Abstract: A machine or autonomous system includes a diagnostic controller and is configured to perform a method for monitoring health of a machine. The method includes monitoring a set of first electrical signals indicative of control of a motor of the machine while the machine is operated in a first autonomous mode, determining that an abnormal operating condition has occurred in response to the set of first electrical signals meeting a first criteria, having the machine operate in a test mode in response to the determination that the abnormal operating condition has occurred, monitoring a set of second electrical signals indicative of control of the motor during the test mode, and determining a fault condition in response to the set of second electrical signals meeting a second criteria.

Abstract: A method of measuring quality in a machining operation of a device includes measuring lost motion for at least one axis of the device during the machining operation, calculating a spindle lag of a spindle of the device during the machining operation, determining a lost motion deviation, determining a spindle lag deviation, and identifying a machining defect based on the lost motion deviation coinciding with the spindle lag deviation.

Abstract: A method of measuring quality in a machining operation of a device includes measuring lost motion for at least one axis of the device during the machining operation, calculating a spindle lag of a spindle of the device during the machining operation, determining a lost motion deviation, determining a spindle lag deviation, and identifying a machining defect based on the lost motion deviation coinciding with the spindle lag deviation.

Abstract: A machine or autonomous system includes a diagnostic controller and is configured to perform a method for monitoring health of a machine. The method includes monitoring a set of first electrical signals indicative of control of a motor of the machine while the machine is operated in a first autonomous mode, determining that an abnormal operating condition has occurred in response to the set of first electrical signals meeting a first criteria, having the machine operate in a test mode in response to the determination that the abnormal operating condition has occurred, monitoring a set of second electrical signals indicative of control of the motor during the test mode, and determining a fault condition in response to the set of second electrical signals meeting a second criteria.

Abstract: A machine assessment system of the present disclosure is for a machining tool including a spindle. The machine assessment system includes a calibrated spindle tool configured to couple to a distal end of the spindle, a displacement sensor configured to measure a performance characteristic of the machining tool based on a controlled excitation of the calibrated spindle tool, and a controller communicably coupled to the displacement sensor to acquire the performance characteristic. In measuring the performance characteristic, the displacement sensor is detached from the calibrated spindle tool. The controller is configured perform a machine health assessment based on the performance characteristic.

Abstract: This disclosure is generally directed to 3D tolerance analysis. In one exemplary method, a combination of a variation analysis procedure and a finite element analysis (FEA) procedure is executed by a computer. The variation analysis procedure involves determining a first simulated force for effecting a mating between a first surface of a first part and a first surface of a second part. A first set of deformation parameters is determined by applying the first simulated force to the first surface of the first part. The FEA procedure involves determining a second simulated force for effecting the mating between the two surfaces based on one or more assembly loads. A second set of deformation parameters is determined by applying the second simulated force to the first surface of the first part. Various deformation parameters of the mated assembly can be obtained by combining the first and second set of deformation parameters.

Abstract: The present disclosure relates to a system for measuring a dynamic response of a machine. The system includes a vibration mechanism, an accelerometer, a controller and a casing. The vibration mechanism is operable to generate an excitation signal, and the accelerometer is operable to measure dynamic energy in response to the excitation signal and output a dynamic response signal indicative of the dynamic energy. The controller includes a communication interface and operates the vibration mechanism to output the excitation signal and transmit a vibration input signal based on the excitation signal by way of the communication interface. The casing houses the vibration mechanism and the controller.

Abstract: A milling method includes moving a milling tool having at least two axially spaced apart sets of cutting inserts to an axial position within a bore in a material and rotating the milling tool about a longitudinal axis. The method further includes initiating contact between the milling tool and a wall of the bore in a region of the wall having a least amount of material at the axial position. The method further includes moving the milling tool around a perimeter of the bore.

Abstract: A milling method includes moving a milling tool having at least two axially spaced apart sets of cutting inserts to an axial position within a bore in a material and rotating the milling tool about a longitudinal axis. The method further includes initiating contact between the milling tool and a wall of the bore in a region of the wall having a least amount of material at the axial position. The method further includes moving the milling tool around a perimeter of the bore.

Abstract: Milling tools and methods are disclosed. The method may include moving a milling tool having at least two axially spaced apart sets of cutting inserts to an axial position within a bore in a material and rotating the milling tool about a longitudinal axis. Contact between the milling tool and a wall of the bore may be initiated in a region of the wall having a least amount of material at the axial position. The milling tool may include a tool shaft having a longitudinal axis, a first set of radially spaced cutting inserts coupled to the tool shaft, and a directly adjacent second set of radially spaced cutting inserts coupled to the tool shaft and spaced from the first set of cutting inserts along the longitudinal axis. The first and second sets of cutting inserts may be staggered from each other by at least 10 degrees.

Abstract: The present disclosure relates to a system for measuring a dynamic response of a machine. The system includes a vibration mechanism, an accelerometer, a controller and a casing. The vibration mechanism is operable to generate an excitation signal, and the accelerometer is operable to measure dynamic energy in response to the excitation signal and output a dynamic response signal indicative of the dynamic energy. The controller includes a communication interface and operates the vibration mechanism to output the excitation signal and transmit a vibration input signal based on the excitation signal by way of the communication interface. The casing houses the vibration mechanism and the controller.

Abstract: Milling tools and methods are disclosed. The method may include moving a milling tool having at least two axially spaced apart sets of cutting inserts to an axial position within a bore in a material and rotating the milling tool about a longitudinal axis. Contact between the milling tool and a wall of the bore may be initiated in a region of the wall having a least amount of material at the axial position. The milling tool may include a tool shaft having a longitudinal axis, a first set of radially spaced cutting inserts coupled to the tool shaft, and a directly adjacent second set of radially spaced cutting inserts coupled to the tool shaft and spaced from the first set of cutting inserts along the longitudinal axis. The first and second sets of cutting inserts may be staggered from each other by at least 10 degrees.