Numerical Controller Halt Point Specification for Machine Tools
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Solution Overview
Problem
Existing numerical controllers for machine tools require multiple halt commands to be inserted into machining programs for unplanned halts, leading to inefficiencies and potential machining flaws or tool damage, especially in programs with many minute blocks or low-speed processes.
Innovation Solution
A numerical controller that allows specification of a halt block within the machining program, enabling halts at the start, intermediate, or end points of a block, with options to register and enable/disable halt commands and analyze non-cutting states to safely execute halts without affecting machining operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple halt commands are inserted into machining programs to enable unplanned halts, then the machine tool can be halted at various points, but the program creation time increases and the device complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-defining specific blocks in the machining program as halt blocks before execution. These blocks are marked in advance with halt permission flags, so when an unplanned halt is needed, the controller can immediately identify and execute the halt at the next appropriate block without requiring multiple halt commands to be manually inserted throughout the program.
Solution Approach 2:
The patent segments the machining program into regular blocks and halt blocks. Each block is independently evaluated for halt permission, allowing the system to selectively enable halts at specific segments (blocks) rather than requiring halt commands throughout the entire program. This segmentation reduces program complexity while maintaining halt adaptability.
2Adaptability or versatility
If halt commands are inserted at multiple points in the machining program, then unplanned halts can be executed, but the machining program creation becomes time-consuming and complicated
Solution Approach 1:
The system performs preliminary action by automatically identifying and marking suitable blocks for halts during program preparation. The controller pre-calculates which blocks have halt permission based on machining conditions, so that when unplanned halts are needed during execution, no additional program modification is required. This eliminates the time-consuming process of manually inserting multiple halt commands.
Solution Approach 2:
The machining program itself contains the information needed to determine where halts can occur. Each block includes metadata about whether it permits halts, allowing the controller to autonomously determine halt positions without external intervention or complex program creation. The program serves its own halt management needs.
3Ease of operation
If the automatic operation is halted using feed-hold stop or single block stop function, then the operation can be halted, but the operator must wait and observe the machining state until a favorable condition is reached, increasing operation time
Solution Approach 1:
The system uses feedback by continuously monitoring the current block execution status and comparing it against pre-defined halt block information. When a halt request occurs, the controller immediately checks whether the current block has halt permission and provides feedback about the next available halt position. This eliminates the need for operators to wait and observe, as the system automatically identifies favorable halt conditions in real-time.
Solution Approach 2:
The controller performs preliminary analysis of the machining program to identify all blocks with halt permission before execution begins. This preliminary action creates a ready list of valid halt positions, so when an unplanned halt is needed during operation, the system can immediately execute at the next appropriate block without requiring the operator to wait for favorable conditions to naturally occur.
4Speed
If the halt operation is executed in minute blocks with successive paths, then the halt can be performed quickly, but it is necessary to perform start-up operation repeatedly in single block stop function, making operation complicated
Solution Approach 1:
The patent segments the control logic into block evaluation, halt permission checking, and execution phases. Each minute block is independently evaluated for halt permission, and the system automatically manages the transition between blocks. This segmentation eliminates the need for repeated manual start-up operations, as the controller autonomously handles block transitions and halt execution within the segmented structure.
Solution Approach 2:
The machining program and controller work together in a self-service manner where each block contains information about its halt permissions. When halting in minute blocks, the system automatically uses this embedded information to determine execution flow without requiring external start-up commands. The program serves its own control needs, reducing operational complexity.
Data Source
AI summary
A numerical controller of the invention includes a halt block specifying unit that specifies, from among blocks corresponding to unmachined sections of a machining program, a command block in which halting is allowed to occur as a halt block during an automatic operation of a machine tool, a halt position selecting unit that selects, as a position at which the automatic operation is halted, any one of a start point, an intermediate point, and an end point of the halt block, and a halting unit that halts the automatic operation at a position selected by the halt position selecting unit.