Machine Tool Collision Prediction Using Deceleration Stop Position
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Solution Overview
Problem
Existing collision detection methods for machine tools are inadequate, particularly in manual mode, as they fail to predict collisions accurately, leading to potential damage and reduced processing utilization rates.
Innovation Solution
A method and system that utilize a data acquisition unit to capture motion information from the machine tool's processing unit, an arithmetic unit to calculate the stop position after deceleration, and a collision detection unit to perform anti-collision detection by comparing the stop position with the workpiece position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If online real-time collision detection is used, then collision can be detected before machine stops, but deceleration distance cannot be ensured and collision may still occur after machine stops
Solution Approach 1:
The system performs preliminary collision detection by calculating the predicted stop position based on current motion parameters (feed rate, acceleration, deceleration) and compares it with the workpiece position before the machine actually stops. This advance prediction allows the system to detect potential collisions and issue warnings or stop the machine before the actual stop position is reached, ensuring both reliability and precise deceleration control.
2Reliability
If external computer simulation detection is used, then collision detection capability is provided, but excessive system resources are consumed for external testing and data transmission
Solution Approach 1:
The collision detection functionality is extracted from external simulation software and integrated directly into the machine tool controller. The system uses the controller's existing processing unit to perform real-time collision detection calculations using motion information already available in the control system, eliminating the need for external instruments, sensors, and data transmission, thereby significantly reducing system resource consumption while maintaining detection capability.
3Reliability
If dry motion detection is used, then collision detection is performed, but additional system resources are consumed to perform idle motion detection
Solution Approach 1:
The system merges collision detection functionality with the existing motion control operations. Instead of performing separate idle motion detection, the collision detection is integrated into the normal motion control flow, using the same motion information (feed rate, acceleration, deceleration) that is already being processed for controlling the machine tool. This eliminates redundant resource consumption while maintaining continuous collision detection capability.
4Ease of operation
If manual mode is used for machine tool operation, then operator control is provided, but collision losses occur due to human error causing downtime
Solution Approach 1:
The system provides continuous real-time feedback to the operator by monitoring the predicted stop position and comparing it with the workpiece position. When a potential collision is detected, the system immediately issues a warning or stops the machine, preventing collision losses due to human error. This feedback mechanism maintains operator control while adding a safety layer that compensates for potential human mistakes.
Data Source
AI summary
A method for predicting collision detection of moving path of machine tool includes the following steps. Firstly, the motion information of a processing unit is acquired through the data acquisition unit. Then, based on the motion information, the arithmetic unit calculates the stop position of the processing unit after deceleration; and, further based on the stop position of the processing unit, the collision detection unit performs anti-collision detection to compare the stop position of the processing unit and the workpiece position of the workpiece. In additional, a system for predicting collision detection of moving path of machine tool is also provided.