Machine Tool Program Flow Simulation for Collision Avoidance
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Solution Overview
Problem
Current machine tool automation lacks efficient methods to prevent undesirable conditions such as impending collisions during individual production or high-quality part machining, leading to increased time expenditure and cautious operator behavior, which can hinder productivity while ensuring safety.
Innovation Solution
A system and method for machine-level program flow simulation in NC-controlled machine tools, allowing seamless transition to a direct simulation mode where the simulation unit processes virtual workpieces using machine control data, enabling continued processing without real axis movements, thus preventing collisions and other operational disruptions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional CNC simulation is used for collision avoidance, then safety is improved by detecting impending collisions, but productivity deteriorates due to increased time expenditure and cautious operator behavior
Solution Approach 1:
The patent merges the simulation unit with the machine control unit into a single integrated system. The simulation unit accesses machine control data directly from the CNC controller through a data interface, eliminating the need for separate simulation hardware and software. This integration allows collision detection to occur without adding external complexity or time delays, resolving the contradiction between safety and productivity
Solution Approach 2:
The system performs preliminary collision detection by running simulation calculations in parallel with actual machining operations. The simulation unit processes machine control data ahead of time to predict potential collisions before they occur in real machining, allowing operators to take preventive actions without interrupting the current workflow, thus maintaining productivity while ensuring safety
2Reliability
If parallel simulation is used for collision detection, then safety is improved by early detection of impending collisions, but device complexity increases due to additional simulation infrastructure
Solution Approach 1:
The patent combines the simulation unit and CNC controller into one integrated device, sharing hardware resources and data pathways. The simulation unit accesses control data directly from the CNC controller's internal data structures through a standardized data interface, eliminating the need for separate simulation infrastructure and reducing overall system complexity while maintaining collision detection capabilities
Solution Approach 2:
The integrated system serves multiple functions simultaneously: the simulation unit performs both collision detection and machining simulation, while the CNC controller handles both actual machining control and provides data to the simulation unit. This multi-functionality reduces the need for dedicated separate systems, lowering device complexity while maintaining comprehensive safety monitoring
Data Source
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AI summary
A system (100) for simulating the program sequence of a machine tool (10) comprises a machine tool (10) with a tool holder (22) and a workpiece fixture (26) that are movable relative to each other in at least three axes (40, 42, 44), and a machine control unit (60) assigned to the machine tool (10) that controls the movements of the at least three axes (40, 42, 44). The machine control unit (60) executes a machining program and, based on machining program data (102), generates machine control data (106) for the at least three axes (40, 42, 44), which, as axis control data (116), can be supplied to the at least three axes (40, 42, 44) for machining a real workpiece (24) in a first time plane (92).A simulation unit (86) coupled to the machine control unit (60) accesses the machine control data (106) generated by the machine control unit (60), bypassing the machining program data (102), and processes this data for simulation purposes to machine a virtual workpiece (84) in a second time plane (94). An operator interface (70) includes a control element that, if necessary, interrupts the transmission of the axis control data (116) to the at least three axes (40, 42, 44) and activates a direct simulation mode of the simulation unit (86), in which the simulation unit (86) accesses the machine control data (106) and, analogous to the machining of the real workpiece (24), performs machining of the virtual workpiece (84) in the first time plane (92). A corresponding method is used to simulate the program sequence in machine tools (10).