Machine Tool Motion Planning for Continuous Air-Cut to Cutting
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Solution Overview
Problem
Existing machine tool motion planning methods struggle to minimize cycle time in multi-segment trajectories while ensuring collision-free tool paths and adhering to geometric and kinematic constraints.
Innovation Solution
A method that programs a multi-segment motion plan using program points directly on the workpiece surface, computing a time-optimal trajectory that transitions from air cut to cutting without stopping, and combines air cut and cutting commands into a single command to optimize cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional separate air cut and cutting commands are used with stop at transition points, then collision avoidance is ensured and machining precision is maintained, but cycle time increases and productivity decreases
Solution Approach 1:
The patent combines separate air cut commands and cutting commands into a single unified command structure. The motion planning system integrates multiple motion segments (air cut segments and cutting segments) into one continuous trajectory, eliminating the need for separate command processing and intermediate stops. This merging allows the tool to transition directly from air cut to cutting mode without stopping, thereby reducing cycle time while maintaining collision avoidance through comprehensive trajectory optimization.
Solution Approach 2:
The patent implements continuous motion by eliminating stops at transition points between air cut and cutting segments. The time-optimal trajectory computation ensures that the tool maintains continuous motion throughout the entire path, transitioning smoothly from air cut to cutting without interruption. This continuity of useful action maximizes productivity by eliminating idle time while the collision-free constraint ensures safety throughout the continuous motion.
2Productivity
If time-optimal trajectory computation is implemented across all segments, then cycle time is minimized and productivity is enhanced, but computational complexity and programming difficulty increase
Solution Approach 1:
The patent creates a universal programming interface that handles both air cut and cutting operations through a single command structure. The motion planning system uses unified function calls that can process multiple motion segments with different modes (air cut or cutting) without requiring separate programming routines for each segment type. This universal approach simplifies the programming interface while enabling complex time-optimal trajectory computation across all segments.
Solution Approach 2:
The motion planning system automatically computes the time-optimal trajectory and determines the optimal transition points between air cut and cutting segments without requiring manual intervention or complex user programming. The system self-optimizes the trajectory by analyzing the workpiece geometry, tool path requirements, and machine constraints, thereby reducing programming complexity while achieving cycle time optimization.
3Manufacturing precision
If program points are defined directly on workpiece surface features, then machining precision and feature accuracy are improved, but trajectory computation complexity and collision detection difficulty increase
Solution Approach 1:
The patent performs preliminary computation of the time-optimal trajectory and collision-free verification before actual machining execution. The motion planning system pre-calculates the entire multi-segment trajectory, including all air cut and cutting segments, and verifies collision-free operation in advance. This preliminary action allows program points to be defined directly on workpiece surface features with high precision while the complex trajectory computation is handled automatically by the system before machining begins.
Data Source
AI summary
A method for programming a multi-segment motion plan for a machine tool which uses program points defined directly on a workpiece surface, and computes a time-optimal trajectory which transitions from air cut to cutting without stopping, while arriving at a cutting start waypoint traveling at a specified cutting feed speed. The programming method also combines what are traditionally separate air cut and cutting commands into a single command, and computes the time-optimal trajectory for all segments. The underlying time-optimal trajectory computation calculates an initial motion profile for each segment based on the waypoint geometry and other constraints, and motion states at the waypoints which join the segments are optimized to provide the shortest total trajectory time. The optimized waypoint states include velocities and accelerations with non-zero values.