Machine Tool Axis Blocking for Simpler Multi-Axis Control
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Solution Overview
Problem
Existing machine tools face challenges in efficiently machining complex geometries with increasing machine axes while requiring cost-effective control units, ensuring compatibility across different machines, and minimizing computing effort.
Innovation Solution
A method that blocks at least one axis of rotation, determines control commands for remaining axes, and adjusts these commands to account for the blocked axis, allowing simpler control units to operate complex machines with reduced degrees of freedom.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the number of machine axes is increased to machine complex geometries, then manufacturing capability is improved, but control unit complexity and cost increase
Solution Approach 1:
The control of machine axes is segmented into two groups: actively controlled axes and blocked axes. The blocked axes are mechanically locked or have their control suppressed, effectively dividing the control system into simpler subsystems that can be managed by less complex control units while still achieving complex machining through coordinated motion of the active axes.
Solution Approach 2:
A coordinate transformation mechanism acts as an intermediary between the parts program and the machine tool execution. This transformation converts machining paths defined in a global coordinate system into commands suitable for the reduced set of active axes, allowing complex geometries to be machined without requiring the control unit to directly manage all machine axes.
2Productivity
If more machine axes are actuated to increase productivity, then material removal rate is improved, but computing effort and control complexity increase
Solution Approach 1:
The control system extracts and isolates the essential degrees of freedom needed for machining by blocking unnecessary rotational axes. This reduces the computing burden on the control unit while maintaining productivity through efficient coordination of the remaining active axes, allowing complex workpieces to be machined without requiring computationally intensive real-time control of all axes.
3Manufacturing precision
If complex high-performance control units are used to manage multiple axes, then machining precision is improved, but cost and availability decrease
Solution Approach 1:
Instead of using complex control units to manage complex multi-axis coordination, the approach inverts the strategy by mechanically simplifying the system through blocked axes and using coordinate transformations to achieve the desired machining precision. This allows standard, more affordable control units to deliver high-precision results for complex geometries.
Data Source
AI summary
A method for operating a machine tool having a first number of machine axes that are movable via a drive and actuatable via a control unit that is configured such that, relative to a reference point on the machine tool, a coordinates transformation is performed around a second number of machine axes, includes providing a parts program for machining of a workpiece via the machine tool, a second step of determining at least one axis of rotation from among the first number of machine axes and blocking the determined at least one axis of rotation for actuations, determining control commands for a plurality of machine axes, excluding the at least one axis of rotation determined in the second step, and a fourth step in which the at least one axis of rotation determined in the second step is brought into a machining position and a corresponding rotational movement is determined.