DESC:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003

COMPLETE SPECIFICATION

(See Section 10 and Rule 13)

Title of invention:
A SYSTEM AND METHOD FOR REAL TIME DETECTION OF A CNC MACHINE AXES TILT

Applicant:
BEML Limited
A company Incorporated in India under the Companies Act, 1956
Having Address As:
BEML Soudha, 23/1, 4th Main,
Sampangirama Nagar, Bengaluru - 560 027,
Karnataka, India

The following specification particularly describes the invention and the manner in which it is to be performed.
CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
[001] The present invention claims priority from Indian patent application numbered IN 202241057327filed on 06th October, 2022.
FIELD OF THE INVENTION
[002] The present subject matter described herein generally relates to a system and method for real-time detection of a CNC machine axes tilt, and more specifically for the system and method for real-time detection of a CNC machine axes tilt or deviation.
BACKGROUND
[003] In conventional method the vibrational sensors like accelerometers are fitted near the motor or the machine body to identify or analyze the vibrations of the machine for predicting the condition of the machine. This is a manual method to detect the tilt in the machine axes. Manually checking the machine geometry is done using a spirit level, a dial gauge or a granite square. The dial gauge will give the deviation of each axes but the same is corrected by trial and error method only which is a tedious process. There are no direct method to identify the tilt.
[004] Also, the telescopic covers or the guards of the machine are opened to ensure if any disturbances or abnormalities have occurred on the machine guideways. The operator of the machine will come to know about the any deviations or abnormalities only when it is reflected on the component or probing.
[005] Hence to overcome the aforesaid drawbacks a method has to be developed to detect real time axes tilt of a machine.
OBJECTS OF THE INVENTION
[006] Main object of the present disclosure is to provide a system and method for real-time detection of a CNC machine axes tilt to continuously detect the physical tilt or deviation of CNC machine axes.
[007] Another object of the present disclosure is to provide the system and method for real-time detection of a CNC machine axes tilt due to any reasons like aging, machine accidents and others.
[008] Yet another object of the present disclosure is to provide the system and method for real-time detection of a CNC machine axes tilt by using gyro and accelerometer sensors module.
[009] Another object of the present disclosure is to provide the system and method for real-time detection of a CNC machine axes tilt to help in reverting the original geometrical position of the CNC machine.
[0010] Yet another object of the present disclosure is to provide the system and method for real-time detection of a CNC machine axes tilt to initiate corrective action immediately for such tilting of the machine.
[0011] Another object of the present disclosure is to provide the system and method for real-time detection of a CNC machine axes tilt to provide a real time monitoring of the physical tilt or shift in the CNC machine axes.
[0012] Yet another object of the present disclosure is to provide the system and method for real-time detection of a CNC machine axes tilt to avoid damages to the CNC machine and components or job.
[0013] Another object of the present disclosure is to provide the system and method for real-time detection of a CNC machine axes tilt to calibrate a new position as zero position for tuning the axes of the CNC machine after resetting.
[0014] Yet another object of the present disclosure is to provide the system and method for real-time detection of a CNC machine axes tilt which is simple, cost effective and easy to implement.
SUMMARY
[0015] Before the present system is described, it is to be understood that this application is not limited to the particular machine, device or system, as there can be multiple possible embodiments that are not expressly illustrated in the present disclosures. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope of the present application. This summary is provided to introduce aspects related to system and method for real-time detection of a CNC machine axes tilt t, and the aspects are further elaborated below in the detailed description. This summary is not intended to identify essential features of the proposed subject matter nor is it intended for use in determining or limiting the scope of the proposed subject matter.
[0016] The present subject matter discloses a system for real-time detection of a CNC machine axes tilt comprising atleast one guideway provided on the CNC machine, plurality of sensors are mounted on the corners of said atleast one guideway for sensing tilt in any of the x, y, z axes. A controller is provided to receive signals from the plurality of sensors. An audio, a CNC alarm and a visual alarm is activated by the controller. A power source serves as a backup supply for the controller.
[0017] A method for real-time detection of a CNC machine axis tilt comprising the steps of mounting plurality of sensors on the corners of atleast one guideway. Generating a pitch Y, a roll X and a yaw Z signals from the plurality of sensors. Receiving the pitch Y, the roll X and the yaw Z signals by the controller from the plurality of sensors. Analyzing the signals received from the plurality of sensors by the controller for detecting the tilt if any. Displaying and generating plurality of tilt values on the visual display, a fault signal to the CNC machine along with an audio signal to hooter. Calibrating positions of the CNC machine axes to zero values.
STATEMENT OF INVENTION
[0018] The present subject matter discloses a system for real-time detection of a CNC machine axes tilt comprising atleast one guideway provided on the CNC machine, plurality of sensors are mounted on the corners of said atleast one guideway for sensing tilt in any of the x, y, z axes. A controller is provided to receive signals from the plurality of sensors. An audio, a CNC alarm and a visual alarm is activated by the controller. A power source serves as a backup supply for the controller.
[0019] In an embodiment, the plurality of sensors are provided to be a gyro and an accelerometer sensors (G1, G2, G3 and G4).
[0020] In an embodiment, the plurality of sensors are for monitoring a pitch Y, a roll X and a yaw Z.
[0021] In an embodiment, the controller is a microcontroller.
[0022] In an embodiment, the visual alarm is a liquid-crystal display (LCD) or a light-emitting diode (LED) display), and the audio signal is a hooter and a fault signal to the CNC machine.
[0023] In an embodiment, the power source is a battery for supplying backup power to the controller.
[0024] In another embodiment, a method for real-time detection of a CNC machine axis tilt comprising the steps of mounting plurality of sensors on the corners of atleast one guideway. Generating a pitch Y, a roll X and a yaw Z signals from the plurality of sensors. Receiving the pitch Y, the roll X and the yaw Z signals by the controller from the plurality of sensors. Analyzing the signals received from the plurality of sensors by the controller for detecting the tilt if any. Displaying and generating plurality of tilt values on the visual display, a fault signal to the CNC machine along with an audio signal to hooter. Calibrating positions of the CNC machine axes to zero values.
[0025] In an embodiment, each of the pitch Y is the vertical rotation seen from front, each of the roll X is the horizontal rotation seen from front, and the yaw Z is the horizontal rotation on a flat surface seen from top.
[0026] In an embodiment, the tilt signals of the pitch (Y), the roll (X) and the yaw (Z) are detected in both positive and negative axes.
[0027] In an embodiment, the preset value is in the range of zero values with 0±5micron.

BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The foregoing summary, as well as the following detailed description of embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the disclosure, there is shown in the present document example constructions of the disclosure, however, the disclosure is not limited to the specific methods and device disclosed in the document and the drawing. The detailed description is described with reference to the following accompanying figures.
[0029] Figure 1 illustrates a CNC Machine linear axis with two guideways of a system for real-time detection of a CNC machine axes tilt, in accordance with an embodiment of the present subject matter.
[0030] Figure 2 illustrates sensors axis movement of the system for real-time detection of a CNC machine axes tilt, in accordance with an embodiment of the present subject matter.
[0031] Figure 3 illustrates the CNC machine with single linear guideways of the system for real-time detection of a CNC machine axes tilt, in accordance with an embodiment of the present subject matter.
[0032] Figure 4 illustrates a block diagram of the system and method for real-time detection of a CNC machine axes tilt, in accordance with an embodiment of the present subject matter.
[0033] Figure 5 illustrates a logic table for the system and method for real-time detection of a CNC machine axes tilt, in accordance with an embodiment of the present subject matter.
[0034] Figure 6 illustrates a method for real-time detection of a CNC machine axes tilt, in accordance with an embodiment of the present subject matter.
[0035] The figures depict various embodiments of the present disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION OF INVENTION
[0036] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words "comprising", “having”, and "including," and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Although any devices and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the exemplary, devices and methods are now described. The disclosed embodiments are merely exemplary of the disclosure, which may be embodied in various forms.
[0037] Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art will readily recognize that the present disclosure is not intended to be limited to the embodiments illustrated, but is to be accorded the widest scope consistent with the principles and features described herein.
[0038] The present subject matter discloses a system (100) for real time detection of a CNC machine axes tilt as shown in figure 1. Figure 1 (100) illustrates single linear axis of a CNC machine comprises of two guideways (102). A gyro and an accelerometer sensor modules G1, G2, G3 and G4 (104) are fitted on the four corners of the CNC machines guideways (102) as shown in figure 1. The sensors (104, 304) monitors continuously the pitch Y (204), the roll X (202) and the yaw Z (206) as shown in figure 2. The pitch Y (204) represents the vertical rotation seen from front. The roll X (202) represents the horizontal rotation seen from front. The yaw Z (206) represents the horizontal rotation on a flat surface seen from top. The signals pitch (Y) (204), roll (X) (202) and yaw (Z) (206) in positive and negative axes are collected from all four sensors (104). Further, each sensors (104) generates 3 values (202, 204 and 206). These 3 values (202, 204 and 206) provides the information on the tilt of the CNC machine (102).
[0039] Now referring to figure 4, the signals from the four sensors (402, 404, 406 and 408) are received by a microcontroller (410) for analyzing the data as per the logic table (500) of figure 5. Further, the microcontroller (410) displays the tilt values on the display (412), provides a fault signal (416) to the CNC machine and hooter for audio signal (414) if the limit exceeded the allowable set values. The three axes values pitch X, roll Y and yaw Z from each sensors (104, 304) are displayed on the LCD or LED display (412).
[0040] Now referring to figure 5, once the CNC machine (100, 300) is installed and commissioned. The original positions are calibrated as zero values as shown in the logic table (500). Further, the original position calibration can range between 0±5micron.
[0041] In another embodiment as shown in figure 3, relates to the system (300) for real time detection of a CNC machine axes tilt. The CNC machine (300) has a single linear guideway (302) with two sensors G1, G2 (304) at two corners of the guideway. Further, the method of detecting tilt or deviation of the CNC machine (300) remains the same as described previously. This method can be implemented in all the linear axes of the CNC machine to get the complete tilt of all the axes of the whole CNC machine.
[0042] The Sensors (104, 304) are fitted permanently with the CNC machine guideways (102, 302) to achieve the real time detection of CNC machine axes tilt. The microcontroller (410) are energized with machine supply and also protected with battery backup supply (not shown in figure).
[0043] Now referring to figure 6, relates to a method (600) for real time detection of a CNC machine axes tilt comprising the step of plurality of sensors (104, 304) are mounted on the corners of atleast one guideway (102, 302) as shown in step 602. In step 604, a pitch Y (204), a roll X (202) and a yaw Z (206) signals are generated from the plurality of sensors (104, 304). In step 606, the pitch Y (204), the roll X (202) and the yaw Z (206) signals are received by the controller (410) from the plurality of sensors (104, 304). In step 608, the signals received from the plurality of sensors (104, 304) are analyzed by the controller (410) for detecting the tilt if any. In step 610, plurality of tilt values are displayed on the visual display (412), an audio signal (414) to hooter along with a fault signal (416) for CNC machine is generated. In step 612, positions of the CNC machine axes are calibrating zero values.
[0044] This method for real time detection of machine tilt or deviation can be used in any other machines with guide ways.
[0045] Exemplary embodiments discussed above may provide certain advantages. Though not required to practice aspects of the disclosure, these advantages may include the following.
[0046] Some embodiments of the subject matter enable to provide the system and method for real time detection of a CNC machine Axes tilt to continuously detect the physical tilt or deviation of CNC machine axes.
[0047] Some embodiments of the subject matter enable to provide the system and method for real time detection of a CNC machine Axes tilt due to any reasons like aging, machine accidents and others.
[0048] Some embodiments of the subject matter enable to provide the system and method for real time detection of a CNC machine Axes tilt by using gyro and accelerometer sensors module.
[0049] Some embodiments of the subject matter enable to provide the system and method for real time detection of a CNC machine Axes tilt to help in reverting the original geometrical position of the machine.
[0050] Some embodiments of the subject matter enable to provide the system and method for real time detection of a CNC machine Axes tilt to initiate corrective action immediately for such tilting of the machine.
[0051] Some embodiments of the subject matter enable to provide the system and method for real time detection of a CNC machine Axes tilt to provide a real time monitoring of the physical tilt or shift in the CNC machine axes.
[0052] Some embodiments of the subject matter enable to provide the system and method for real time detection of a CNC machine Axes tilt to avoid damages to the CNC machine and components or job.
[0053] Some embodiments of the subject matter enable to provide the system and method for real time detection of a CNC machine Axes tilt to calibrate a new position as zero position for tuning the axes of the CNC machine after resetting.
[0054] Some embodiments of the subject matter enable to provide the system and method for real time detection of a CNC machine Axes tilt which is simple, cost effective and easy to implement.
[0055] Following is a list of elements and reference numerals used to explain various embodiments of the present subject matter.
Reference Numeral Element Description
100 CNC Machine linear axis With Two Guideways
102 CNC Machine Guideways
104 Gyro And Accelerometer Sensors Modules
200 Sensors Axes Movement
202 Roll X Axis
204 Pitch Y Axis
206 Yaw Z Axis
300 CNC Machine with Single Linear Guideways
302 CNC Machine Guideway
304 Gyro And Accelerometer Sensors Modules
400 Block Diagram
402 Gyro And Accelerometer Sensor 1
404 Gyro And Accelerometer Sensor 2
406 Gyro And Accelerometer Sensor 3
408 Gyro And Accelerometer Sensor 4
410 Microcontroller
412 LCD/ LED Display
414 Audio Signal to Hooter
416 Signal To CNC Machine
500 Logic Table
600 Method for Real time Detection

Equivalents
[0056] With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
[0057] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances, where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."
[0058] Although implementations for the system and method for real-time detection of a CNC machine axes tilt have been described in language specific to structural features and/or methods, it is to be understood that the appended claims are not necessarily limited to the specific features described. Rather, the specific features are disclosed as examples of implementation for the system and method for real-time detection of a CNC machine axes tilt.
,CLAIMS:
1. A system (100, 300) for real-time detection of a CNC machine axes tilt comprising:
atleast one guideway (102, 302) configured to be provided on the CNC machine (100, 300);
plurality of sensors (104, 304) configured to be mounted on the corners of said atleast one guideway (102, 302) for sensing tilt in any of the x, y, z axes;
a controller (410) configured to receive signals from the plurality of sensors (104, 304);
an audio, a CNC alarm and a visual alarm (414, 416, 412) configured to be activated by the controller (410); and
a power source configured to serve as a backup supply for the controller (410).

2. The system (100, 300) as claimed in claim 1, wherein the plurality of sensors (104, 304) are configured to be a gyro and an accelerometer sensors (G1, G2, G3 and G4).

3. The system (100, 300) as claimed in claim 1, wherein the plurality of sensors (104, 304) are configured to monitor a pitch Y (204), a roll X (202) and a yaw Z (206).

4. The system (100, 300) as claimed in claim 1, wherein the controller (410) is a microcontroller.

5. The system (100, 300) as claimed in claim 1, wherein the visual alarm (412) is configured to be a liquid-crystal display (LCD) or a light-emitting diode (LED) display (412), and the audio signal is a hooter (414) and a fault signal (416) to the CNC machine (100, 300).

6. The system (100, 300) as claimed in claim 1, wherein the power source is a battery for supplying backup power to the controller (410).

7. A method (600) for real-time detection of a CNC machine axis tilt comprising the steps of:
mounting, plurality of sensors (104, 304) on the corners of atleast one guideway (102, 302);
generating, a pitch Y (204), a roll X (202) and a yaw Z (206) signals from the plurality of sensors (104, 304);
receiving, the pitch Y (204), the roll X (202) and the yaw Z (206) signals by the controller (410) from the plurality of sensors (104, 304);
analyzing, the signals received from the plurality of sensors (104, 304) by the controller (410) for detecting the tilt if any;
displaying and generating, plurality of tilt values on the visual display (412), a fault signal to the CNC machine (416) along with an audio signal to hooter (414); and
calibrating, positions of the CNC machine axes to zero values.

8. The method (600) as claimed in claim 7,wherein each of the pitch Y (204) is configured to be the vertical rotation seen from front, each of the roll X (202) is configured to be the horizontal rotation seen from front, and the yaw Z (206) is configured to be the horizontal rotation on a flat surface seen from top.

9. The method (600) as claimed in claim 7, wherein the tilt signals of the pitch (Y) (204), the roll (X) (202) and the yaw (Z) (206) are detected in both positive and negative axes.

10. The method (600) as claimed in claim 7, wherein the preset value is configured to be ranging zero values with 0±5micron.