US 12,339,642 B2
On-machine monitoring system for failure state of rotating tool and detection method therefor
Xi Zhang, Shanghai (CN)
Assigned to Shanghai Weiyan Precision Technology Co., Ltd, Shanghai (CN)
Appl. No. 17/800,998
Filed by Shanghai Weiyan Precision Technology Co., Ltd, Shanghai (CN)
PCT Filed Jul. 5, 2021, PCT No. PCT/CN2021/104497
§ 371(c)(1), (2) Date Aug. 19, 2022,
PCT Pub. No. WO2022/022232, PCT Pub. Date Feb. 3, 2022.
Claims priority of application No. 202010731121.9 (CN), filed on Jul. 27, 2020.
Prior Publication US 2023/0096314 A1, Mar. 30, 2023
Int. Cl. G05B 19/4065 (2006.01); B23Q 17/24 (2006.01)
CPC G05B 19/4065 (2013.01) [B23Q 17/2457 (2013.01); G05B 2219/37226 (2013.01); G05B 2219/50185 (2013.01)] 19 Claims
OG exemplary drawing
 
1. An on-machine monitoring system for a failure state of a rotating tool, comprising a detector, a data processing controller, a tool data server, and a Hall current sensor, wherein
the data processing controller is connected to the detector through a signal cable and also connected to a computer numerical control (CNC) controller, the tool data server, and the Hall current sensor; the Hall current sensor is configured to sense a spindle current signal; the detector is internally provided with a telecentric lens and a backlight source, the telecentric lens and the backlight source are configured to perform parallel projection on a tool to obtain image sequences of the tool during a rotation process of the tool, the image sequences of the tool are configured to show a variation trend of the tool in size; the size of the tool comprises a tool diameter and a tool length; the data processing controller is configured to monitor the failure state of the tool according to the image sequences of the tool and the spindle current signal; and the failure state of the tool comprises a wear state, a breakage state, an edge chipping state, and a breaking state of the tool;
wherein the detector comprises a protective shell, a camera module, the telecentric lens, a 45° reflective mirror, an optical window, a pneumatic plunger, and an optical fiber sensor, wherein
the optical fiber sensor comprises a transmitter of the optical fiber sensor and a receiver of the optical fiber sensor; the protective shell is a concave protective shell; a first side cavity of the concave protective shell is internally provided with the camera module, the telecentric lens, the 45° reflective mirror, the optical window, the pneumatic plunger, and the transmitter of the optical fiber sensor, a second side cavity of the concave protective shell is internally provided with the receiver of the optical fiber sensor; the transmitter of the optical fiber sensor and the receiver of the optical fiber sensor are symmetrically arranged with the tool as a center; and the backlight source is arranged in the second side cavity and configured to provide uniform back lighting illumination during imaging to form a tool image with light-dark contrast; and
the telecentric lens is arranged at a lens mount of the camera module and has an axis parallel to an axis of the tool; the camera module and the telecentric lens are configured to obtain a parallel projection image of the rotating tool; the 45° reflective mirror is arranged on an upper portion of the telecentric lens and configured to turn an optical imaging path by 90°; the optical window is arranged at a reflecting end of the 45° reflective mirror and configured to seal the camera module, the telecentric lens, and the 45° reflective mirror; the pneumatic plunger at the same optical imaging path as the optical window has an axis perpendicular to a normal direction of a plane of the optical window and is configured to control the camera module to acquire the tool image and protect the optical imaging path.