Machine Tool Control System Adaptive Response
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Solution Overview
Problem
Existing machine tool control systems lack the flexibility to adapt to changing tool conditions and operator preferences, leading to potential damage, reduced tool lifetime, and suboptimal manufacturing processes.
Innovation Solution
A control system that integrates a programmable logic control section with a numerical control section, allowing for evaluation of input signals related to tool and process states, enabling customizable responses by providing information to the numerical control section for improved operation and allowing quick intervention through editable programs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional PLC control system is used for machine tools, then the control system is simple and reliable, but it lacks flexibility to adapt to changing tool conditions and operator preferences
Solution Approach 1:
The control system is segmented into two distinct sections: a PLC control section for basic automated functions and a numerical control section for adaptive responses. This segmentation allows the system to maintain simplicity for routine operations while enabling complexity only where adaptability is needed, resolving the contradiction between adaptability and system complexity.
Solution Approach 2:
The numerical control section acts as an intermediary between the PLC control section and the machine tool. It receives input signals from the PLC, evaluates them against stored conditions, and generates adaptive control signals. This intermediary structure enables flexibility without requiring the entire control system to be complex.
2Duration of action of stationary object
If the control system continuously monitors tool states and provides adaptive control, then tool lifetime is extended and damage is prevented, but manufacturing time increases due to additional processing
Solution Approach 1:
The numerical control section pre-stores multiple response programs and evaluation conditions in its memory before operation begins. When a tool state change is detected, the system can immediately retrieve and execute the appropriate pre-programmed response without requiring complex real-time calculations, thus extending tool life without significantly increasing manufacturing time.
Solution Approach 2:
The system evaluates input signals against stored conditions and skips directly to executing the appropriate pre-determined response program. This approach avoids lengthy analysis and decision-making processes, allowing continuous monitoring and adaptive control to occur with minimal time penalty.
3Ease of operation
If the control system allows operator customization of response programs, then ease of operation improves, but device complexity increases
Solution Approach 1:
The numerical control section provides operators with the ability to independently customize response programs and evaluation conditions through its own programmable interface. Operators can modify the control program to match their specific preferences and requirements without requiring external programming assistance, improving ease of operation while containing complexity within the numerical control section.
Data Source
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AI summary
A control system (110) comprises a programmable logic control section (111) controlling operation of a machine (200) and a numerical control section (112) controlling relative motion between a tool (210) of the machine and a work piece (220). A method (300), performed in the control system, comprises: evaluating (310) an input signal (190), 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 (320) 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.