Multi-Axis Machining Control for Fixed Tool Contact on Complex Shapes
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Solution Overview
Problem
Existing machining systems with one rotational axis and one linear axis struggle to maintain consistent tool contact with workpieces during machining of complex shapes, leading to uneven finishes and accuracy fluctuations, especially when machining eccentric or elliptical shapes, due to the lack of effective cutting point fixation control methods and increased development and maintenance costs associated with rotational axis structures.
Innovation Solution
A control device that calculates and commands the positions of one rotational axis and two linear axes based on machining line information and tangential direction data, allowing for cutting point fixation control by determining the angle of the rotational axis and positions of the linear axes to maintain consistent tool contact during machining of freely-selected machining lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a machine with one rotational axis and one linear axis is used for machining, then the structure is simple, but the cutting point cannot be fixed during machining of complex shapes leading to uneven finish and accuracy fluctuation
Solution Approach 1:
The patent adds a second linear axis (Y-axis) orthogonal to the existing X-axis, transforming the machine from a one-dimensional linear movement system to a two-dimensional linear movement system. This dimensional expansion enables the tool to maintain a fixed contact point with the workpiece during machining of complex shapes by providing additional degrees of freedom for position adjustment, thereby resolving the cutting point fixation problem without requiring a complex rotational axis structure.
2Manufacturing precision
If a rotational axis is added to control tool direction for cutting point fixation, then cutting point fixation is achieved, but development and maintenance costs increase
Solution Approach 1:
The patent replaces the mechanical rotational axis system with a control system that uses two linear axes (X and Y) to achieve the same cutting point fixation function. Instead of mechanically rotating the tool or workpiece to maintain contact point, the system uses coordinated linear movements along two orthogonal axes controlled by a CNC system. This substitution eliminates the need for complex rotational mechanisms, reducing development and maintenance costs while achieving the desired precision.
3Adaptability or versatility
If conventional cutting point fixation control is used with linear axes, then control method is available for straight lines, arcs, and involutes, but no method exists for elliptic shapes or eccentric shapes
Solution Approach 1:
The patent creates a universal control method that can machine any planar shape including straight lines, arcs, involutes, elliptic shapes, and eccentric shapes using the same two-linear-axis system. The CNC control system calculates appropriate X and Y axis movements based on the desired machining path, making the system adaptable to various shapes without requiring different mechanical configurations or complex control methods for each shape type.
Data Source
AI summary
A control device generates, for each command cycle on the basis of machining line information expressing a plane machining line with a function displayed by a prescribed parameter and tangential line information showing a tangential line direction at respective positions of the machining line, a position command on a rotational axis and two linear axes with a position on the machining line obtained when the parameter is changed by a prescribed amount set as a machining position. The position command generated by the control device includes a command on a position of the rotational axis at which the tangential line at the machining position forms a prescribed angle set in advance with respect to any one of the linear axes and a command on the position of the two linear axes at which a tool is set at the machining position when the rotational axis is located at the position of the rotational axis.