Machine Tool Control System for Drive Axis Reversal Streaks
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Solution Overview
Problem
Machine tools often produce streaks or stripes on machined surfaces due to delays in drive axis reversal, such as backlash, which existing technologies fail to effectively detect and address.
Innovation Solution
A control system for machine tools that uses a vision sensor to capture images of the machined surface, performs image processing on the data, and identifies the drive axis causing failures by associating chronological control data with spatial machined surface measurement data from multiple machining directions, allowing for adjustment of the machining program to reduce drive axis ratios and minimize surface defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If drive axis reversal is performed during machining, then machining coverage is improved, but streaks or stripes occur on the machined surface due to backlash and reversal delays
Solution Approach 1:
The system changes the machining parameters by varying the machining direction (e.g., from X-axis primary to Y-axis primary) to alter which drive axis performs reversal operations. This parameter change allows the problematic reversal-induced streaks to be minimized by assigning reversal to a different axis with better performance characteristics.
Solution Approach 2:
The system dynamically adjusts the machining strategy by selecting different primary machining directions based on detected surface quality issues. When streaks are detected, the system switches from one machining direction configuration to another, making the machining process adaptive to the identified problems.
2Manufacturing precision
If machining is performed in a single direction, then drive axis reversal is minimized, but machining coverage and efficiency are reduced
Solution Approach 1:
The system employs a dynamic machining approach where the primary machining direction is not fixed but can be switched based on detected surface quality. The system starts with one machining direction, monitors for streaks, and switches to an alternative direction (e.g., from X-primary to Y-primary machining) when quality degradation is detected, thereby maintaining both efficiency and surface quality.
Solution Approach 2:
The system changes the fundamental machining parameter of direction by utilizing multiple drive axes. Instead of being constrained to a single machining direction, the system can reconfigure which axis serves as the primary machining axis, allowing optimization of both productivity and surface quality through parameter variation.
3Area of stationary object
If multiple machining directions are used to improve coverage, then drive axis reversal operations increase, but this exacerbates backlash effects and surface defects
Solution Approach 1:
The system strategically changes the machining direction parameter only when necessary to eliminate surface defects. By switching from one primary machining axis to another (e.g., from X-axis to Y-axis primary), the system redistributes reversal operations to different axes, thereby maintaining machining coverage while minimizing the impact of backlash on any single axis.
Solution Approach 2:
The system dynamically adapts the machining direction configuration based on real-time quality feedback. When streaks or stripes are detected on the machined surface, the system switches to an alternative machining direction that uses different drive axes for primary motion and reversal, thereby dynamically optimizing surface quality while maintaining coverage.
4Productivity
If drive axis reversal speed is increased to improve productivity, then machining efficiency improves, but backlash effects and surface defects worsen
Solution Approach 1:
The system changes the operational parameters by switching which drive axis performs reversal operations. When high-speed reversal on one axis causes surface defects, the system switches to an alternative machining direction where a different axis performs the reversal, thereby maintaining productivity while avoiding the backlash problems associated with high-speed reversal on the original axis.
Data Source
AI summary
A control system of a machine tool includes an analysis device, the analysis device includes acquisition portions which acquire chronological control data when a work is machined and which acquire spatial machined surface measurement data after the machining of the work, a storage portion which stores the control data and the machined surface measurement data, a data-associating processing portion which associates the control data and the machined surface measurement data with each other in two machining directions, a machined surface failure detection portion which detects a failure on the machined surface of the work and a location thereof based on the machined surface measurement data in the two machining directions and an identification portion which identifies a drive axis that causes the failure from the detected failure and the machining direction of the control data corresponding to the detected failure location.