Description:FIELD
The present disclosure relates to a load monitoring system of a tool spindle in a machine. In particular, the disclosure relates to a, system for detecting mismatch in a deployed component(s) in relation to a corresponding part-program fed to the machine and a method thereof.
DEFINITION
As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicates otherwise.
PRE-DEFINED LOAD: The term "pre-defined load" hereinafter refers to a range of load generated on a spindle of machine tool when the tool starts removing a layer of material from a workpiece in an operative configuration of the machine.
PRE-DEFINED TIME: The term "pre-defined time" hereinafter refers to initial time interval when the tool is just approaches a tip of workpiece for removing a layer of material thereof.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Generally, during machining, a stock or material is progressively machined until the stock reaches an intended shape and size. The machining operation primarily involves different operations such as turning, drilling and milling for processing the material or semi-finished part into a finished or a desired part, which respectively require removing the material by rotating the raw material against a stationary cutting tool or vice versa. Cutting tool/s, comes into contact with the workpiece, and achieves the operations, for example the turning, the cutting, the drilling, sanding, knurling, facing, deformation, or other operations as required.
Generally, on a single machine, different types of semi-finished workpieces are required to be loaded on the workpiece holder (one at a time) for machining the desired surfaces. The different workpiece requires different part-programs for machining i.e the different workpiece have specific machining sequences as per the requirements. Since, some of the semi-finished workpiece looks identical in shapes except only the difference in size or dimension; it is possible that wrong or incorrect workpiece may get loaded on to the machine with respect to the part-program selected or a wrong part-program gets selected with respect to the workpiece to be machined. In both the cases, thereby causing a mismatch between the selected program and the workpiece loaded on to the machine. As the different semi-finished workpiece have different dimensions, therefore, each of the workpiece would require different part-programs for their processing. Therefore, there is a possibility that, if operator forgets to change the part programs on the machine system as per the loaded workpiece or if the operator selected a wrong part-program with respect to the loaded workpiece, it might result in a component rejection, machine accident, and the tool breakage.
Therefore, there is a need of a system which can detect the mismatch of the component being loaded (a deployed component(s)) in relation to the corresponding part-program selected and that eliminates the aforementioned drawbacks.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide a system for detecting anomalies in a deployed component(s) during machining.
Another object of the present disclosure is to provide a system for detecting anomalies in a deployed component(s), which is programmable as per the requirement.
Still another object of the present disclosure is to provide a system for detecting anomalies in a deployed component(s), which is economical.
Yet another object of the present disclosure is to provide a system for detecting anomalies in a deployed component(s) that does not make change in machine configuration.
Still another object of the present disclosure is to provide a system for detecting anomalies in a deployed component(s) that generates alerts for the anomalies in the deployed component(s) with respect to the corresponding selected part-program.
Yet another object of the present disclosure is to provide a system for detecting anomalies in a deployed component(s) that eliminates the component rejection.
Still another object of the present disclosure is to provide a system for detecting anomalies in a deployed component(s) that avoids the tool breakage.
Yet another object of the present disclosure is to provide a system for detecting anomalies in a deployed component(s) that avoids the machine accident.
Yet another object of the present disclosure is to provide a system for detecting anomalies in a deployed component(s) that enhances the productivity of the machine.
Still another object of the present disclosure is to provide a method for detecting anomalies in the deployed component(s) during machining.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a system for detecting anomalies in a deployed component(s) during machining. The system comprises a cutting tool, a control unit and at least one sensing unit. The cutting tool is mounted on a spindle of a machine, for machining the deployed component(s). The control unit is configured to receive at least one selected part-program so as to actuate the cutting tool. The sensing unit is configured with the spindle to detect the load acting on the cutting tool for an initial predefined-time during machining, and to thereby generate a load signal. The control unit configured to receive the load signal and to detect the anomalies if the generated load signal not matches with the selected part-program in an operative configuration, and further configured to generate an alert for the anomalies.
In an embodiment, the system further comprises a programmable logic control (PLC). The PLC is configured to input the selected part-program and is further configured to actuate and control the cutting tool in accordance with the part-program.
Further, the control unit is configured to receive the load signal from the at least one sensing unit. The alert is configured to be generated by the control unit based on the comparison of the generated load signal with the at least one predefined-load as defined by the part-program fed to the control unit.
In an embodiment, the control unit is configured to stop the machining of the component(s) when the control unit identifies anomalies that the generated load signal not matches with the part-program.
In another embodiment, the control unit is configured to continue the machining of the component(s) when the control unit identifies that the generated load signal matches with the selected part-program.
In another embodiment, the machine is selected from a group consisting of a numerically controlled (NC) machine, and a computer numerically controlled (CNC) machine.
Further, the control unit comprises a memory, an analog-to-digital converter, a comparator and an alerting module. The memory is configured to store the at least one predefined load for the deployed component(s). The analog-to-digital converter is communicating with the sensing unit. The analog-to-digital converter is being configured to receive the sensed load signal, and is further configured to convert the sensed load signal to a digital sensed load. The comparator is communicating with the analog-to-digital converter. The comparator is being configured to receive the digital sensed load, and is further configured to compare the digital sensed load with the at least one predefined load. The alerting module is communicating with the comparator, and configured to generate the alert.
In an embodiment, the predefined time is in the range of 03 sec to 05 seconds.
Further, the present disclosure also envisages a method for detecting the anomalies in the deployed component(s) during machining. The method comprises the following steps:
• mounting the cutting tool on the spindle of the machine, configured to machine the deployed component(s);
• selecting at least one part-program for the control unit;
• sensing load acting on the cutting tool using at least one sensing unit configured with the spindle and further generating the load signal; and
• receiving the generated load signal by the control unit and detecting the anomalies in the deployed component(s) if the generated load signal not matches with the selected part-program in an operative configuration and generating an alert for the anomalies.
In an embodiment, the method includes the steps of replacing the deployed component(s) in accordance with the part programs to eliminate the anomalies of with the deployed component(s).
In another embodiment, the method includes the steps of selecting another part-program in accordance with the deployed component(s) to stop further alert.
Therefore, the above anomalies are corrected either by replacing the deployed component(s) in accordance with the part-programs or selecting another part-program in accordance with the deployed component(s) to stop further alert.
Since, the system provides alerts for the anomalies when the generated load signal not matches with the selected part-program in the initial pre-defined time, thereby; the system saves a large number of components from rejection. Also, since the system generates the alert, therefore it saves the tool from the tool breakage and any type of component rejection.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The system and method for detecting anomalies in a deployed component(s) during machining, of the present disclosure, will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates a flow chart for a conventional system;
Figure 2 illustrates a block diagram arrangement of the component system as per an embodiment of the present disclosure;
Figure 3 illustrates a flow chart for machining the deployed component(s) as per an embodiment of the present disclosure;
Figure 4 illustrate an arrangement of the deployed components as per an exemplary embodiment of the present disclosure; and
Figure 5A and Figure 5B illustrate a programmable machine control (PMC) ladder flow chart and an alert message as per the system disclosed in Figure 4.
LIST OF REFERENCE NUMERALS
100 system
70 first model
60 second model
50 control unit
50A memory
50B analog-to-digital converter
50C comparator
50D alerting module
40 deployed components
30 programmable logic control (PLC)
20 sensing unit
15 spindle
10 cutting tool
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms “a”, “an”, and “the” may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms “comprises”, “comprising”, “including”, and “having”, are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
When an element is referred to as being “mounted on”, “engaged to”, “connected to”, or “coupled to” another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region or section from another component, region, or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Terms such as “inner”, “outer”, “beneath”, “below”, “lower”, “above”, “upper”, and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.
Typically, in a single machine, the different semi-finished workpiece are required to be loaded on the workpiece holder (one at a time) for machining the desired surfaces. Since, the semi-finished workpiece looks identical in shapes except only the difference in size or dimension; it is possible that wrong or incorrect workpiece may get loaded on to the machine with respect to the part-program selected or a wrong part-program gets selected with respect to the workpiece to be machined. In both the cases, thereby causing a mismatch between the selected program and the workpiece loaded on to the machine. Therefore, there is a possibility that, if operator forgets to change the part programs on the machine system as per the loaded workpiece or if the operator selected a wrong part-program with respect to the loaded workpiece, it might result in a component rejection, machine accident, and the tool breakage. The Figure 1 illustrates a flow chart for a conventional system.
To overcome the aforementioned drawbacks, the present disclosure envisages a system 100 for detecting anomalies in a deployed component(s) 40 during machining as shown in Figure 2 and Figure 3. The Figure 2 illustrates a block diagram arrangement of the component system as per an embodiment of the present disclosure; and the Figure 3 illustrates a flow chart for machining of deployed component(s) as per an embodiment of the present disclosure.
The system 100 is configured to detect the anomalies in a deployed component(s) 40 during machining. The system 100 comprises a cutting tool 10, a control unit 50 and at least one sensing unit 20. The cutting tool 10 is mounted on a spindle 15 of a machine. The cutting tool 10 is configured for machining the deployed component(s) 40. The control unit 50 is configured to receive at least one selected part-program by means of a programmable logic control (PLC) 30. The part-program is configured to actuate the cutting tool 10. The sensing unit 20 is configured with the spindle 15 to detect the load acting on the cutting tool 10 for an initial predefined-time during machining. The sensed load is being transmitted to the control unit 50 in the form a load signal.
In an embodiment, the machine is selected from a group consisting of a numerically controlled (NC) machine, and a computer numerically controlled (CNC) machine.
Further the control unit 50 comprises a memory 50A, an analog-to-digital converter 50B, a comparator 50C and an alerting module 50D. The memory 50A is configured to store the at least one predefined load for the deployed component(s) 40. The analog-to-digital converter 50B is communicating with the at least one sensing unit 20. The analog-to-digital converter 50B is being configured to receive the sensed load signal, and is further configured to convert the sensed load signal to a digital sensed load. The comparator 50C is communicating with the analog-to-digital converter 50B. The comparator 50C is being configured to receive the digital sensed load, and is further configured to compare the digital sensed load with the at least one predefined load stored in the memory 50A. The alerting module 50D is communicating with the comparator 50C to generate the alert. Therefore, the control unit 50 detects the inconsistency or mismatch between the generated digital sensed load and the data derived from the selected part-program. And, if the system 100 detects any anomalies in the sensed load signal in relation to the selected part-program in the initial predefined time, then the alerting module 50D is configured to generate the alert or an alarm.
In a preferred embodiment, the alert generated by the system 100 is based on the comparison of the generated load signal with the at least one predefined-load as defined by the part-program fed to the control unit 50.
Further, the control unit 50 is configured to stop the machining of the component(s) when the control unit 50 identifies anomalies that the generated load signal does not match with the selected part-program. Also, the control unit 50 is configured to continue the machining of the component(s) 40 when the control unit 50 identifies that the generated load signal matches with the selected part-program.
In an embodiment, the predefined time is in the range of 03 seconds to 05 seconds respectively.
Further, the present disclosure also envisages a method for detecting anomalies in the deployed component(s) during machining. The method comprises the following steps:
• mounting the cutting tool 10 on the spindle 15 of the machine, configured to machine the deployed component(s) 40;
• selecting at least one part-program for the control unit 50;
• sensing load acting on the cutting tool 10 using at least one sensing unit 20 configured with the spindle 15 and further generating the load signal; and
• receiving the generated load signal by the control unit 50 and detecting the anomalies in the deployed component(s) 40 if the generated load signal not matches with the part-program in an operative configuration and generating an alert for the anomalies.
In an embodiment, the method includes the steps of replacing the deployed component(s) 40 in accordance with the selected part-program to eliminate the anomalies of the deployed component(s).
In another embodiment, the method includes the steps of selecting another part-program in accordance with the deployed component(s) to stop further alert.
EXAMPLE 1
For exemplary embodiments, the deployed components (Differential) 40 are being selected from a first model 70 and a second model 60. The basic difference between the first model 70 and the second model 60 is the height of the model, else the shape of both models 70, 60 are similar and very difficult to differentiate by naked eyes. For example, the first model 70 height is 27 mm more than the second model 60 .i.e. the difference between the height of the first model 70 and the second model 60 is 27mm, as shown in Figure 4. Since the height of both the models is different, therefore both the models would require different part-program for machining to generate a desired shape and dimensions. So, based on the deployed component(s) 40 (i.e. the first model 70 or the second model 60), the desired part-program is selected in the PLC 30, and based on the selected part-program, the cutting tool 10 is being actuated for performing the machining on any of the deployed model 40.
The cutting tool 10 is a rough cutter of dia.100 mm which is configured to perform milling on the operating top surface of the deployed model(s) 40. The machine is a CNC (computer numerical control) machine configured with the PLC. In the VMC, generally the spindle load is monitored as below 3% when no cutting or machining is involved but the spindle is rotating (idle condition) and, when the cutting tool begins to perform the machining, the spindle load exceeds 8% of the predefined load. However, these limiting percentages of the spindle load depend on the type of deployed component to be machined, type of machine, and the machining parameters selected during machining.
Further, the system is configured to generate an alarm if anyone of the predefined logic of the part-program is not matched with the sensed spindle load.
Therefore, to verify the performance of the system 100, in a first exemplary embodiment, the machine is loaded with the first model 70 but the operator selects a second model part program. Therefore, based on the second model part program, the cutting tool 10 adjusts its cutting depth based on the second model 60. However, the cutting tool 10 started- its cutting operation on the top of the first model 70 as the first model 70 is wrongly mounted on the machine and mistakenly not replaced with the second model 60 by the operator or the user. As the height of the first model 70 is 27 mm above the height of the second model 60, therefore the cutting tool 10 experiences comparatively more force in machining the top surface in the initial predefined time, and thereby the sensing unit 20 mounted on the spindle 15 detects the generated load signal as 5% more than the predefined load in the initial predefined time of the machining. Thus, the system 100 identified the anomalies, as the generated load signal not matches with the selected part-program in the initial pre-defined time. And, thereby, the system 100 stops the operation with an alarm “WRONG COMP DETECTED”.

EXAMPLE 2
In a second exemplary embodiment, the above parameters and the logic of the part programs kept as same, only the second model 60 is loaded but the operator selects a first model part-program. Therefore, based on the first model part-program, the cutting tool 10 adjusts its cutting depth based on the first model 70. However, the cutting tool 10 started its cutting operation on the top of the second model 60 as the second model is wrongly mounted on the machine and mistakenly not replaced with the first model 70 by the operator or the user. As the height of the second model 60 is 27 mm less the height of the first model 70, therefore the cutting tool does not touches the top surface of the second model 60 and the sensing unit mounted on the spindle detects the generated load signal as less than 3% than the predefined load in the initial predefined time of the machining. Thus, the system 100 identified the anomalies, as the generated load signal not matches with the selected part-program in the initial pre-defined time. Thereby, the system 100 stops the operation with the alarm “WRONG COMP DETECTED”. Figure 5A and Figure 5B illustrate a PMC (programmable machine control) ladder flow chart and an alert as per the system disclosed in Figure 4.
In an embodiment, when the first model 70 is loaded with the corresponding first model part-program, the system continues to operate without any alert or alarm.
In another embodiment, when the second model 60 is loaded with the corresponding second model part-program, the system continues to operate without any alert or alarm.
The above anomalies can be corrected either by replacing the deployed model(s) (the first model 70 or the second model 60) in accordance with the selected part-programs or selecting another part-program in accordance with the deployed model(s) (the first model 70 or the second model 60) to stop the further alert.
Advantageously, the system 100 saves a large number of components from rejection. Also, since the system generates the alert, therefore it saves the tool from the tool breakage and any type of component rejection due to machine co-ordinate shift.
Further, the production plan per month at the same machine (CNC) is approx. 2950 components and rejection of components due to the loading of the wrong component was observed approx. 2%. However, as per the system disclosed in the present disclosure, the rejection reduced to zero.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCES AND ECONOMICAL SIGNIFICANCE
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of the system and method for detecting anomalies in a deployed component(s) during machining, that:
• allow a user to change or alter the program as per their requirement and generate a user-defined alert;
• is economical;
• does not require to change or alter any machine configuration;
• generates alerts for the anomalies in the deployed component(s) (if any);
• minimizes the component rejection;
• enhances the productivity of the machine; and
• avoids the tool breakage.
The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.
, C , Claims:WE CLAIM:
1. A system (100) for detecting anomalies in a deployed component(s) (40) during machining, said system (100) comprising:
• a cutting tool (10) mounted on a spindle (15) of a machine for machining said deployed component(s) (40);
• a control unit (50) configured to receive at least one selected part-program; and
• at least one sensing unit (20) configured with said spindle (15) to detect load acting on said cutting tool (10) for an initial predefined-time during machining, and generate a load signal;
wherein said control unit (50) configured to receive said load signal and to detect said anomalies if said generated load signal not matches with said selected part-program in an operative configuration, and further configured to generate an alert for said anomalies.
2. The system (100) as claimed in claim 1, wherein said system (100) further comprises a programmable logic control (PLC) (30), configured to input said selected part-program and is further configured to actuate and control said cutting tool (10) in accordance with said part-program.
3. The system (100) as claimed in claim 1, wherein said control unit (50) is configured to receive said load signal from said at least one sensing unit (20).
4. The system (100) as claimed in claim 1, wherein the alert is configured to be generated by said control unit (50) based on comparison of said generated load signal with at least one predefined-load as defined by said part-program fed to said control unit (50).
5. The system (100) as claimed in claim 1, wherein said control unit (50) is configured to stop the machining of said component(s) (40) when said control unit (50) identifies anomalies that said generated load signal not matches with said part-program.
6. The system (100) as claimed in claim 1, wherein said control unit (50) is configured to continue the machining of said component(s) (40) when said control unit (50) identifies that said generated load signal matches with said part-program.
7. The system (100) as claimed in claim 1, wherein said machine is selected from a group consisting of a numerically controlled (NC) machine, and a computer numerically controlled (CNC) machine.
8. The system (100) as claimed in claim 1, wherein said control unit (50) comprises:
• a memory (50A) configured to store said at least one predefined load for said deployed component(s) (40);
• an analog-to-digital converter (50B) communicating with said sensing unit (20), said analog-to-digital converter (50B) being configured to receive said sensed load signal, and further configured to convert said sensed load signal to a digital sensed load;
• a comparator (50C) communicating with said analog-to-digital converter (50B), said comparator (50C) being configured to receive said digital sensed load, and further configured to compare said digital sensed load with said at least one predefined load; and
• an alerting module (50D) communicating with said comparator (50C) and configured to generate the alert.
9. The system (100) as claimed in claim 1, wherein said predefined time is in the range of 3 second to 5 second.
10. A method for detecting anomalies in a deployed component(s) (40) during machining, said method comprising the following steps;
• mounting a cutting tool (10) on a spindle (15) of a machine, configured to machine said deployed component(s) (40);
• selecting at least one part-program for a control unit (50);
• sensing load acting on said cutting tool (10) using at least one sensing unit (20) configured with said spindle (15) and further generating a load signal; and
• receiving said generated load signal by said control unit (50) and detecting said anomalies in said deployed component(s) (40) if said generated load signal not matches with said part-program in an operative configuration and generating an alert for said anomalies.
11. The method as claimed in claim 11, which includes the steps of replacing said deployed component(s) (40) in accordance with said part programs to eliminate said anomalies of said deployed component(s) (40).
12. The method as claimed in claim 11, which includes the steps of selecting another part-program in accordance with said deployed component(s) (40) to stop the further alert.

Dated this 02nd day of August, 2022

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant