Modular CNC Programming Backplane for Flexible Machine Reconfiguration

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Solution Overview

Problem

Existing methods for programming and integrating electronically cammed computer numerical control (CNC) machines are inflexible and do not allow users to fully leverage the increased customization and flexibility these machines offer, requiring extensive custom code development and manual reprogramming for changes.

Innovation Solution

A self-contained and modular software control system using a software backplane that interfaces with configurable applications to control tooling components, allowing users to configure and control actuators, sensors, and motion systems through a modular and programmable architecture, enabling easier adaptation and customization without extensive reprogramming.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If custom code is written to control hardware actuators in electronically cammed CNC machines, then the machines can perform specific tasks, but any changes require rewriting and retesting the custom code, reducing flexibility and increasing programming time

Engineering Contradiction:

ImproveflexibilityVSAvoidprogramming time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The control system is segmented into modular functional blocks (electronic camming modules, motion control modules, I/O modules) that can be independently configured and programmed. Each module handles specific functions, allowing changes to be made in isolated segments rather than rewriting entire custom codebases.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements universal configuration files and standardized communication protocols that allow the same control architecture to handle multiple different actuator types and manufacturing tasks. This multi-functionality eliminates the need for task-specific custom code, enabling rapid adaptation to new applications.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If custom code is written for programmable logic controllers to control all aspects of hardware actuators, then the CNC machine can be customized for specific tasks, but system complexity and difficulty of maintenance increase

Engineering Contradiction:

ImprovecustomizationVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent introduces configuration files as an intermediary layer between the user and the control system. These files serve as a standardized interface that translates high-level manufacturing requirements into control signals, eliminating the need for users to write complex custom code while maintaining full customization capability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the mechanical paradigm of custom code development with an electronic/configuration-based paradigm. Instead of manually programming and debugging custom code, users configure the system through standardized files and parameters, reducing complexity while preserving customization.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If manual reprogramming is performed to change how the CNC machine operates, then the machine can be adapted to new tasks, but production overhead and inefficiencies increase

Engineering Contradiction:

ImproveadaptabilityVSAvoidproduction overhead

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent implements pre-configured functional modules and standardized communication protocols that are prepared in advance. When adaptation is needed, users simply load different configuration files rather than performing manual reprogramming, dramatically reducing production overhead and enabling rapid task changes.

Inventive Principle:

Principle #10Preliminary action

4Manufacturing precision

If extensive custom code development is required to program electronically cammed CNC machines, then the machines can be controlled precisely, but the time and resources required for programming and testing increase

Engineering Contradiction:

Improvecontrol precisionVSAvoidprogramming and testing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent uses configuration files as templates or copies that define control parameters and behaviors. Instead of writing custom code from scratch for each application, users can copy and adapt existing configuration files, maintaining precision while dramatically reducing programming and testing time.

Inventive Principle:

Principle #26Copying

Data Source

PatentUS20230123063A1Methods and systems for programming computer numerical control machines

Publication Date: 2023.04.20 ATS CORPORATION

AI summary

There is described systems and methods for programming and configuring part-processing devices and production stations. Methods of programming the control system of a part-processing device for controlling one or more tooling components, sensors and/or motion systems includes the step of loading a software backplane onto the control system, the software backplane being configured to run on an operating system of the control system and to interface with one or more configurable applications. The method also comprises the step of loading one or more configurable applications associated with the one or more tooling components onto the control system, the one or more applications being configured to interface with the software backplane. The method also comprises the step of configuring the one or more configurable applications to control the one or more tooling components, sensors and/or motion systems pf the part-processing device.