Adaptive Drilling Motor Control for Torque and Thrust Limits
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Solution Overview
Problem
Existing drilling technologies struggle to maintain stable cutting forces and adapt to variations in cutting conditions due to changes in material properties, lubrication, or tool geometry, leading to suboptimal drilling quality and equipment wear.
Innovation Solution
A method and device that measure torque and thrust during drilling, adjusting motor control to maintain stable cutting conditions by switching to current control when thresholds are exceeded, ensuring a predetermined feed per revolution of the cutting tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If speed control is used for motors during drilling, then productivity is improved, but manufacturing precision deteriorates when cutting forces become variable
Solution Approach 1:
The control system dynamically switches between speed control and current control modes based on real-time monitoring of cutting forces. When cutting forces are within normal ranges, speed control maintains high productivity. When cutting forces exceed thresholds (indicating material transitions or abnormal conditions), the system transitions to current control to maintain manufacturing precision and prevent tool damage.
Solution Approach 2:
The system continuously monitors cutting forces through torque and thrust measurements and uses this feedback to adaptively adjust motor control parameters. This closed-loop feedback mechanism enables the system to respond to changing drilling conditions in real-time, switching control modes to optimize both productivity and precision based on actual cutting force levels.
2Device complexity
If cutting parameters are kept constant for simplicity, then device complexity is reduced, but adaptability deteriorates when drilling through varied materials
Solution Approach 1:
The control system automatically detects material transitions and adjusts cutting parameters without external intervention. By monitoring cutting forces and autonomously switching between control modes, the system provides self-service adaptation, eliminating the need for complex manual parameter adjustments while maintaining high adaptability to varying material conditions.
Solution Approach 2:
The system changes control parameters (switching between speed control and current control modes) based on detected cutting force levels. This automatic parameter adaptation allows the system to handle diverse materials and drilling conditions effectively without requiring complex pre-programming or manual intervention for each material type.
3Productivity
If high feed speed is maintained throughout drilling, then productivity is improved, but reliability deteriorates when encountering high-resistance materials
Solution Approach 1:
The feed speed is dynamically adjusted based on real-time cutting force monitoring. The system maintains high feed speed for productivity when drilling through low-resistance materials, but automatically reduces feed speed when cutting forces indicate high-resistance materials or abnormal conditions, thereby preserving tool reliability and preventing catastrophic failures.
Solution Approach 2:
The system proactively detects approaching material transitions or abnormal conditions through cutting force monitoring and preemptively adjusts feed speed before tool damage can occur. This beforehand cushioning approach allows the system to maintain high productivity during normal operation while protecting tool reliability by reducing feed speed in advance when resistance increases.
Data Source
AI summary
A method for drilling using a cutting tool capable of being rotated and translated about/along the same axis by a drilling device, which includes a cutting motor capable of causing the cutting tool to rotate about the axis and a feed motor capable of causing the cutting tool to translate along the axis. The method includes adapting control of the motors. The speeds of the cutting motor and the feed motor are controlled as long as the torque and the thrust are below the torque threshold and the thrust threshold, respectively; when the torque or the thrust reaches or exceeds the torque threshold or the thrust threshold, the current of the motor generating the torque or the thrust whose threshold has been exceeded is controlled, whereas the other motor is still subject to speed control, so the feed per revolution of the cutting tool is equal to a predetermined value.