CNC Machining Time Prediction Using Virtual Axis Simulation
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Solution Overview
Problem
It is challenging to predict an accurate machining time for CNC machine tools when stop commands for axes are frequently described in the machining program or when axes with high inertia are used, as existing methods require actual machining data, which is time-consuming and labor-intensive to collect.
Innovation Solution
A machining time predicting apparatus and method that analyze the machining program to generate operation commands for the axes, manage the execution of these commands, and simulate axis operations to predict machining time without relying on actual machining data. The apparatus includes an analysis unit, an execution control unit, an axis control unit, a machining time predicting unit, and an axis operation simulation unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If actual machining data is used to predict machining time, then prediction accuracy is improved, but data collection time and labor are increased
Solution Approach 1:
The patent creates a virtual copy of the machining system through simulation, where a virtual machine tool replicates the behavior of the actual machine tool. This virtual model allows machining time prediction without needing actual machining data, as the simulation environment reproduces the physical system's characteristics and responses.
Solution Approach 2:
The patent replaces the mechanical data collection process with a computational simulation system. Instead of physically measuring machining times on actual machine tools and compiling data, the system uses computer-based simulation to predict machining times, substituting physical experimentation with virtual modeling.
2Reliability
If actual machining data is collected for prediction, then prediction reliability is improved, but the complexity of data collection and processing increases
Solution Approach 1:
The simulation system creates a virtual replica of the machining process that inherently captures the reliability characteristics of the actual system. The virtual machine tool model incorporates the same kinematic and dynamic properties, ensuring that simulation results reliably reflect actual machining behavior without requiring extensive data collection.
Solution Approach 2:
The simulation system is self-sufficient in generating prediction results without requiring external data collection efforts. The virtual model contains all necessary information about the machine tool's behavior, allowing it to autonomously predict machining times based on machining programs alone, eliminating the need for separate data collection and processing systems.
3Adaptability or versatility
If frequent stop commands are present in the machining program, then machining flexibility is improved, but accurate machining time prediction becomes more difficult
Solution Approach 1:
The simulation system accurately replicates the effect of stop commands in the virtual environment. When the machining program contains frequent stop commands, the virtual machine tool model responds accordingly, pausing operations at the same points as the actual machine tool would, thereby maintaining prediction accuracy despite the complexity introduced by frequent stops.
Solution Approach 2:
The simulation system dynamically processes the machining program, evaluating commands in real-time virtual execution. This dynamic approach allows the system to adapt to frequent stop commands and other program variations, accurately tracking the virtual tool's progression through the machining operations regardless of how often the program pauses or changes direction.
4Power
If axes with high inertia are used, then machine tool performance is improved, but machining time prediction accuracy deteriorates
Solution Approach 1:
The virtual machine tool model incorporates accurate representations of high-inertia axes, including their mass, moment of inertia, and dynamic characteristics. This faithful copying of the physical system's inertial properties allows the simulation to correctly predict the time required for acceleration and deceleration of high-inertia components, maintaining prediction accuracy despite the challenging dynamics.
Solution Approach 2:
The simulation system adjusts virtual parameters such as acceleration rates, velocity profiles, and positioning times based on the specific inertial characteristics of each axis. By dynamically modifying these parameters according to the actual machine tool's high-inertia properties, the system achieves accurate prediction of machining times even for axes with significant mass and momentum.
Data Source
AI summary
A machining time prediction device for a machine tool that controls at least one axis to machine a workpiece on the basis of a machining program, the machining time prediction device comprising: an analysis unit that analyzes the machining program and generates operation instructions for the axis; an execution control unit that supervises the execution of operation instructions, instructs the operation of the axis on the basis of the result of analyzing the machining program and determines that the operation of the axis is complete; an axis control unit that generates control commands on the basis of the axis operation instructions; a machining time prediction unit that measures the time required to execute the machining program and predicts the machining time; and an axis operation simulation unit that simulates the operation of the axis on the basis of the control commands and outputs virtual responses.