Numerical Controller Braking Paths for Collision-Free Machine Stops
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Solution Overview
Problem
Existing systems for avoiding collisions in production machines fail to effectively consider real-time events, leading to potential collisions and reduced productivity due to uncontrolled braking and restrictions on movement.
Innovation Solution
An operating method for a numerical controller that ascertains current and expected position setpoint values, checks for collision risks, and if a risk is identified, brings the position-controlled axes to a standstill along a previously checked safe path stored in a braking path memory.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the numerical controller checks for collision risks in real-time and brings axes to standstill upon detecting a risk, then collision avoidance reliability is improved, but productivity deteriorates due to frequent unplanned stoppages
Solution Approach 1:
The numerical controller performs preliminary collision risk checks for future position setpoint values before the actual movement occurs. By predicting potential collision risks in advance and planning stopping points along the trajectory, the system can guide the axis to stop at safe positions rather than making sudden unplanned stoppages, thereby maintaining productivity while ensuring collision avoidance reliability.
Solution Approach 2:
The system dynamically adjusts the control strategy based on real-time collision risk assessments. When risks are detected, the controller modifies the motion trajectory and stopping points dynamically, allowing the system to respond flexibly to changing conditions while maintaining optimal productivity through intelligent path planning rather than rigid stop-and-go operations.
2Reliability
If the numerical controller restricts movements to maintain minimum distances between elements, then collision risk is reduced, but productivity deteriorates due to reduced movement freedom and speed
Solution Approach 1:
The controller preliminarily identifies safe stopping points along the intended trajectory where minimum distance requirements are satisfied. By pre-calculating these positions and guiding the axis to stop there rather than restricting the entire movement, the system maintains movement freedom and speed while still ensuring collision risk reduction through proactive positioning at safe locations.
Solution Approach 2:
The system changes the position parameter dynamically by selecting optimal stopping points along the trajectory where the minimum distance constraint is satisfied. This allows the axis to maintain its motion parameters (speed, acceleration) up to the stopping point, and only then adjust the position parameter to a safe location, thereby maintaining productivity while ensuring collision risk reduction.
3Productivity
If the numerical controller accepts the risk of real-time events leading to collisions, then productivity is improved by allowing unrestricted movements, but reliability deteriorates due to potential collisions
Solution Approach 1:
The controller performs preliminary collision risk assessments for expected position setpoint values before executing movements. This allows the system to maintain unrestricted movements for safe trajectories (improving productivity) while identifying and preventing risky movements in advance (maintaining reliability), thus resolving the contradiction between productivity and collision avoidance reliability.
4Reliability
If uncontrolled braking is applied to avoid collisions, then collision avoidance reliability is improved, but productivity deteriorates due to abrupt stoppages and potential damage
Solution Approach 1:
The controller preliminarily identifies appropriate stopping points along the trajectory where the axis can be brought to a controlled halt. By guiding the axis to these pre-determined positions rather than applying sudden uncontrolled braking, the system achieves collision avoidance reliability through planned stopping while maintaining productivity through smooth, controlled deceleration that prevents damage and allows quicker resumption of motion.
Data Source
AI summary
A numerical controller uses specifications to control position-controlled axes of a production machine and determines a current group of position setpoint values and groups of position setpoint values expected for a forecast horizon. The numerical controller checks for the risk of a collision between at least one element moved by the position-controlled axes and at least one other element. The numerical controller carries out the same check for the expected groups. If there is no risk of collision, it stores the expected groups in a braking path memory and uses the current group. If there is the risk of a collision, it changes the axes along a path to a standstill defined by the braking path memory and braking is effected along a path which has been previously checked for the risk of a collision and for which no risk of a collision has been detected.