Industrial Machine Controller for Custom Callback Error Checks
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Solution Overview
Problem
Machining failures in CNC machine tools often result from user operation mistakes, such as incorrect tool length compensation, work coordinate system errors, and lack of simulation checks, which existing countermeasures cannot completely prevent due to their inflexibility and potential for user disregard.
Innovation Solution
A controller system that customizes checking content based on specific machine and site conditions, using a receiving unit to register conditions and actions as callback processes, allowing for automated and appropriate checking of user operations, including tool changes, simulation execution, and program runs, to prevent human errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If users are required to follow management rules and pay attention to prevent mistakes, then human errors may be reduced, but users may still ignore or forget the rules making complete prevention difficult
Solution Approach 1:
The system enables self-service by automatically checking operation conditions and executing predetermined actions without requiring user adherence to external rules. The controller autonomously monitors tool length compensation values, work coordinate system origins, and simulation execution status, then automatically prevents machining errors by rejecting unsafe operations or prompting users, eliminating the need for users to manually follow management rules.
2Reliability
If mechanical checking is implemented to prevent operation mistakes, then error prevention capability is improved, but the checking content must be customized for different machines and sites increasing system complexity
Solution Approach 1:
The system applies dynamics by making the checking content configurable and adaptable rather than fixed. The controller includes a setting unit that allows customization of checking parameters, conditions, and predetermined actions based on specific machine types, sites, and operational requirements. This enables the system to dynamically adjust its error prevention mechanisms to match different operational contexts without requiring separate hardwired systems for each configuration.
Solution Approach 2:
The system utilizes parameter changes by allowing modification of checking conditions and thresholds through programmable parameters. Different machines and sites can define custom parameter sets for tool length compensation validation, coordinate system verification, and simulation requirements. The controller adjusts its checking behavior based on these parameter configurations, enabling flexible adaptation to various operational environments without increasing hardware complexity.
3Ease of manufacture
If standardized checking procedures are used across all machines, then ease of implementation is improved, but the checking may not reflect specific machine and site circumstances reducing effectiveness
Solution Approach 1:
The system achieves universality through a standardized controller architecture that can perform multiple checking functions across different machine types and sites. The same basic controller hardware and software framework is used universally, but it incorporates configurable parameters and customizable checking rules that adapt to specific operational requirements. This allows a single standardized platform to provide effective error prevention tailored to each machine and site context.
Data Source
AI summary
A controller capable of preventing human mistakes by customizing checking contents upon operations of users to automatically perform customized checking appropriately is provided. A controller that controls an industrial machine includes: a receiving unit that receives a condition of a callback process associated with control of the industrial machine and an action corresponding to the condition; and a designated condition registering unit that registers the condition and the action received by the receiving unit as a callback process.