Machine Tool Feed Axis Controller Runout Correction
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Solution Overview
Problem
Existing position controllers for machine tools require external devices and prior measurement to identify runout amounts of cutting edges, leading to increased labor and costs, and fail to uniformly distribute machining allowances, resulting in tool chipping during machining of hard-to-cut materials.
Innovation Solution
A position controller with a runout amount correcting device that estimates cutting edge runout values from rotation angle information and reference signals, leveling influences across cutting edges without external measurement, using a servo motor and feedback mechanisms to adjust position commands and torque commands for uniform machining allowances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external devices and prior measurement are used to identify runout amounts of cutting edges, then measurement precision of runout amounts is improved, but device complexity and labor requirements increase
Solution Approach 1:
The machine tool controller performs runout measurement functions internally using existing sensors and processing capabilities, eliminating the need for external measurement devices. The controller detects cutting load variations during normal machining operations and automatically calculates runout amounts, allowing the system to serve its own measurement needs without additional equipment.
Solution Approach 2:
The patent replaces mechanical/runout measurement devices with an electronic control system that uses electrical signals and computational algorithms. Instead of physical measurement instruments, the controller uses electrical detection of cutting load variations and mathematical processing to determine runout amounts, substituting mechanical systems with electronic ones.
2Manufacturing precision
If runout amounts are not corrected, then device complexity is reduced, but manufacturing precision deteriorates due to tool chipping and uneven machining allowances
Solution Approach 1:
The controller implements a feedback mechanism where cutting load variations detected during machining are used to identify runout amounts, which then feed into correction calculations. The detected runout information is fed back to adjust feed axis positioning commands, creating a closed-loop system that automatically compensates for runout effects and ensures uniform machining allowances.
Solution Approach 2:
The patent changes the positioning parameters of the feed axis dynamically based on detected runout conditions. By adjusting feed axis position commands in response to varying cutting loads and identified runout amounts, the system modifies operational parameters to compensate for tool installation errors, maintaining consistent machining allowances despite physical imperfections.
3Manufacturing precision
If feed axis position is adjusted to compensate for runout, then manufacturing precision is improved, but device complexity increases due to additional correction mechanisms
Solution Approach 1:
The patent merges the runout measurement, analysis, and correction functions into the existing machine tool controller. Instead of adding separate correction devices, the controller integrates multiple functions (cutting load detection, runout calculation, correction amount determination, and feed axis positioning adjustment) into a unified system, reducing overall device complexity while achieving precision improvements.
Data Source
AI summary
A position controller includes a position detector, a speed command operator, a first adder, a torque command operator, a second adder, a drive unit, a runout amount correcting device, and a third adder. The runout amount correcting device is configured to employ a value related to deviation between a command value and a detection value in physical quantity of a movable part as a reference signal. The runout amount correcting device is configured to calculate a position correction amount from rotation angle information of the main spindle and the reference signal. The runout amount correcting device is configured to estimate a runout amount of a cutting edge of the tool from the reference signal. The runout amount correcting device is configured to calculate the position correction amount such that influences of the respective cutting edges appearing in the reference signal are leveled.