Machine Tool Process Monitoring for Adaptive NC Response
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Solution Overview
Problem
Existing machine tool control systems lack flexibility in responding to changing tool or process states, often leading to suboptimal operation, tool damage, and reduced product quality due to predefined response protocols that do not account for real-time conditions or operator preferences.
Innovation Solution
A method that allows for the evaluation of input signals related to tool or process states, enabling the transfer of information from a programmable logic control section to a numerical control section, where customizable responses can be executed by editable programs, allowing operators to adapt machine responses based on current circumstances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If predefined response protocols are used in machine tool control systems, then the system structure is simple and reliable, but the system lacks flexibility in responding to changing tool or process states
Solution Approach 1:
The control system is divided into two distinct sections: a programmable logic control section (PLC) that handles basic automated functions, and a numerical control section (NC) that executes customizable programs. This segmentation allows each section to have specialized responsibilities, with the NC section providing flexible, editable programs while the PLC section maintains reliable automated control, thus resolving the contradiction between adaptability and system complexity.
Solution Approach 2:
The system transitions from static, predefined response protocols to dynamic, editable programs in the numerical control section. Operators can modify NC programs in real-time to adapt to changing tool or process states, making the control system dynamic and flexible while maintaining a relatively simple overall structure through the separation of fixed PLC functions and flexible NC functions.
2Manufacturing precision
If predefined response protocols are used, then the control system is simple to operate, but the system leads to suboptimal operation and reduced product quality
Solution Approach 1:
The system continuously monitors tool and process states through input signals and uses this feedback to trigger customized responses via editable NC programs. This feedback mechanism enables the system to adapt to actual operating conditions, improving product quality by responding appropriately to changing states while providing operators with customization capability through editable programs.
Solution Approach 2:
The system allows operators to change control parameters and response behaviors by editing NC programs. This enables optimization of manufacturing processes for different tool states or workpiece conditions, improving product quality while maintaining ease of operation through a user-friendly programming interface that doesn't require deep system knowledge.
3Adaptability or versatility
If customizable responses are enabled through editable programs, then the system improves adaptability and product quality, but the system complexity increases
Solution Approach 1:
By segmenting the control system into PLC and NC sections with distinct roles, the patent enables customizable responses through editable NC programs without significantly increasing overall system complexity. The PLC section maintains simple, reliable automated control, while the NC section provides customization capability, thus achieving adaptability with manageable complexity.
Solution Approach 2:
The numerical control section serves multiple functions: it executes standard machining programs, handles customizable response protocols, and provides real-time adaptation to tool and process states. This multi-functionality consolidates various capabilities into a single section, enabling customizable responses without proportionally increasing system complexity.
Data Source
AI summary
A control system includes a programmable logic control section controlling operation of a machine and a numerical control section controlling relative motion between a tool of the machine and a work piece. A method, performed in the control system, includes: evaluating an input signal, received by the programmable logic control section, in relation to a first condition, wherein the input signal includes information about a state of the tool or of a subtractive process performed via interaction of the tool and the work piece; and in response to the input signal satisfying the first condition, providing the information to the numerical control section. The state may for example be tool breakage, tool wear or wrong cutting data. An operator of the machine may for example specify via programs in the numerical control section how the machine is to respond to such states.