Numerical controller
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional machining simulations fail to accurately consider the influence of mechanical vibration on machined surface quality, making it difficult to predict and improve surface quality without actual machining, which leads to potential tool wear and inefficient processes.
Innovation Solution
A numerical controller that uses feedback data from idling machine tool axes to simulate machining paths, allowing for the visualization of vibration-induced path errors and their components, enabling precise identification and adjustment of axis settings to minimize surface quality issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional machining simulation is performed based on calculated relative paths, then machining time can be calculated, but the influence of mechanical vibration on surface quality cannot be identified
Solution Approach 1:
The patent applies feedback by acquiring actual relative position data from the servo mechanism during idling operation and using this feedback information to correct and update the machining simulation results, thereby reflecting actual mechanical vibration effects on surface quality
Solution Approach 2:
The patent creates a virtual copy of the actual machining process by acquiring feedback data during idling and using it to simulate the machining paths and surface quality outcomes, allowing prediction without actual machining
2Manufacturing precision
If machining simulation uses feedback data from idling operation, then the influence of mechanical vibration on surface quality can be identified, but the system complexity increases
Solution Approach 1:
The patent makes the idling operation serve multiple functions: both for machine tool calibration/positioning and for acquiring feedback data for machining simulation, thereby reducing the need for separate testing operations and simplifying the overall system
Solution Approach 2:
The system uses its own servo mechanism and control units to generate and process the feedback data needed for simulation, making the machine tool self-diagnostic and self-evaluating without requiring external testing equipment
3Manufacturing precision
If actual machining is performed to ascertain surface quality, then vibration influence can be identified, but tool wear increases and process efficiency decreases
Solution Approach 1:
The patent performs preliminary action by conducting machining simulation using feedback data from idling operation before actual machining, allowing surface quality to be predicted and optimized in advance, thereby preventing unnecessary tool wear from trial-and-error machining
Solution Approach 2:
The patent uses virtual copying by simulating the machining process and its vibration effects on a computer system, creating a digital twin of the machining outcome without physical contact between tool and workpiece, thus eliminating tool wear during the evaluation phase
Data Source
AI summary
A numerical controller is provided with a control unit configured to control a machine tool and acquire feedback data in relative positions of a tool and a workpiece, a machining simulation unit configured to perform simulation processing for machining based on a machining program and create the shape of the machined workpiece, and a display unit configured to display the machined workpiece shape created by the machining simulation unit. The machining simulation unit performs machining simulation processing using the feedback data acquired by the control unit, in place of relative movement paths for the tool and the workpiece based on a command by the machining program.