Distributed CNC Look-Ahead Processing for Stable Feed Rate
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Solution Overview
Problem
High-speed and high-precision machining programs face issues with speed control abnormalities due to insufficient look-ahead blocks, leading to unstable acceleration/deceleration and reduced machining quality, especially in systems with multiple axes, where processing power is insufficient to secure look-ahead blocks.
Innovation Solution
A numerical control system where multiple numerical controllers are connected via a network, allowing each controller to request another to look ahead at positions with insufficient look-ahead blocks, thereby stabilizing feed rate and cutting speed by dividing the machining program into surplus and substitute look-ahead ranges and allocating memory regions for parallel look-ahead operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the processing time for executing the program is shorter than the time required for look-ahead processing, then high-speed machining is achieved, but the look-ahead blocks cannot be secured and acceleration/deceleration cannot be determined properly
Solution Approach 1:
The patent segments the look-ahead processing function into multiple independent numerical controllers. Each controller has its own look-ahead processing unit that operates independently, allowing parallel processing of look-ahead blocks across multiple controllers. This segmentation enables the system to maintain sufficient look-ahead blocks even at high command speeds by distributing the processing load.
Solution Approach 2:
The patent combines multiple numerical controllers into a coordinated system where each controller contributes to the overall look-ahead processing. The controllers work together to process machining programs, with each controller handling specific portions of the look-ahead blocks. This merging of resources increases the total processing capacity while maintaining individual controller reliability.
2Manufacturing precision
If the number of look-ahead blocks is increased to ensure stable acceleration/deceleration, then machining quality improves, but the processing time increases and command speed decreases
Solution Approach 1:
The patent divides the look-ahead processing workload into segments handled by multiple numerical controllers simultaneously. Each controller processes a portion of the look-ahead blocks in parallel, reducing the total processing time while maintaining the necessary number of look-ahead blocks for stable acceleration and deceleration. This enables high command speeds without sacrificing machining quality.
Solution Approach 2:
The patent implements preliminary look-ahead processing across multiple controllers before the actual machining operation begins. By pre-processing and distributing look-ahead blocks to multiple controllers in advance, the system prepares sufficient acceleration/deceleration data without delaying the start of high-speed machining, thus maintaining both machining quality and productivity.
3Reliability
If the processing power of the numerical controller is increased to secure look-ahead blocks, then speed control stability improves, but system cost and complexity increase
Solution Approach 1:
Instead of concentrating all look-ahead processing capability in a single high-power controller, the patent segments the processing function across multiple standard numerical controllers. Each controller handles a portion of the look-ahead processing, allowing the use of simpler, more cost-effective controller units while achieving the same overall processing capability through parallel operation.
Solution Approach 2:
The patent designs each numerical controller with multi-functional capabilities, where each controller can independently perform look-ahead processing, program execution, and coordinate with other controllers. This universal design allows standard controllers to fulfill multiple roles, reducing the need for specialized high-power controllers and simplifying the overall system configuration.
Data Source
AI summary
To provide a numerical controller that can detect a position in a machining program at which a speed control abnormality is likely to occur due to an insufficient look-ahead blocks that are used to determine an acceleration/deceleration operation, and start a look-ahead processing function from the position in parallel with looking ahead at the machining program from the start of the machining program in order to stabilize feed rate, cutting speed and other factors. A numerical controller includes a program execution unit that executes a machining program, a first program look-ahead unit and a second program look-ahead unit that simultaneously look ahead at the machining program from different blocks in the machining program in parallel with execution of the machining program, and a look-ahead allocation unit that divides a storage unit into a first region and a second region and instructs the first program look-ahead unit to perform a look-ahead action of storing look-ahead blocks in the first region and instructs the second program look-ahead unit to perform a look-ahead action of storing look-ahead blocks in the second region.