Machined Surface Simulation for Diagnosing CNC Machining Abnormalities
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Solution Overview
Problem
Current machining simulation devices struggle to efficiently determine the causative factors of abnormalities on machined surfaces, requiring time-consuming and labor-intensive processes to adjust machining programs, control commands, and servo control operations.
Innovation Solution
A simulation device and method that stores machining position data from multiple sources, including machining programs, control commands, and feedback information, allowing for multiple machined surface simulations to be performed and displayed in juxtaposed manner, facilitating the identification of causative factors and effectiveness of adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple simulations are performed to determine causative factors of machining abnormalities, then the accuracy of diagnosis is improved, but the time and effort required increases significantly
Solution Approach 1:
The system performs preliminary simulations by automatically executing multiple simulation conditions in advance, storing the results for later comparison. This allows the diagnosis process to utilize pre-computed simulation data, reducing the time required when actual abnormalities need to be diagnosed while maintaining high diagnostic accuracy through comprehensive simulation coverage.
Solution Approach 2:
The simulation process is segmented into multiple independent simulation conditions that can be executed separately and stored. Each simulation condition represents a different hypothesis about the causative factor, and results are segmented and stored for efficient retrieval and comparison during diagnosis, allowing parallel processing and reducing overall diagnosis time.
2Reliability
If multiple simulations are performed to determine causative factors of machining abnormalities, then the reliability of determination is improved, but the operational complexity increases
Solution Approach 1:
The system performs self-service by automatically executing multiple simulations, comparing results, and determining causative factors without requiring manual intervention for each simulation condition. The control unit automatically manages the simulation workflow, data comparison, and conclusion drawing, maintaining high determination reliability while simplifying the operator's task to merely initiating the diagnosis process.
Solution Approach 2:
The system implements feedback by automatically comparing simulation results with actual machining outcomes and using this information to determine causative factors. The feedback mechanism allows the system to iteratively refine its diagnosis by comparing predicted versus actual results, improving determination reliability while the automated feedback loop reduces operational complexity by eliminating manual analysis steps.
3Manufacturing precision
If adjustments to machining programs or control commands are made and verified through simulation, then the manufacturing precision is improved, but the productivity decreases due to additional verification time
Solution Approach 1:
The system performs preliminary verification simulations before actual machining adjustments are implemented. By pre-verifying the effectiveness of proposed adjustments through automated simulation, the system ensures manufacturing precision improvements while reducing the time required for iterative adjustment verification, thereby maintaining productivity.
Solution Approach 2:
The system creates virtual copies of the machining process through simulation, allowing adjustments to be tested on these copies rather than on actual machining operations. This copying approach enables precision verification without consuming real production time, as multiple adjustment scenarios can be tested in the virtual environment before implementing the optimal solution in actual machining.
Data Source
AI summary
To provide easy determination of a causative factor of a machining problem in a machining target or easy checking of the effectiveness of an adjustment of, e.g., a machining program, a control command such as a position command, a servo control, or machine operation. This invention includes: storage units storing pieces of machining position data obtained from machining performed based on at least two of a machining program, a control command for performing servo control on a servo motor for driving a machine tool, and pieces of feedback information related to the servo control and machine operation, the machining being performed on a machining target by the machine tool; a machined surface simulation unit performing machined surface simulations based on the stored machining position data; and a display unit displaying images of machined surfaces resulting from the machined surface simulations in a juxtaposed manner.