Machine Tool Control for Irregular Scratch Spacing on Gear Teeth
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for reducing noise in gear meshing due to equally spaced scratches on machined surfaces lack reproducibility and can adversely affect machining quality.
Innovation Solution
A control device for a machine tool that calculates and implements an oscillation command to make the intervals between scratches on machined surfaces unequal, using a surface pattern calculation unit and oscillation command generation unit to control the relative motion of the workpiece and tool, thereby reducing noise and ensuring desired machining quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If feedrate is dynamically changed to make intervals between scratches irregular, then noise when gears mesh is reduced, but reproducibility of the effect is poor and machining quality varies
Solution Approach 1:
The patent applies dynamics by making the feedrate variable during machining rather than constant. The control device dynamically adjusts the feedrate according to a calculated oscillation pattern, which causes the intervals between scratches to be unequal. This dynamic adjustment is the core mechanism that generates the desired surface pattern while ensuring reproducibility through precise control.
Solution Approach 2:
The patent implements periodic action by using an oscillation pattern with a specific period to modulate the feedrate. The surface pattern calculation unit calculates an oscillation command with a determined period, and the control device applies this periodic variation to the feedrate, creating regular unequal intervals between scratches that consistently reduce meshing noise.
2Object-affected harmful factors
If feedrate is dynamically changed to make intervals between scratches irregular, then noise when gears mesh is reduced, but machining quality varies
Solution Approach 1:
The control device dynamically adjusts the feedrate according to a precisely calculated oscillation pattern. This dynamic control allows the system to create unequal intervals between scratches for noise reduction while maintaining overall machining precision through the structured and calculable nature of the oscillation command.
Solution Approach 2:
The patent changes the feedrate parameter during machining according to a calculated oscillation pattern. By systematically varying this parameter rather than keeping it constant, the system achieves both noise reduction through unequal scratch intervals and maintained machining quality through controlled parameter variation.
3Manufacturing precision
If oscillation command is generated to achieve unequal intervals between scratches, then noise is reduced and machining quality is ensured, but device complexity increases
Solution Approach 1:
The control device integrates multiple functions into a unified system: it calculates the surface pattern, generates the oscillation command, and controls the feedrate adjustment all through one integrated control unit. This multi-functionality reduces the need for separate dedicated components for each function, managing system complexity while achieving the desired outcomes.
Solution Approach 2:
The control device performs self-calculation of the oscillation command based on the desired surface pattern and automatically generates the control signals needed. This self-service capability reduces the need for external complex control systems or manual intervention, managing complexity while ensuring precise control for noise reduction and quality maintenance.
Data Source
AI summary
Provided is a control device for a machine tool, the control device being capable of reliably reducing noise when gears mesh with each other and providing intended machining quality. A control device 10 for a machine tool machines a workpiece W including at least one tooth surface and comprises: a machining condition input unit 15 which can input a machining condition including at least one of specifications of the workpiece W, specifications of a tool T, a feed speed, the rotational speed of a spindle, and the number of teeth; a surface pattern calculation unit 16, which calculates, on the basis of the machining condition, a surface pattern defined on the basis of intervals of scratches occurring on a machined surface; a swing command generation unit 17, which generates, on the basis of the surface pattern, a swing command for achieving a surface pattern including a portion in which the intervals of the scratches are unequal; and a position and speed control unit 14 which carries out the machining while swinging the workpiece W and the tool T relatively to each other on the basis of the swing command generated by the swing command generation unit 17.