Machining Path Segmentation for High-Speed Precision Control
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Solution Overview
Problem
Existing machining processes in machining machines, such as cutting, painting, and laser deposition welding machines, face limitations due to mass inertia and kinematic restrictions, leading to deviations in machining parameters and geometry, particularly at high speeds, resulting in suboptimal machining results.
Innovation Solution
The method involves dividing the movement path into machining and acceleration portions, adjusting travel speeds and accelerations along these portions to achieve predetermined machining parameters, using flexible configurations in three spatial directions (x, y, z) to optimize travel speed and reduce interference, allowing for high-speed machining up to 500 m/min.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the machining speed is increased to improve productivity, then the machining time is reduced, but the machining precision deteriorates due to mass inertia and kinematic restrictions causing parameter deviations and path deviations
Solution Approach 1:
The movement path is segmented into machining portions and acceleration portions. During machining portions, the tool operates at high speed for productivity, while during acceleration portions, the speed is adjusted to allow precise parameter control. This segmentation allows the system to achieve both high productivity during machining and maintained precision during parameter-critical phases.
Solution Approach 2:
Acceleration and deceleration actions are performed in advance during dedicated acceleration portions before entering machining portions. This preliminary action ensures that by the time the tool reaches the machining portion, the predetermined machining parameters are already achieved and maintained, preventing parameter deviations during the actual machining process.
2Productivity
If the acceleration is increased to reach predetermined machining parameters faster, then the productivity is improved, but the machining precision deteriorates due to mass inertia causing the parameters to be undershot at the starting point
Solution Approach 1:
The movement path is divided into acceleration portions and machining portions. During acceleration portions, the system can apply higher acceleration rates to quickly build up speed, while during machining portions, the acceleration is controlled to maintain precise predetermined parameters. This segmentation allows aggressive acceleration without compromising machining parameter accuracy.
Solution Approach 2:
The control system continuously monitors the actual machining parameters and compares them with predetermined target parameters. Based on this feedback, the system adjusts the acceleration profile in real-time to ensure that predetermined parameters are accurately reached and maintained at the starting point of machining portions, compensating for mass inertia effects.
3Manufacturing precision
If the machining parameters are adjusted in a time-resolved or spatially resolved manner to maintain precision, then the machining quality is improved, but the device complexity increases
Solution Approach 1:
The movement path is segmented into distinct acceleration portions and machining portions, each with predetermined speed profiles and machining parameters. This segmentation simplifies the control logic by creating clear phases with specific control objectives, making the time-resolved and spatially resolved parameter adjustment more manageable and less complex than continuous control would require.
Data Source
AI summary
In a method for machining workpieces within a machining machine a tool is moved relative to a workpiece (1). The tool or the workpiece (1) travels at a predeterminable travel speed in a travel direction which is predetermined by a movement path (3). The movement path (3) is divided into machining portions (4) and acceleration portions (5). Within the machining portions (4), the workpiece is machined between a starting point (6) and an end point (7) of the machining portion (4) at a predeterminable machining travel speed in a machining travel direction. The travel speed is adjusted along the acceleration portion (5), which is defined by the end point (7) of a first machining portion (11) and the starting point (6) of a second machining portion (12), such that the predetermined machining travel speed is reached at the starting point (6) of the machining portion (4).