Machining Force Feedback Control for Deflection-Corrected CNC Quality
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Solution Overview
Problem
Subtractive manufacturing methods, such as turning, drilling, and milling, face challenges in achieving dimensional accuracy and surface roughness without requiring additional costly machining processes like grinding or honing, as existing systems rely on human intervention for correcting machining forces.
Innovation Solution
A method and device that automatically measure and correct machining forces by determining deflection/test force relations, measuring actual machining forces, and generating corrected drive control signals to adjust for deviations, ensuring precise product quality without human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additional machining processes such as grinding or honing are performed to fulfill quality properties, then dimensional accuracy and surface roughness are improved, but production time and manufacturing cost increase
Solution Approach 1:
The patent applies preliminary action by determining deflection/test force relations before actual machining operations. The system pre-calculates correction deflections based on anticipated machining forces, allowing the CNC device to proactively compensate for expected deviations rather than requiring post-processing. This preliminary characterization of device behavior enables real-time correction without additional machining passes.
Solution Approach 2:
The patent implements feedback by continuously monitoring actually exerted machining forces during operation and comparing them against reference values. When deviations are detected, the system automatically adjusts drive control signals based on pre-determined deflection/test force relations. This closed-loop feedback mechanism ensures quality properties are maintained during machining without requiring time-consuming post-processing operations.
2Manufacturing precision
If additional machining processes such as grinding or honing are performed to fulfill quality properties, then dimensional accuracy and surface roughness are improved, but manufacturing cost increases
Solution Approach 1:
The patent applies self-service by enabling the CNC device to automatically monitor and correct its own machining forces without human intervention. The system uses pre-determined deflection/test force relations to autonomously calculate and apply correction deflections, adjusting drive control signals in real-time. This self-correcting capability eliminates the need for costly additional machining processes and reduces dependency on operator skill and post-processing operations.
3Manufacturing precision
If human intervention is used to correct machining forces, then quality properties can be adjusted, but productivity and automation level are reduced
Solution Approach 1:
The patent implements automated feedback control by continuously monitoring machining forces and automatically adjusting drive control signals based on pre-determined deflection/test force relations. The system compares actually exerted forces against reference values and autonomously applies correction deflections without human intervention, maintaining quality properties while maximizing productivity through uninterrupted automated operation.
Solution Approach 2:
The patent replaces manual mechanical adjustment with automated electronic control. Instead of operators physically adjusting machine parameters, the system uses electronic sensors to monitor machining forces and electronic control systems to automatically modify drive control signals. This substitution of manual mechanical operations with automated electronic control enhances both precision and productivity.
4Productivity
If automated monitoring and correction of machining forces is implemented, then productivity and automation level are improved, but device complexity increases
Solution Approach 1:
The patent reduces operational complexity during machining by performing complex calculations in advance. Deflection/test force relations are determined before production, and correction deflections are pre-calculated based on anticipated forces. During actual machining, the system only needs to monitor forces and apply pre-determined corrections, significantly simplifying real-time operations while maintaining high automation and productivity.
Data Source
AI summary
A method to ascertain a quality of a product formed by a subtractive manufacturing device from a workpiece includes: determining a deflection/test force relation for a deflection of the device; measuring an actually exerted machining force applied by the device to the workpiece; automatically determining a machining force reference for the actually exerted machining force; automatically evaluating whether the actually exerted machining force deviates from the machining force reference. If an actually exerted machining force deviates from the machining force reference, then the method uses the deflection/test force relation to automatically determine for the actually exerted machining force, at least one correction deflection of the device and automatically creating at least one corrected drive control signal to fully or partially reduce the correction deflection.