Machine Control State Restoration for Tool Adjustment Restarts
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Solution Overview
Problem
The existing control devices for machine tools and industrial robots require manual repetition of stopping and restarting programs for tool adjustments, which is inefficient and prone to errors, especially in ensuring the tool is adjusted before resuming operations.
Innovation Solution
A control device with an operating condition analyzing unit, storage unit, state restoration confirming unit, and executing unit that automatically analyzes and stores operating conditions, confirms the restorability of machine and control device states, and restores these states for seamless program restarts, eliminating the need for manual cursor positioning and code insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual stopping and restarting of programs is used for tool adjustments, then the control process is simple, but the adjustment efficiency is low and error-prone
Solution Approach 1:
The system performs preliminary actions by automatically storing operating conditions and confirming restorability before tool exchange occurs. This preparation enables seamless program restarting without manual intervention, thereby improving adjustment efficiency while maintaining control simplicity.
Solution Approach 2:
The control device serves itself by automatically analyzing operating conditions, storing relevant data, confirming state restorability, and executing state restoration without operator intervention. This self-service capability eliminates manual stopping and restarting operations, significantly improving adjustment efficiency while keeping the control process simple.
2Productivity
If automatic program stopping and restarting is implemented, then adjustment efficiency improves, but the risk of unadjusted tools being used increases
Solution Approach 1:
The system implements feedback by notifying the operator when a tool is not adjusted before program restart. This feedback mechanism ensures that unadjusted tools are identified and addressed, maintaining reliability while enabling automatic program stopping and restarting for improved efficiency.
Solution Approach 2:
The system takes preliminary anti-action by proactively notifying the operator of unadjusted tools before program restart occurs. This preventive measure counteracts the potential harm of using unadjusted tools, ensuring reliability is maintained while automation improves productivity.
3Ease of operation
If manual cursor positioning and code insertion are required for program restart, then control logic is simple, but operator workload and error rate increase
Solution Approach 1:
The control device performs self-service by automatically positioning the program cursor and restoring internal states without operator intervention. This eliminates manual cursor positioning and code insertion, greatly improving ease of operation while the underlying automated logic handles the complexity internally.
Solution Approach 2:
The system introduces an intermediary layer that automatically manages cursor positioning and program state restoration. This intermediary handles the complex control logic internally, presenting a simple interface to the operator while maintaining control logic sophistication behind the scenes.
4Manufacturing precision
If internal state restoration is automated, then program restart accuracy improves, but system complexity increases
Solution Approach 1:
The system performs preliminary actions by storing operating conditions and confirming restorability before tool exchange. This preparation enables accurate program restart by ensuring all necessary state information is captured and verified in advance, improving machining precision while managing system complexity through structured preprocessing.
Solution Approach 2:
The system uses feedback by confirming whether internal states are restorable before executing restoration. This verification feedback ensures that only valid state restorations are performed, maintaining high machining dimension accuracy while the systematic feedback mechanism manages the complexity of state tracking and restoration.
Data Source
AI summary
A control device of a machine including: an operating condition analyzing unit that analyzes an operating condition of the program, and performs a notification when the tool to be exchanged is not adjusted; an operating condition storage unit that stores the operating condition of the program at a time of exchanging the tool; a state restoration confirming unit that confirms whether an internal state of the machine and/or the control device is restorable so that an operation of a predetermined block of the program is performed again after the operation and a stop of the predetermined block after exchanging the tool; and a state restoration executing unit that, in a case in which the internal state is confirmed to be restorable, restores the internal state to a state at the time of exchanging the tool based on the stored operating condition of the program at the time of exchanging the tool.