Gantry Machine Tool Control for Asymmetric Load Acceleration
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Solution Overview
Problem
Gantry machines are often operated below their maximum acceleration potential due to asymmetrical load distribution, leading to extended working times for machining a workpiece.
Innovation Solution
A machine tool system with adjustable crossbeam and tool holder head positions, controlled by a facility that sets kinematic parameters like velocity, acceleration, and jerk based on the tool holder head's position, allowing adaptation to asymmetrical loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the maximum acceleration of the gantry assembly is set for the most asymmetric case, then the drives have sufficient current capacity, but the machine cannot operate at higher acceleration speeds
Solution Approach 1:
The patent applies dynamics by making the kinematic parameters (acceleration, velocity, jerk) variable rather than fixed. The control facility dynamically adjusts these parameters based on the real-time position of the tool holder head, allowing the machine to operate at higher accelerations when loads are more favorable while still maintaining safety margins when loads are asymmetric. This resolves the contradiction by enabling speed improvement without permanently compromising drive reliability.
Solution Approach 2:
The patent changes the parameters of the system by making acceleration, velocity, and jerk dependent on the tool holder head position. Instead of using fixed conservative parameter values, the system continuously adapts these parameters based on the current load distribution. This allows the machine to achieve higher speeds when conditions permit while automatically reducing parameters when asymmetric loads are detected, thus resolving the contradiction between speed and reliability.
2Productivity
If the machine operates at lower acceleration to avoid drive overload, then drive safety is maintained, but machining time increases
Solution Approach 1:
The control facility dynamically determines position-dependent maximum values for acceleration, velocity, and jerk, allowing the machine to operate at optimal speeds for each position rather than being constrained by the worst-case scenario throughout the entire workspace. This dynamic approach significantly reduces unnecessary time loss while maintaining drive safety.
Solution Approach 2:
The system performs self-optimization by automatically adjusting kinematic parameters based on its own state (tool holder head position). The control facility continuously monitors position and autonomously determines the appropriate maximum acceleration and velocity values, eliminating the need for conservative fixed settings and enabling the machine to achieve maximum productivity without external intervention or manual reconfiguration.
3Speed
If fixed conservative kinematic parameters are used, then drive overload is prevented, but the machine does not utilize full acceleration potential
Solution Approach 1:
The patent implements parameter changes by making kinematic parameters (acceleration, velocity, jerk) variable functions of the tool holder head position. The control facility stores and applies position-dependent maximum values, allowing the machine to achieve higher speeds when loads are favorable while maintaining safety when loads are asymmetric. This approach increases speed capability without requiring overly complex real-time calculations, as the parameters are pre-determined and stored.
Data Source
AI summary
A machine tool system has a machine tool with a stationary machine base, support elements connected to the machine base, and a crossbeam connected to the support elements. The crossbeam is adjustable relative to the support elements in a Z-direction or the support elements are adjustable relative to the machine base in an X-direction. A tool holder head is mounted on the crossbeam and adjustable for travel in a Y-direction along the crossbeam. The X-, Y- and Z directions form a cartesian coordinate system. A control facility is connected to the machine tool for controlling travel in the Y-direction and adjustment in at least one of the X- and/or Z-directions based on a kinematic parameter specified as a function of a position of the tool holder head relative to the Y-axis and thus takes into account asymmetric load distribution caused by movement of the tool holder head.