Gear Processing Control Device Bus Synchronization
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Solution Overview
Problem
Existing gear processing machines face challenges in achieving high-accuracy synchronization between the workpiece and tool axes due to transmission delays caused by the need to pass position feedback data through an upper controller, which also increases costs and limits flexibility in axis configuration, particularly when trying to synchronize multiple slave axes with a single master axis.
Innovation Solution
A control device that directly connects the tool axis controller and workpiece axis controller via a bus, allowing the tool axis position detection data to be supplied directly to the workpiece axis controller, enabling the generation of motion commands that synchronize the workpiece axis with the tool axis without using a branch circuit, thus reducing transmission delays and allowing for synchronization of one or multiple slave axes with one master axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If position feedback data is transmitted through the upper controller, then centralized control is achieved, but transmission delay increases and synchronization accuracy deteriorates
Solution Approach 1:
The control system is segmented into hierarchical levels: the upper controller handles high-level coordination while the tool axis controller and workpiece axis controller handle low-level real-time control independently. This segmentation allows position feedback to be transmitted directly between axis controllers without passing through the upper controller, reducing transmission delay while maintaining centralized coordination for complex operations.
Solution Approach 2:
A communication bus is introduced as an intermediary channel that directly connects the tool axis controller and workpiece axis controller. This intermediary enables fast position feedback transmission between controllers without requiring upper controller intervention, thus reducing transmission delay while the upper controller remains the mediator for synchronization coordination.
2Loss of time
If a branch circuit is used to connect the master axis position detection sensor directly to the slave axis controller, then transmission delay is reduced, but device complexity and cost increase
Solution Approach 1:
The communication bus serves multiple functions: it transmits position feedback data from the tool axis controller to the workpiece axis controller, carries synchronization commands from the upper controller to axis controllers, and enables bidirectional communication between all controllers. This multi-functionality eliminates the need for separate branch circuits while reducing device complexity.
3Device complexity
If the control system is designed for one-to-one axis synchronization, then control simplicity is maintained, but adaptability to multiple slave axes deteriorates
Solution Approach 1:
The control system dynamically adapts to different axis configurations through software-based synchronization modes. The workpiece axis controller can operate in slave mode to synchronize with the tool axis, or in independent mode when not requiring synchronization. This dynamic flexibility allows the same hardware architecture to support one-to-one, one-to-many, and many-to-many axis synchronization configurations without structural changes.
Data Source
AI summary
A control device (1) of a gear processing machine has a bus (51) that communicates by directly connecting between a tool axis controller (22) and a workpiece axis controller (12), and, in this control device, the position of a tool axis (40) that is detected by a tool axis position detection sensor (25) is supplied to a workpiece axis controller via a bus, an upper controller (10) supplies a predetermined synchronization ratio and a superimposition command for applying a twisting operation to a workpiece axis controller, and the workpiece axis controller adds a value that is generated by multiplying the position of the tool axis that is supplied via the bus, by the synchronization ratio, and the superimposition command, and generates a motion command for a workpiece axis (30).