Cutting tool data verification system and method

A method of operating a machining system includes comparing one or more features of a cutting tool to information stored on a data chip secured to a tool holder of the cutting tool. The cutting tool is loaded into the machining system, and the information stored on the data chip is compared to cutting tool requirements of a machining program for instructing operation of the machine. When a result of one or more of the comparisons is outside of a predetermined threshold, operation of the machining system is stopped.

BACKGROUND OF THE INVENTION

The subject matter disclosed herein relates to industrial machining. More specifically, the present disclosure relates to management and verification of cutting tool data for an industrial machining center.

Machining of large complex components requires the removal of a great amount of material from an initial piece of raw material. To achieve this material removal a variety of cutting tools are used, some for long durations of time. Each cutting tool has unique characteristics, such as length, diameter, fluting pattern, etc. One or more cutting program, typically NC programs are developed including cutting tool selection and cutting path for various parts of the machining process. When the program or programs are executed correctly, including using the correct cutting tools and following the correct cutting paths, the result is the desired finished component. If an incorrect cutting tool is used at any point in the process, it may result in collision between the tool or tool holder and the part, or other event which damages or even causes the material to be scrapped. The potential sources of cutting tool error include: 1) the cutting tool does not correspond to the programmer's intent such that the cutting tool may be set correctly in its tool holder, but may be dimensionally incorrect (length, diameter, shape does not match programmer's intent; 2) each cutting tool is marked with identifying data in the form of a tag, data chip, or the like on the tool holder, which in some instances, this data may be incorrect; 3) the tool is set in the tool holder incorrectly; or 4) the incorrect cutting tool and tool holder are loaded into the machine for a particular part of the machining program. While the cutting tool is correctly identified, the tool changer apparatus of the machining center may malfunction resulting in the incorrect cutting tool being loaded for use. Reducing or eliminating errors of this sort would result in reduced machining costs through reduction in scrap and/or repair caused by such errors.

BRIEF DESCRIPTION OF THE INVENTION

According to one aspect of the invention, a method of operating a machining system includes comparing one or more features of a cutting tool to information stored on a data chip secured to a tool holder of the cutting tool. The cutting tool is loaded into the machining system, and the information stored on the data chip is compared to cutting tool requirements of a machining program for instructing operation of the machine. When a result of one or more of the comparisons is outside of a predetermined threshold, operation of the machining system is stopped.

According to another aspect of the invention, a machining system includes a machine and a cutting tool operably connectable to the machine. The cutting tool including one or more measurable features. A tool holder is receptive of the cutting tool and includes a data chip including information about the measurable features of the cutting tool. A controller compares contents of the data chip to cutting tool requirements of a machining program for instructing operation of the machine.

DETAILED DESCRIPTION OF THE INVENTION

Shown inFIG. 1is a schematic view of a machining system10, for example a 5-axis machining system. The machining system10includes a machine12having a cutting tool14at an end of the machine12. The cutting tool14is held in a tool holder16. When the machining system10is operating, the cutting tool14rotates about a tool axis and removes material from a workpiece18shown on a worktable20. In some embodiments, the worktable20is moveable, translating and/or rotating as desired. Machining of the workpiece18is controlled by a controller22operably connected to the machine10. One or more machining programs are loaded into the controller22providing instructions regarding path of the cutting tool14and also identifying information regarding which cutting tool14is used for each portion of the machining program. The various cutting tool14/tool holder16assemblies are located in a tool magazine24for retrieval by the machine12when instructed by the program. Referring toFIG. 2, the tool holder16includes a data chip26in which identifying data is stored regarding the cutting tool14in the tool holder16. When the tool holder16/cutting tool14assemblies are loaded into the tool magazine24, the tool magazine24reads the data chip26and transmits the cutting tool14location in the tool magazine24to the controller22.

Referring toFIG. 3, a method will now be described to verify that the correct cutting tool14is utilized when called for by the machining program. As stated above, each tool holder16/cutting tool14assembly is identified with information regarding the cutting tool14installed in the tool holder16. This information is stored on a data chip26secured to the tool holder16. This information includes, for example, tool length, tool diameter, tool type, or the like. Prior to the cutting tool14/tool holder16being loaded into the tool magazine24, a cutting tool diameter28, cutting tool length30, and/or other pertinent features are measured in block100, either by an operator, or by a machine probe (not shown). The measured features are compared with the information stored on the data chip26in block102to verify that the data chip26contains accurate information regarding the particular cutting tool14. This process is repeated for each cutting tool14loaded into the tool magazine24. In block104, if measured data matches the data chip26within a threshold, the cutting tool14is loaded in the tool magazine24for use in block106. If the data is outside of the threshold, in block108the cutting tool14is not loaded into the tool magazine24before the information on the data chip26is modified to correspond to the actual cutting tool14measurements.

Next, when a cutting tool14is installed in the machine10for use in block112, either at the beginning or at a tool change step of the machining program, a subprogram in the controller22is initiated. This subprogram compares, in some embodiments the comparison occurs automatically, the information on the data chip26with the cutting tool diameter28and cutting tool length30and other cutting tool14information called for by the program in block114. This “soft check” block110verifies that the information on the data chip26matches the intent of the programmer. In block116, if the comparison results in a value outside of a threshold, for example, a cutting tool diameter28is too small or too large, or a cutting tool length30is too short or too long, an alarm is initiated and the machine10will not operate with such a cutting tool14installed as in block118.

Once the soft check is completed, a hard check, block120, is performed to verify that the actual cutting tool14, not just the data chip26, matches the intent of the programmer In this hard check, once the cutting tool14is loaded into the machine10, then in block122one or more features such as cutting tool diameter28and/or cutting tool length30are measured, either manually by the operator or by use of the machine touch probe. In block124, the measurement(s) are compared to the cutting tool14information called for by the program. This verifies that: 1) the cutting tool14information corresponds with the information residing on the data chip26and 2) that the actual cutting tool14features match the cutting tool14required by the program. This is useful not only in situations where the incorrect tool is loaded into a tool holder16or the incorrect data is on the data chip26, but in cases where a cutting tool14is used over a long period of time in a particular program and has become worn, so that when reloaded into the machine10the cutting tool14no longer meets the intent of the programmer As with the soft check, if the measurements of the cutting tool14fall outside of a selected threshold in block126, the alarm is initiated in block128and the machine10will not operate with such a cutting tool14installed. If the result of the comparison is within the threshold, the machine10will operate in block130with the cutting tool14installed.