Machine tool monitoring

• US 10,228,669 B2
• Filed: 05/17/2016
• Issued: 03/12/2019
• Est. Priority Date: 05/27/2015
• Status: Active Grant

• Current Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce Corporation (Rolls-Royce Holdings Plc)
• Inventors: Dunkin, Mike R.
• Primary Examiner(s): Hartman, Jr., Ronald D
• Application Number:
  US15/156,384
• Publication Number:
  US 20160346890A1
• Time in Patent Office: 1,029 Days
• CPC Class Codes: B23Q 17/0966 by measuring a force on parts of the machine other than a motor
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G05B 19/4065 Monitoring tool breakage, life or condition
• CPC Class Codes: G05B 2219/37234 Monitor tool before, after and during machining
• CPC Class Codes: G05B 2219/37246 Compare estimated torques of different axis with reference for breakage

Abstract

A method includes sending, by a computing device, control signals to a machine tool to machine a component located on a platform to form a feature in the component, monitoring, by the computing device, while machining the feature into the component with the machine tool, torque forces of the machine tool against the component caused by the machining of the feature into the component via at least one sensor positioned on the platform, evaluating, by the computing device, while machining the feature into the component with the machine tool, a quality of the machine tool based on the monitored torque forces; and, in response to the evaluation of the quality of the machine tool indicating an undesirable quality of the machine tool, sending, by the computing device, control signals to the machine tool to interrupt the machining of the component and replace a machining element of the machine tool.

Claims

1. A method comprising:

sending, by a computing device, control signals to a machine tool to machine a component located on a platform to form a feature in the component according to the control signals;

monitoring, by the computing device, while machining the feature into the component with the machine tool, torque forces of the machine tool against the component caused by the machining of the feature into the component with the machine tool via at least one sensor positioned on the platform;

evaluating, by the computing device, while machining the feature into the component with the machine tool, a quality of the machine tool based on the monitored torque forces; and

in response to the evaluation of the quality of the machine tool indicating an undesirable quality of the machine tool, controlling, by the computing device, the machine tool to interrupt the machining of the component and facilitate replacement of a machining element of the machine tool.

2. The method of claim 1, further comprising monitoring, by the computing device, while machining the feature into the component with the machine tool, thrust forces of the machine tool against the component caused by the machining of the feature into the component with the machine tool via the at least one sensor positioned on the platform,

wherein evaluating, by the computing device, the quality of the machine tool is further based on the monitored thrust forces.

3. The method of claim 1, wherein evaluating, by the computing device, the quality of the machine tool based on the monitored torque forces includes determining whether the monitored torque forces exceed a predetermined maximum threshold.

4. The method of claim 3, wherein evaluating, by the computing device, the quality of the machine tool based on the monitored torque forces includes determining whether the monitored torque forces are below a predetermined minimum threshold.

5. The method of claim 1, wherein sending, by the computing device, control signals to the machine tool to machine the component to form the feature in the component according to the control signals comprises sending, by the computing device, control signals to perform peck drilling.

6. The method of claim 1, wherein monitoring the torque forces of the machine tool against the component caused by the machining of the feature into the component with the machine tool includes continuously monitoring, by the computing device, during the machining of the feature into the component, the torque forces produced by the machining of the component by the machine tool.

7. The method of claim 1, wherein the machining element is a drill bit with a diameter of no greater than 0.01 inches.

8. The method of claim 1,

wherein the component is a blade airfoil, and

wherein the feature includes an array of thin film cooling holes.

9. A system comprising:

a machine tool including a platform;

at least one sensor positioned on the platform; and

a computing device, wherein the computing device;

sends control signals to the machine tool that cause the machine tool to machine a component located on the platform to form a feature in the component;

monitors torque forces of the machine tool against the component caused by the machining of the feature into the component with the machine tool via the at least one sensor;

during the machining of the feature into the component, evaluates a quality of the machine tool based on the monitored torque forces; and

in response to the evaluation of the quality of the machine tool indicating an undesirable quality of the machine tool, controls the machine tool to interrupt the machining of the component and facilitate replacement of a machining element of the machine tool.

10. The system of claim 9,

wherein the computing device, while machining the feature into the component with the machine tool, monitors thrust forces of the machine tool against the component caused by the machining of the feature into the component with the machine tool via the at least one sensor positioned on the platform,

wherein the evaluation of the quality of the machine tool is further based on the monitored thrust forces.

11. The system of claim 9, wherein the at least one sensor includes a multi-axis piezoelectric force transducer.

12. The system of claim 9, further comprising a work holding fixture that secures the component to the platform,

wherein the at least one sensor is positioned between the platform and the work holding fixture.

13. The system of claim 9, wherein the control signals to the machine tool that cause the machine tool to form the feature in the component according to the control signals comprise control signals instructing the machine tool to perform peck drilling.

14. The system of claim 9, wherein the machining element is a drill bit with a diameter of no greater than 0.01 inches.

15. The system of claim 9, further comprising the component,

wherein the component is a blade airfoil, and

wherein the feature includes an array of thin film cooling holes.

16. A non-transitory computer-readable data storage medium having instructions stored thereon that, when executed by one or more processors of a computing device, cause the computing device to:

send control signals to a machine tool for causing the machine tool to machine a component located on a platform to form a feature in the component;

monitor torque forces of the machine tool against the component caused by the machining of the feature into the component with the machine tool via at least one sensor;

during the machining of the feature into the component, evaluate a quality of the machine tool based on the monitored torque forces; and

in response to the evaluation of the quality of the machine tool indicating an undesirable quality of the machine tool, control the machine tool to interrupt the machining of the component and facilitate replacement of a machining element of the machine tool.

17. The non-transitory computer-readable data storage medium of claim 16, wherein the instructions are further configured to cause the computing device to, while machining the feature into the component with the machine tool, monitor thrust forces of the machine tool against the component caused by the machining of the feature into the component with the machine tool via the at least one sensor positioned on the platform, and

wherein the evaluation of the quality of the machine tool is further based on the monitored thrust forces.

18. The non-transitory computer-readable data storage medium of claim 16, wherein evaluating the quality of the machine tool based on the monitored torque forces includes determining whether the monitored torque forces exceed a predetermined maximum threshold.

19. The non-transitory computer-readable data storage medium of claim 16, wherein the control signals to the machine tool that cause the machine tool to machine the component located on the platform to form the feature in the component comprise control signals to perform peck drilling.

20. The non-transitory computer-readable data storage medium of claim 16, wherein the instructions are further configured to cause the computing device to store an indication of the torque forces of the machine tool on the non-transitory computer-readable data storage medium.

21. The non-transitory computer-readable data storage medium of claim 16, wherein the instructions are further configured to cause the computing device to store an indication of the evaluation of the quality of the machine tool on the non-transitory computer-readable data storage medium.