Programmable Logic Controller for CNC Tool Offset and Multi-Machine Management
Solution Overview
Problem
CNC machine tools require cumbersome and time-consuming processes for tool offset adjustments, often requiring multiple attempts to properly align tools, and lack efficient methods for operating multiple machines simultaneously or running the same process across different tools.
Innovation Solution
A programmable numeric control (PNC) system that includes a programmable logic controller (PLC) with a memory portion for storing part programs and offset information, allowing for communication with operator interfaces and machine tools to execute part programs, decode commands, and manage multiple machine tools from a single interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a CNC machine uses standard tool offset adjustment procedures, then the tool can be aligned to the correct position, but the process is cumbersome and time-consuming requiring multiple attempts
Solution Approach 1:
The patent replaces manual visual verification and mechanical adjustment procedures with an automated optical measurement system. The probe automatically measures tool positions and the controller calculates offsets, eliminating the need for operators to manually adjust and visually verify tool positions, thereby reducing both time and human error.
Solution Approach 2:
The system enables self-service through automated tool measurement and offset calculation. The probe automatically positions itself, measures tool locations, and the controller autonomously computes the offset values without requiring operator intervention for each measurement cycle.
2Productivity
If multiple CNC machines are used to run the same process, then production capacity is increased, but the operator must load and manage separate part programs on each machine
Solution Approach 1:
The controller is designed with universal functionality to manage multiple machine tools through a single interface. The system can load, store, and execute part programs for different machines from one centralized controller, eliminating the need for separate program management on each machine while maintaining full control over multiple production units.
Solution Approach 2:
The patent merges the control functions of multiple CNC machines into a single integrated controller. The controller consolidates program management, offset storage, and machine coordination in one unit, reducing the complexity associated with managing separate control systems for each machine.
3Adaptability or versatility
If a part program is edited on a CNC machine, then the program can be updated to meet new requirements, but the machine must be stopped during the editing process
Solution Approach 1:
The controller separates program editing functions from program execution functions. The system divides control operations into distinct segments: program loading, editing, verification, and execution. This allows the editor to modify stored programs while the controller continues to execute current programs without interruption.
Solution Approach 2:
The system performs preliminary verification and simulation of program changes before implementing them on the running machine. The controller allows operators to edit and verify program changes in advance, then automatically implement the updated program without requiring machine shutdown, ensuring smooth transitions.
Data Source
AI summary
A method of controlling a machine tool and other controlled devices, as well as a programmable numerical control (PNC) system, are disclosed. In at least one embodiment, the method of controlling includes receiving a first part program at a programmable logic controller (PLC), and storing the first part program in a string array library of a memory portion of the PLC. The method further includes communicating information between the PLC and an operator interface regarding the first part program, and providing a first signal from the PLC to a first port so as to cause the first machine tool to be operated in accordance with the first part program. Also, in at least some embodiments, the PNC system allows for control of multiple machine tools and/or other controlled devices, by way of one or more part programs, and/or for editing of a part program while that program is being executed.