Controller Dynamic Oscillation Synchronization
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Solution Overview
Problem
High-accuracy oscillation control in machining processes is compromised by changes in the rotational speed of the main spindle, leading to synchronization errors and inconsistent machined surface quality due to fixed oscillation periods and phases.
Innovation Solution
A controller that dynamically adjusts the reference speed of the oscillation command based on the actual rotational speed of the main spindle, ensuring that the oscillation period and phase remain synchronized with the spindle's rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a fixed oscillation period is used in high-accuracy oscillation control, then the control parameters are simple to set, but synchronization errors occur when the main spindle rotational speed changes
Solution Approach 1:
The oscillation period is changed from a fixed value to a dynamically adjustable parameter that varies according to the main spindle rotational speed. The control system continuously monitors the spindle speed and adjusts the oscillation period in real-time to maintain synchronization, transforming a static parameter into a dynamic one that adapts to changing operating conditions.
Solution Approach 2:
The oscillation period parameter is modified based on the main spindle rotational speed. When the spindle speed changes, the oscillation period is automatically adjusted to maintain the correct synchronization relationship. This parameter change ensures that the oscillation control remains accurate regardless of variations in spindle speed.
2Reliability
If the main spindle rotational speed is kept constant, then the oscillation period can be maintained, but the relative speed between tool and workpiece varies on conical workpieces
Solution Approach 1:
The oscillation period parameter is dynamically adjusted based on the main spindle rotational speed. When machining conical workpieces where the circumferential speed varies with diameter, the system modifies the oscillation period to compensate for these variations, ensuring consistent chip subdivision and surface quality across the entire workpiece surface.
3Manufacturing precision
If the oscillation period is adjusted to maintain contact during grinding, then grinding effectiveness improves, but phase shifts occur when spindle speed changes instantaneously
Solution Approach 1:
The control system implements feedback by continuously monitoring the main spindle rotational speed and using this information to adjust the oscillation period. When the spindle speed changes instantaneously, the feedback mechanism detects this change and immediately adjusts the oscillation parameters to maintain the correct phase relationship, preventing impacts between the grindstone and workpiece surface.
Data Source
AI summary
A controller performs high-accuracy oscillation control in which an axis driven by a motor is rocked in accordance with the rotation of a spindle motor for driving a main spindle. This controller determines a reference speed of rocking motion based on a reference speed set in advance, a reference main spindle rotational speed of the spindle motor, and an actual main spindle rotational speed, and calculates a rocking motion speed for each control period based on the determined reference speed of the rocking motion. The calculated rocking motion speed for each control period is added to a command outputted by the controller for controlling the position of the motor for each control period.