. It is noted that the controller 42, the vibration sensor 50 and the vibration signal processing unit are basically the same as those disclosed in the prior embodiment, but at different locations. Thus, the description relating to the structures and functions of the controller 42, the vibration sensor 50 and the vibration signal processing unit 51 will not be described further hereinafter.
Moreover, the vibration sensor 50 can be selectively arranged at the spindle 40, the workbench 41 or the workpiece holder 43, and the vibration signal processing unit 51 is electrically connected to the controller 42 and the vibration sensor 50.
To sum up, the present disclosure provides an on-line vibration detected and intelligent control apparatus for cutting process, designed to be integrated with an input/output (I/O) module of a machine tool, which can detect vibration of the machine tool during a machining process by the use of vibration sensors that are selectively arranged at the spindle, the workbench, the blade holder or the workpiece holder, and then calculate a gain according to the detected vibration signal. Thereafter, by adding the gain to the current spindle speed or the current feed rate of the machine tool, an updated spindle speed or an updated feed rate is obtained so as to be used in the machining of the machine tool for compensating and thus preventing the vibration of the machine tool during the machining process, resulting that not only the wear and tear of the cutting tools used in the machining process can be reduced, but also the spindle accuracy of the machine tool can be maintained for achieving a better machining accuracy.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the disclosure, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present disclosure.
| Number | Date | Country | Kind |
|---|---|---|---|
| 100110038 | Mar 2011 | TW | national |
This non-provisional application claims priority under 35 U.S.C. §119(a) on Patent Application No. 100110038 filed in Taiwan, R.O.C. on Mar. 24, 2011, the entire contents of which are hereby incorporated by reference.
