Machine Component Deflection Calculation With Self-Weight Compensation
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Solution Overview
Problem
Existing numerical control devices for industrial machines require a vast number of measurements to accurately calculate the deflection amount between the workpiece and tool, making the compensation process cumbersome.
Innovation Solution
A deflection amount calculation device that includes an actual deflection amount acquisition unit, an ideal deflection amount calculation unit, and a self-weight deflection amount calculation unit, which use measured values and ideal models to calculate the self-weight deflection amount and compensate position coordinates, simplifying the process by reducing the number of necessary measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a vast number of measurements are performed to accurately calculate the deflection amount between the workpiece and tool, then the manufacturing precision is improved, but the device complexity and ease of operation deteriorate
Solution Approach 1:
The patent extracts and separates the self-weight deflection component from the total deflection measurement. By using a measurement device to obtain only the self-weight deflection amount independently, the complex task of measuring all deflection components is simplified into a focused measurement of the self-weight effect alone, reducing the number of measurements required while maintaining accuracy.
Solution Approach 2:
The patent segments the deflection calculation into distinct components: self-weight deflection (measured by the measurement device) and load-induced deflection (calculated separately). This segmentation allows each component to be measured and calculated independently, reducing the overall measurement complexity while preserving the accuracy of the total deflection calculation.
2Manufacturing precision
If a vast number of measurements are performed to accurately calculate the deflection amount, then the manufacturing precision is improved, but the ease of operation deteriorates
Solution Approach 1:
The measurement device extracts and measures only the self-weight deflection component, which is then used by the control device to calculate and compensate for deflections. This extraction approach simplifies the operator's task from performing numerous measurements to simply operating the measurement device once to obtain the self-weight deflection data, significantly improving ease of operation while maintaining precision.
3Ease of operation
If the self-weight deflection is not compensated, then the ease of operation is maintained, but the manufacturing precision deteriorates
Solution Approach 1:
The measurement device performs preliminary measurement of the self-weight deflection before the actual machining operation begins. The control device then uses this pre-measured self-weight deflection data to calculate and apply compensation values during machining. This preliminary action ensures that the compensation is already prepared, maintaining operational simplicity while achieving high precision without requiring complex real-time measurements during machining.
Data Source
AI summary
A deflection amount calculation device configured to calculate a deflection amount in a reference direction of a component constituting an industrial machine, the deflection amount calculation device including: a deflection amount acquisition unit configured to acquire, as an actual deflection amount, a measured value of a deviation amount at a predetermined position before and after an actual load is applied to a given position of the component; an ideal deflection amount calculation unit configured to, based on an ideal model of the component, calculate an ideal value of the actual deflection amount as an ideal deflection amount; and a self-weight deflection amount calculation unit configured to, based on the actual deflection amount and the ideal deflection amount, calculate a self-weight deflection amount caused by a self-weight of the component.