Machine Tool Speed Switching Control for Collision Prevention
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Solution Overview
Problem
Current machine tool control systems require significant operator input to prevent collisions by manually stopping and restarting override potentiometers for rapid traversing movements, leading to increased operational time and risk of unintended high-speed movements.
Innovation Solution
A control device that automatically stops the machine tool before executing a movement with a speed greater than a predetermined factor of the previous speed, allowing operators to trigger the faster movement with a single input device, eliminating the need for additional potentiometers and reducing the risk of collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the NC program is executed in single block mode with manual stopping after each step, then operator control and collision prevention are improved, but operator workload and time required for run-in are significantly increased
Solution Approach 1:
The control system applies single-block mode selectively only when transitioning from low speed to high speed movements, rather than requiring manual intervention after every single program step. This partial application of the safety mechanism maintains collision prevention for critical transitions while allowing contiguous execution of standard feed movements, significantly reducing operator workload and run-in time.
2Productivity
If rapid traversing movements are executed automatically without manual intervention, then productivity is improved, but the risk of unintended high-speed movements and collisions increases
Solution Approach 1:
The control system performs a preliminary speed comparison before executing any rapid traversing movement. By automatically comparing the upcoming movement speed with the previous movement speed and identifying transitions exceeding a predetermined threshold, the system proactively prepares for potential high-speed transitions, ensuring operator confirmation is required before executing potentially dangerous movements while allowing automatic execution of safe movements.
3Ease of operation
If override potentiometers are used to control movement speeds, then operator control over feed and rapid traversing speeds is improved, but device complexity and operator workload increase
Solution Approach 1:
The invention extracts and eliminates the need for the second override potentiometer (rapid traversing potentiometer) by implementing automatic speed comparison logic in the control system. The control device now handles the function of the second potentiometer through automated threshold-based speed monitoring and selective single-block mode activation, reducing hardware complexity while maintaining operator control through the existing feed override potentiometer and automatic intervention mechanism.
4Productivity
If contiguous execution of multiple program steps is allowed, then productivity is improved, but the ability to react to incorrect movements is reduced
Solution Approach 1:
The control system continuously monitors program execution and provides automatic feedback by comparing the speed of each upcoming movement with the previous movement. When a speed transition exceeding the predetermined threshold is detected, the system automatically interrupts contiguous execution and switches to single-block mode, alerting the operator to the potentially dangerous high-speed transition and allowing manual confirmation before proceeding.
Data Source
AI summary
A control device for controlling a machine tool, wherein the machine tool and the control device are configured such that a tool and/or workpiece disposed on the machine tool can be moved with at least one first speed and at least one second speed. When switching from a movement with the first speed to a movement with the second speed, the tool or the workpiece is at first stopped prior to the execution of the movement with the second speed, if the second speed is greater than the first speed by at least a predetermined factor. The control device has an input device for triggering the movement with the second speed, and the subsequent execution of the movement with the second speed is triggered by an operator input on the input device. A corresponding control method for controlling a machine tool is also described.