Dual-Tool Composite Cycle Programming for Balance Cut Accuracy
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Solution Overview
Problem
Conventional lathe processing methods using a composite fixed cycle are limited in achieving high accuracy due to deflection issues when cutting with a single tool, and the balance cut method with two tools cannot utilize a composite fixed cycle effectively.
Innovation Solution
A program creation device that analyzes a composite fixed cycle to create command blocks for each tool, adding delay commands to synchronize the cutting process of two tools, allowing one tool to cut while the other follows and cuts deeper into the workpiece using a composite fixed cycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single tool performs cutting in conventional lathe processing, then the device complexity is low, but manufacturing precision deteriorates due to work deflection
Solution Approach 1:
The patent combines two independent tool systems into a coordinated balance cut operation. By merging the control of two tools that cut from opposite sides of the workpiece, the system achieves high precision machining while managing the complexity through integrated control programming.
Solution Approach 2:
The patent applies the counterweight principle by using two tools pressing against the workpiece from opposite sides. This balanced approach prevents workpiece deflection that occurs with single-sided cutting, thereby improving manufacturing precision without requiring excessively rigid or complex single-tool systems.
2Manufacturing precision
If two tools perform balance cut with different cutting depths, then manufacturing precision improves by preventing work deflection, but device complexity increases due to requiring two independent control systems
Solution Approach 1:
The patent makes the composite fixed cycle program universally applicable to both single-tool and dual-tool balance cut operations. By designing the control program to handle multiple tool configurations through the same basic cycle structure, the system reduces device complexity while maintaining the precision benefits of balance cut.
Solution Approach 2:
The patent segments the balance cut process into discrete command blocks that can be independently controlled and timed. This segmentation allows each tool's cutting action to be precisely managed with appropriate delay commands, achieving high precision while organizing the dual-system control into manageable, modular units.
3Manufacturing precision
If two tools perform balance cut with synchronized cutting, then manufacturing precision improves, but productivity decreases due to requiring coordination and delay commands
Solution Approach 1:
The patent employs periodic action by structuring the balance cut operation as a repeating composite fixed cycle. Each cycle includes approach, cutting, escape, and return phases with built-in delay commands that rhythmically coordinate the two tools. This periodic structure ensures synchronized precision cutting while optimizing the timing to maintain productive machining rates.
Data Source
AI summary
A program creation device includes an analysis unit that analyzes a composite fixed cycle in which a predetermined cycle is repeated multiple times to create a plurality of command blocks CB1 to CB4 for each of the cycles for executing the cycle; a distribution unit that distributes the plurality of command blocks CB1 to CB4 created by the analysis unit sequentially as a command program for each of the plurality of tools; and a command adding unit that adds a first command word indicating a delay amount of delaying a start timing of the cycle of the second tool from a start timing of the cycle of the first tool on the basis of an analysis result obtained by the analysis unit to the command block CB2 or CB4.