CNC Tool Geometry Compensation for Real-Time Deflection Control
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Solution Overview
Problem
Existing methods for compensating tool deflection during machining are computationally complex and difficult to apply in complex machining procedures, especially when considering machining forces.
Innovation Solution
Dynamically adjust the geometric measurement of the machining tool in real time as a function of the machining force, without altering the tool's actual geometry, by varying the geometric measurement arithmetically to compensate for deflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If axis rigidities are determined individually for each axis and position setpoint values are corrected as a function of axis rigidity and deflection force, then machining precision is improved, but computational complexity increases significantly
Solution Approach 1:
The patent combines the correction of all position-controlled axes into a single unified calculation based on one tool deflection value. Instead of performing separate calculations for each axis as in the prior art, the numerical controller now performs one unified correction computation that accounts for tool deflection and automatically adjusts all affected axes simultaneously, thereby maintaining high machining precision while significantly reducing computational complexity
Solution Approach 2:
The patent creates a universal correction mechanism that handles deflection compensation for multiple axes through a single computational process. The unified calculation serves all position-controlled axes simultaneously, making the system more efficient and easier to implement while maintaining the precision benefits of individualized correction
2Manufacturing precision
If the geometric measurement of the machining tool is varied dynamically and in real time as a function of machining force, then machining precision is improved and individual axis-specific calculations are eliminated, but the complexity of real-time force monitoring increases
Solution Approach 1:
The patent creates a virtual model of the tool geometry that can be dynamically adjusted without physically modifying the actual tool. By varying the geometric measurement in the numerical controller's software model rather than physically changing the tool, the system achieves real-time precision compensation while avoiding the complexity of physical sensors and actuators on the tool itself
Solution Approach 2:
The patent replaces potential mechanical measurement systems with a computational approach. Instead of using physical sensors to measure and react to tool deflection in real time, the system uses force data already available from the machining process and applies computational correction to the geometric model, thereby achieving precision control without adding complex mechanical monitoring hardware
Data Source
AI summary
A machine tool numerical controller receives a parts program which determines a path along which a workpiece should be machined in a material-removing manner by a machining tool. The numerical controller determines control commands by utilising the parts program and controls the position-controlled axes according to the determined control commands. The numerical controller determines the control commands such that the workpiece is machined in a material-removing manner by the machining tool along the path determined by the parts program. During the machining of the workpiece, the numerical controller receives, in real time, actual values characteristic of a machining force exerted on the machining tool and takes a geometrical measurement of the machining tool and the machining force into consideration in the determining of the control commands. During the machining process, the geometrical measurement is varied dynamically and in real time according to the machining force.