Tool wear monitoring is critical for quality and precision of manufacturing of parts in the machining industry. Existing tool wear monitoring and prediction methods are sensor based, costly and pose challenge in ease of implementation. Embodiments herein provide method and system for monitoring tool wear to estimate Remaining Useful Life (RUL) of a tool in machining is disclosed. The method provides a tool wear model, which combines tool wear physics with data fitting, capture practical considerations of a machining system, which makes the tool wear prediction and estimated RUL more stable, reliable and robust. Further, provides cost effective and practical solution. The disclosed physics based tool wear model for RUL estimation captures privilege of physics of tool wear and easily accessible data from CNC machine to monitor and predict tool wear and RUL of the tool in real-time.

A processing system includes a cutting tool for milling, a plurality of sensors, and a processing unit. The plurality of sensors each is configured to measure a physical quantity that indicates a state related to loads on the cutting tool during cutting. The processing unit is configured to generate, based on measurement results from the respective sensors at a plurality of measurement time points, measurement data that is related to the loads in two directions on a plane perpendicular to a rotation axis of the cutting tool and that includes two-dimensional data at each of the measurement time points, and to perform a determination process concerning cutting in which the cutting tool is used, based on a two-dimensional shape indicated by the generated measurement data.

The present invention relates to a composite intelligent detection method and a cutting apparatus. A cutting force F of a tool bit is obtained in real time by a force sensor; an inertia force F2 is obtained through detection in real time by an acceleration sensor and calculation; an actual cutting force F is calculated by F−F2 in real time; and a tool feed is calculated by integration on acceleration in real time. According to the composite intelligent detection method and the cutting apparatus in the present invention, the assembling difficulty and cost of the apparatus are reduced while the detection accuracy is relatively high.

A cutting system includes a cutting tool for milling, a plurality of sensors, and a processor, wherein the cutting tool performs a cutting process using two or more cutting blades, the plurality of sensors measure a physical quantity indicating a state regarding a load of the cutting tool at a time of the cutting process, and the processor generates, based on measurement results of the sensors at a plurality of measurement timings, two-dimensional data for each measurement timing, the two-dimensional data regarding the load in two directions on a plane perpendicular to a rotation axis of the cutting tool, classifies pieces of the generated two-dimensional data into any of a plurality of unit regions, a number of which is equal to or greater than a number of the cutting blades on the plane, and detects, based on the two-dimensional data for each unit region, an abnormality of the cutting blade.

Tool wear monitoring is critical for quality and precision of manufacturing of parts in the machining industry. Existing tool wear monitoring and prediction methods are sensor based, costly and pose challenge in ease of implementation. Embodiments herein provide method and system for monitoring tool wear to estimate Remaining Useful Life (RUL) of a tool in machining is disclosed. The method provides a tool wear model, which combines tool wear physics with data fitting, capture practical considerations of a machining system, which makes the tool wear prediction and estimated RUL more stable, reliable and robust. Further, provides cost effective and practical solution. The disclosed physics based tool wear model for RUL estimation captures privilege of physics of tool wear and easily accessible data from CNC machine to monitor and predict tool wear and RUL of the tool in real-time.

A detection device, detection method, and compensation method for tool wear, applied to a machine tool including a spindle connected to a tool. A first parameter set including a first cutting depth having a zero cutting depth is set, and the machine tool performs a cutting procedure with the first parameter set to record a first loading rate of the spindle. A second parameter set including a second cutting depth having a non-zero cutting depth is set, and the machine tool performs the cutting procedure with the second parameter set to record a second loading rate of the spindle. A processing device calculates an estimated cutting force according to the loading rates and a machine performance database. A fuzzy logic unit outputs a wear level according to a tool wear database and the estimated cutting force. The machine tool adjusts a cutting locus according to the wear level.

A detection device, detection method, and compensation method for tool wear, applied to a machine tool including a spindle connected to a tool. A first parameter set including a first cutting depth having a zero cutting depth is set, and the machine tool performs a cutting procedure with the first parameter set to record a first loading rate of the spindle. A second parameter set including a second cutting depth having a non-zero cutting depth is set, and the machine tool performs the cutting procedure with the second parameter set to record a second loading rate of the spindle. A processing device calculates an estimated cutting force according to the loading rates and a machine performance database. A fuzzy logic unit outputs a wear level according to a tool wear database and the estimated cutting force. The machine tool adjusts a cutting locus according to the wear level.

The invention provides a control device comprising: an actual value obtaining part, obtaining a torque actual value and a velocity actual value, wherein the torque actual value represents a torque generated by the driving source and the velocity actual value represents a velocity of the motion body; an inferring part, which calculates an external force inferred value and a velocity inferred value every other operation period based on the torque actual value by using an operation formula of a predetermined model representing driving of the motion body, wherein the external force inferring value represents an external force generated by the control system; and an output part, evaluating a reliability of the external force inferred value based on the velocity inferred value calculated together if the inferring part calculates the external inferred value, and effectively outputting the external force inferred value when it is judged that there is a designated reliability.

The invention provides a control device comprising: an actual value obtaining part, obtaining a torque actual value and a velocity actual value, wherein the torque actual value represents a torque generated by the driving source and the velocity actual value represents a velocity of the motion body; an inferring part, which calculates an external force inferred value and a velocity inferred value every other operation period based on the torque actual value by using an operation formula of a predetermined model representing driving of the motion body, wherein the external force inferring value represents an external force generated by the control system; and an output part, evaluating a reliability of the external force inferred value based on the velocity inferred value calculated together if the inferring part calculates the external inferred value, and effectively outputting the external force inferred value when it is judged that there is a designated reliability.

A processing system includes a cutting tool for milling, a plurality of sensors, and a processing unit. The plurality of sensors each is configured to measure a physical quantity that indicates a state related to loads on the cutting tool during cutting. The processing unit is configured to generate, based on measurement results from the respective sensors at a plurality of measurement time points, measurement data that is related to the loads in two directions on a plane perpendicular to a rotation axis of the cutting tool and that includes two-dimensional data at each of the measurement time points, and to perform a determination process concerning cutting in which the cutting tool is used, based on a two-dimensional shape indicated by the generated measurement data.