Cam Profile Data Creation Apparatus for Drive Shaft Synchronization
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Solution Overview
Problem
Existing electronic cam systems face errors in operation due to mismatched phase intervals between drive and driven shafts, particularly at increased rotation speeds, leading to inefficient performance and safety concerns, as current methods rely on trial and error for error confirmation.
Innovation Solution
A cam profile data creation apparatus and synchronization controller that predict and display displacement errors, allowing for adjustable drive shaft rotation speeds to maintain allowable error ranges, with autonomous calculation of optimal rotation speeds for error minimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rotation speed of the drive shaft is increased to improve productivity, then the phase interval θ becomes larger than the defined phase interval θ0, causing definition points to be skipped and errors to occur in the electronic cam operation
Solution Approach 1:
The invention performs preliminary calculation of the phase interval θ based on the rotation speed and control cycle before generating cam profile data. This allows the system to predict which definition points will be skipped at high speeds and pre-adjust the cam profile data to compensate for these skips, ensuring accurate driven shaft positioning without actual trial-and-error operation.
Solution Approach 2:
The invention creates a virtual model of the electronic cam operation by calculating and displaying the relationship between the drive shaft phase and driven shaft displacement based on cam profile data before actual operation. This virtual simulation allows users to visualize and adjust the cam profile data to match actual high-speed operation conditions, avoiding errors without physically operating the machine.
2Measurement precision
If actual machine operation is performed to confirm positional deviation and adjust error, then error confirmation becomes possible, but safety risks increase and the process becomes time-consuming trial and error
Solution Approach 1:
The invention creates a virtual simulation that copies the actual machine operation behavior by calculating the phase interval θ and predicting which definition points will be instructed or skipped. This virtual model allows complete error confirmation and adjustment without physical machine operation, eliminating safety risks while maintaining measurement precision through visual display of the cam profile data versus actual operation.
Solution Approach 2:
The system performs preliminary calculation and visual display of the phase interval θ and definition point instruction status before actual operation. This allows complete error confirmation and cam profile data adjustment in advance, eliminating the need for time-consuming trial-and-error actual operation while maintaining operational safety.
3Difficulty of detecting and measuring
If actual machine operation is used for error confirmation, then error detection becomes possible, but the process requires time-consuming trial and error adjustments
Solution Approach 1:
The invention creates a virtual simulation that copies actual machine operation by calculating the phase interval θ and displaying which definition points will be instructed or skipped at high rotation speeds. This virtual model provides complete error detection capability without requiring time-consuming actual machine operation and trial-and-error adjustments.
Solution Approach 2:
The system performs preliminary calculation of the phase interval θ and visual display of definition point instruction status before actual operation. This allows complete error detection and cam profile data adjustment in advance, eliminating time-consuming trial-and-error actual operation while maintaining full error detection capability.
4Manufacturing precision
If the phase interval θ0 in cam profile data is made finer to improve manufacturing precision, then more definition points are created, but the data size increases and processing becomes more complex
Solution Approach 1:
The invention changes the parameter of phase interval θ0 in the cam profile data based on the calculated phase interval θ at high rotation speeds. By adjusting θ0 to match actual operation conditions, the system maintains manufacturing precision while optimizing data size and processing complexity for the specific high-speed application.
Data Source
AI summary
A cam profile data creation apparatus sets cam profile data in which a phase of a drive shaft is associated with a displacement (set displacement) of a driven shaft, a rotation speed of the drive shaft, and an allowable error for the displacement of the driven shaft. A displacement (predictive displacement) of the driven shaft when the drive shaft rotates at the set rotation speed is found based on the set cam profile data, the set displacement and the predictive displacement are displayed to be comparable, and further a form of the display is changed depending on whether an error between the set displacement and the predictive displacement falls within the range of the allowable error.