Microscopic Geometry Cutting Device Timing Control
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Solution Overview
Problem
Conventional microscopic surface cutting devices face challenges in providing highly accurate microscopic geometry due to timing delays in cutter advancement and retraction, requiring trial-and-error for machining conditions, and experiencing amplitude reduction and phase-delay in cutting tracks, leading to increased cutting errors, especially when machining microlens transcription molding dies.
Innovation Solution
A microscopic geometry cutting device with a controller that calculates arrival times and outputs trigger signals for precise cutter movement, combined with a reciprocating stage that quickly changes cutting depth, and a method that analyzes target track frequencies to determine optimal machining conditions, reducing errors and resonance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If pulse signal counting and coincidence determination is used to control cutter timing, then the device can automatically control cutting depth, but timing delays occur and highly accurate microscopic geometry cannot be provided
Solution Approach 1:
The patent replaces the mechanical/electrical pulse counting system with a time-based control system. The arrival time calculator computes the exact time when the cutter should reach the machining start position based on feed speed and position information, and the elapsed time determiner uses a timer to trigger the reciprocating stage at the precise moment, eliminating the timing delays inherent in pulse counting and coincidence determination methods.
2Adaptability or versatility
If trial-and-error process is used to determine machining conditions, then the device can accommodate different machining requirements, but considerable time is required to determine optimal conditions
Solution Approach 1:
The patent performs preliminary calculation of the arrival time before the actual machining operation begins. The arrival time calculator computes when the cutter will reach the machining start position based on pre-input feed speed and position data, allowing the system to be fully prepared and eliminate the need for time-consuming trial-and-error adjustments during actual machining.
Solution Approach 2:
The system uses feedback from the position detector and feed speed information to continuously monitor and adjust the timing control. The elapsed time determiner compares the calculated arrival time with actual elapsed time, ensuring precise synchronization between cutter position and reciprocating stage activation, thereby optimizing machining conditions without trial-and-error.
3Manufacturing precision
If the cutter quickly changes cutting depth during movement, then microscopic geometry can be provided, but amplitude reduction and phase-delay occur relative to target track
Solution Approach 1:
The patent replaces the conventional method of quickly changing cutting depth during cutter movement with a time-synchronized approach. The reciprocating stage is activated at the precisely calculated arrival time when the cutter reaches the machining start position, rather than attempting to change cutting depth dynamically during movement. This eliminates the amplitude reduction and phase-delay that occur when trying to synchronize rapid mechanical response with cutter motion.
4Manufacturing precision
If reciprocating stage quickly changes cutting depth, then microscopic geometry can be formed, but resonance is generated due to intrinsic frequency of device
Solution Approach 1:
The system calculates the arrival time in advance before the reciprocating stage is activated. By determining the exact moment when the cutter reaches the machining start position based on feed speed and position data, the system can trigger the reciprocating stage at the optimal time, avoiding activation during periods that would excite the device's intrinsic frequency and cause resonance.
Data Source
AI summary
A microscopic geometry cutting device includes: a controller that outputs a timer count start command in starting a driving program which controls a drive of an X-axis or a Y-axis moving mechanism; an arrival time calculator that calculates an arrival time from when the timer count start command is output till when the cutter arrives at a machining start position in accordance with relative moving speed information of the moving mechanisms and machining start position information of a workpiece W; an elapsed time determiner that determines whether an elapsed time from when the timer count start command is output is coincident with the arrival time and outputs a trigger signal when the elapsed time is coincident with the arrival time; and a reciprocating stage driver that drives the reciprocating stage in a manner that the cutter advances and retracts in a predetermined cutting depth in response to the trigger signal.