Machine Tool Path Control for Shortcut Entry and Fewer Air Cuts
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Solution Overview
Problem
Existing machine tools face challenges in achieving rapid, precise, and cost-effective machining with minimal non-productive movements, particularly in multi-axis milling, while ensuring reliable detection of workpiece contours.
Innovation Solution
A method that calculates a first positioning command to approach the material entrance point of a tool along a shortcut path, allowing rapid movement and reducing air cuts, utilizing existing collision avoidance units and 3D scanners for contour detection, and generating positioning commands to optimize tool paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the tool follows the original track path specified by the control command set, then machining precision is maintained, but non-productive movement time increases
Solution Approach 1:
The system performs preliminary simulation of tool movement along the original track path to identify air cuts (non-productive movements) before actual machining. Based on this preliminary analysis, alternative track paths are calculated that eliminate air cuts while maintaining material contact continuity, thereby reducing non-productive movement time without compromising machining precision
Solution Approach 2:
The system dynamically adjusts the track path based on real-time analysis of the control command set and detected workpiece contour. By continuously optimizing the tool path to maintain material contact and eliminate air cuts, the system adapts the movement trajectory to minimize non-productive time while preserving machining accuracy
2Productivity
If the traverse speed is increased to reduce machining time, then productivity improves, but detection reliability of workpiece contact deteriorates
Solution Approach 1:
The system replaces mechanical contact detection methods with optical detection using a 3D scanner. This substitution allows for high-speed scanning and contour detection without the limitations of mechanical sensors, enabling reliable workpiece contour acquisition even at increased traverse speeds, thereby maintaining detection reliability while improving productivity
3Manufacturing precision
If additional sensors are added to detect workpiece contour and optimize tool paths, then machining precision improves, but device complexity increases
Solution Approach 1:
The system employs a 3D scanner that serves multiple functions: detecting the workpiece contour, identifying air cuts in the tool path, and providing data for alternative path calculation. This multi-functional approach achieves improved machining precision without adding dedicated sensors for each function, thereby avoiding increased device complexity
Solution Approach 2:
The control unit itself performs the simulation and analysis of tool movement along the original track path to identify air cuts. By utilizing the existing control unit's computing capabilities rather than adding external dedicated hardware, the system achieves enhanced tool path optimization while avoiding additional device complexity
Data Source
AI summary
A computer program product, a control unit, a machine tool and method for operating a machine tool includes providing a control command set for a tool, providing an actual contour of the workpiece, determining a first material entrance point of the tool into the workpiece and generating a first positioning command for an approach to the first material entrance point, wherein the first positioning command specifies a track path which differs from a track path specified by the control command set, where as an alternative, or additionally, a rapid movement of the tool and or clamping of the workpiece is specified by the first positioning command.