Machine Tool Motion Control for Vibration-Limited Finishing
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Solution Overview
Problem
Existing machine tools and production machines face challenges in achieving high surface finish quality and productivity due to unwanted vibrations during machining, leading to increased costs and throughput time from complex and expensive manual re-machining processes.
Innovation Solution
A method that compares target and actual position, speed, and acceleration values of machine axes and tool center points, adjusts feed speed and acceleration in real-time based on deviations, and stores information for re-machining, allowing for dynamic adjustments to maintain target quality values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high feed speeds and accelerations are used during finishing, then productivity increases, but mechanical vibrations increase leading to poor surface finish quality
Solution Approach 1:
The patent applies dynamics by continuously monitoring actual position, speed, and acceleration during machining and dynamically adjusting feed speed and acceleration in real-time based on measured deviations. This allows the system to adapt cutting parameters on-the-fly rather than using static pre-programmed values, enabling high productivity while maintaining surface finish quality through active vibration control.
Solution Approach 2:
The patent implements feedback by measuring actual position, speed, and acceleration values during machining and comparing them with target values. The measured deviations are fed back to the control system which then adjusts feed speed and acceleration accordingly. This closed-loop feedback mechanism enables real-time optimization of cutting parameters to prevent vibrations while maintaining high feed rates for improved productivity.
2Manufacturing precision
If feed speed and acceleration are reduced to prevent vibrations, then surface finish quality improves, but machining time increases reducing productivity
Solution Approach 1:
The system dynamically adjusts feed speed and acceleration based on real-time measurements rather than using permanently reduced values. This allows the system to maintain high feed rates when conditions permit and only reduce speeds when vibrations are detected, optimizing both surface finish quality and productivity throughout the machining process.
Solution Approach 2:
The patent changes cutting parameters (feed speed, acceleration, jerk) in real-time based on measured deviations from target values. By continuously monitoring and adjusting these parameters rather than using fixed conservative values, the system achieves high surface finish quality without permanently sacrificing productivity through reduced feed rates.
3Manufacturing precision
If complex manual re-machining processes are used to correct vibrations, then surface finish quality improves, but costs and throughput time increase
Solution Approach 1:
The machining system performs self-correction by automatically detecting vibrations through measurement of position, speed, and acceleration deviations and autonomously adjusting feed speed and acceleration to prevent or eliminate the vibrations. This eliminates the need for complex manual re-machining operations, reducing both costs and throughput time while maintaining high surface finish quality.
Solution Approach 2:
The closed-loop feedback system continuously monitors machining conditions and automatically adjusts parameters to prevent vibrations before they affect surface finish quality. This real-time correction eliminates the need for subsequent manual re-machining operations, significantly reducing throughput time and costs associated with corrective polishing or re-machining.
Data Source
AI summary
A method for operating a machine tool and/or production machine comprising comparing at least one target position, speed, and/or acceleration value of a machine shaft and/or of a tool center point with an actual position, speed, and/or acceleration value. At least one actual quality value is formed on the basis of the comparison or comparisons. A target quality value is compared with the actual quality value. A feed speed and/or acceleration and/or jerk of the machine shaft and/or of the tool center point is reduced if a defined deviation of the actual quality value from the target quality value is exceeded, or storing information that the defined deviation of the actual quality value from the target quality value has been exceeded if the defined deviation of the actual quality value from the quality target value is exceeded.