Machine Tool Collision Avoidance via Pre-calculated Workpiece Models
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for avoiding collisions between tools and workpieces in machine tools are inefficient, often requiring high computing power, long processing times, and unnecessary safety distances, especially when machining is interrupted or manual control is involved, leading to potential tool and workpiece damage.
Innovation Solution
A method that determines movement setpoints for relative tool and workpiece movements using a parts program and manual operator input, calculates a workpiece model based on material removal, and checks for overlaps using expected future movement setpoints to brake the tool if an overlap is detected, eliminating the need for safety distances and reducing processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a workpiece model is calculated by means of a simulation during machining to implement collision avoidance, then collision detection capability is improved, but computing time increases and processing productivity decreases
Solution Approach 1:
The patent calculates the workpiece model in advance before actual machining begins, rather than during machining. This preliminary calculation allows the collision avoidance system to be ready before processing starts, eliminating the need to pause machining for real-time model calculation while maintaining accurate collision detection throughout the process.
Solution Approach 2:
The patent dynamically updates the workpiece model by calculating material removal based on actual machining progress and manually entered movements. The model is continuously adapted to reflect the current state of the workpiece, enabling accurate collision detection even when machining is interrupted or resumed after manual interventions.
2Reliability
If safety distances are maintained between tool and workpiece during manual operation to prevent collision, then collision avoidance is improved, but manufacturing precision decreases due to inability to machine small or filigree workpieces
Solution Approach 1:
The patent implements a feedback mechanism that continuously monitors the actual position of the tool and workpiece based on manually entered movements and calculated material removal. This real-time feedback allows the system to detect potential collisions and alert the operator, enabling safe machining without requiring conservative safety distances that would prevent machining of delicate workpieces.
3Reliability
If the workpiece model calculation runs ahead of real machining to enable collision avoidance, then collision detection is improved, but processing time increases due to sequential operation
Solution Approach 1:
The workpiece model is calculated in advance before machining begins, allowing the collision avoidance system to be fully prepared. This preliminary action eliminates the need for sequential operation where model calculation must wait for machining to complete, as the model can be pre-computed and then used throughout the entire machining process without delays.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a method for preventing an unwanted collision between a tool (18) and a workpiece (21) in a machine tool (11), wherein, upon starting the execution of a part program (3), the determination of target movement values (x, y, z, ov) for controlling a relative movement between the tool (18) and the workpiece (21) is initiated based on the part program (3), and the material removal (M) from the workpiece (21) by the tool (18) is determined based on the determined target movement values (x, y, z, ov). A tool model (WM) is then determined, and it is checked whether the tool model (WM) overlaps with a workpiece model (WSM). In the event of an overlap being detected, the relative movement between the tool (18) and the workpiece (21) is slowed down until it comes to a standstill. The invention further relates to a corresponding device for controlling a machine tool (11).The invention enables the avoidance of an unwanted collision between a tool and a workpiece in a machine tool, thereby achieving a short machining time of the workpiece.