Machine Tool Motion Control for Automatic Safe Repositioning
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Solution Overview
Problem
Conventional machine tool control software requires manual specification of repositioning moves, which can lead to errors if not aligned with the machine's configuration, potentially causing damage or program termination due to exceeding machine limits or unintended contact with parts or machine components.
Innovation Solution
A motion control system that automatically determines safe repositioning moves within a machine's three-dimensional working space, allowing part programs to be written in a machine-independent fashion, by computing retract and plunge moves while avoiding axis limits and maintaining a safe distance from parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If part programs specify intermediate repositioning moves to avoid machine limits and unintended contact, then safety and reliability are improved, but program complexity and programming time increase
Solution Approach 1:
The motion control system automatically determines safe repositioning moves by itself, using its knowledge of machine limits, part location, and tool dimensions. The system serves its own safety function by autonomously computing retract and plunge moves without requiring external programming of these intermediate moves, thereby improving reliability while reducing program complexity
Solution Approach 2:
The motion control system pre-computes safe repositioning paths before executing part programs. By determining retract and plunge moves in advance based on machine configuration and part geometry, the system ensures safety is built into the control logic beforehand, eliminating the need for programmers to manually specify these protective moves
2Reliability
If part programs are written for specific machine configurations to avoid errors, then reliability is improved, but adaptability and versatility deteriorate
Solution Approach 1:
The motion control system is designed to universally handle different machine configurations by automatically adapting its repositioning calculations. It uses its internal knowledge base of machine limits, working space, and tool characteristics to generate appropriate safe moves for any machine it controls, making part programs machine-independent while maintaining reliability across diverse equipment
Solution Approach 2:
The motion control system dynamically adjusts repositioning strategies based on the specific machine configuration and current operational context. Rather than using fixed pre-programmed moves, the system computes adaptive retract and plunge paths in real-time based on machine limits, part location, and tool dimensions, enabling universal applicability while maintaining error avoidance
3Ease of operation
If manual repositioning moves are specified in part programs, then programming control is improved, but ease of operation deteriorates due to configuration matching requirements
Solution Approach 1:
The motion control system performs the configuration matching task itself by automatically comparing programmed moves against its internal knowledge of machine limits and geometry. This self-service approach eliminates the burden from programmers of manually ensuring configuration compatibility, improving ease of operation while maintaining necessary control
Data Source
AI summary
The present disclosure includes a motion control system for a machine tool system configured to shape a part with a tool, including an I/O module with machine configuration information that defines limits of a three-dimensional working space of the machine tool system. The I/O module further includes a part program that specifies first and second positions of the tool without reference to the working space limits. The motion control system further includes a software controller configured to internally process moves to determine whether the tool can be repositioned from the first position to the second position while maintaining the tool above a minimum clearance from the part and within the working space limits, output the internally processed moves to the machine tool system to cause movement of the tool if the tool can be safely repositioned, and output an error if the tool cannot be safely repositioned.