CNC PLC Simulation for Collision Detection and Utilization
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Solution Overview
Problem
Current simulation systems for machining on CNC machine tools lack the ability to realistically simulate all movement sequences, including PLC-controlled movements, leading to incomplete collision detection and inefficient machine utilization prediction.
Innovation Solution
A device and method that integrate CNC and PLC control systems with a simulation apparatus, using storage means for machine tool, workpiece, and resource data to create a realistic virtual environment, allowing for detailed simulation of machining processes, including tool changes and workpiece automation, and enabling realistic estimation of machine utilization times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If simulation systems only visualize workpiece and machine tool without integrating PLC control sequences, then the system complexity is reduced, but the simulation completeness and collision detection accuracy deteriorate
Solution Approach 1:
The patent combines CNC control simulation and PLC control simulation into a single integrated simulation system. The PLC simulation means receives PLC program data and machine tool data, generates PLC simulation data representing actual PLC control sequences, and integrates this with CNC simulation data to achieve complete movement sequence simulation including tool changes, workpiece changes, and axis limitations.
Solution Approach 2:
The simulation system is divided into distinct functional modules: CNC control means for processing CNC part programs, PLC control means for executing PLC programs, PLC sequence simulation means for generating PLC simulation data, and overall simulation means for integrating all data. This segmentation allows each module to specialize in specific control aspects while maintaining overall system integration.
2Stability of the object's composition
If PLC programs are captively stored and cannot be modified during operation, then the system stability is improved, but the adaptability to different machining scenarios deteriorates
Solution Approach 1:
The system uses virtual copies of PLC programs and machine tool data for simulation purposes. The PLC simulation means creates virtual PLC simulation data that mirrors actual PLC control sequences without modifying the captively stored PLC programs. This allows testing and validation of machining scenarios using copied data while preserving the stability of original PLC programs.
3Adaptability or versatility
If multiple CNC part programs are created for different workpieces, then the production flexibility is improved, but the programming time and system configuration complexity deteriorate
Solution Approach 1:
The system performs preliminary simulation of PLC control sequences and machine tool movements before actual machining operations. By simulating complete movement sequences including tool changes, workpiece changes, and axis limitations in advance, potential issues are identified and resolved before production, reducing programming and setup time for multiple CNC part programs.
Data Source
AI summary
The invention relates to a device and a method for simulating a sequence for machining a workpiece on a machine tool. The invention is characterized by a holistic simulation approach. Particularly, a PLC control means 723 and a PLC sequence simulation means 725 assist in simulating the PLC movement sequences of the machine tool. This enables a realistic simulation of a machine tool in all its substantial aspects, resulting in considerable advantages especially in the field of training and during the determination of machine utilization times.