Multi-Axis Machine Tool Control for Bandwidth-Limited Rotary Axes
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Solution Overview
Problem
The 'zone-by-zone' approach in multi-axis machine tools limits throughput and flexibility due to difficulties in allocating motion between high and low bandwidth actuators, leading to errors in rotary axes when processing workpieces with 5-axis CNC manipulators.
Innovation Solution
A control system that generates low-frequency and high-frequency actuator commands, allowing for synchronized operation of low and high bandwidth actuators, using a scan lens with a positioner that includes acousto-optic deflector, MEMS mirror, or adaptive optical systems to move a focused laser beam along the beam axis, ensuring accurate movement and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the zone-by-zone approach is used to allocate motion between high and low bandwidth actuators, then the complexity of motion control is reduced, but the productivity and flexibility of the machine tool are significantly limited
Solution Approach 1:
The patent implements dynamic allocation of motion commands to actuators based on their current state and capabilities. The controller continuously evaluates which actuator (high or low bandwidth) should execute each motion command, allowing the system to adaptively optimize performance rather than following a static zone-by-zone approach. This dynamic decision-making enables continuous operation without the throughput limitations of fixed zone assignments.
Solution Approach 2:
The system changes operational parameters by adjusting the bandwidth utilization of different actuators based on real-time conditions. Instead of assigning actuators to fixed zones, the controller varies which actuator handles which motion commands based on factors like current position, velocity requirements, and actuator performance characteristics. This parameter-based allocation optimizes both productivity and flexibility while maintaining manageable control complexity.
2Device complexity
If the zone-by-zone approach is used to allocate motion between high and low bandwidth actuators, then the control strategy becomes simpler to implement, but the flexibility of the machine tool is significantly reduced
Solution Approach 1:
The system employs dynamic actuator selection that adapts to different workpiece geometries, toolpaths, and processing requirements. The controller evaluates motion commands in real-time and assigns them to appropriate actuators based on current system state, enabling flexible handling of diverse machining tasks without requiring complex pre-planned zone assignments for each scenario.
Solution Approach 2:
The patent makes both high and low bandwidth actuators universally applicable to multiple zones and task types. Instead of dedicating specific actuators to specific zones, either actuator can execute motion commands in any zone depending on real-time requirements. This multi-functional allocation maximizes flexibility across different workpiece types and processing operations while keeping the control logic relatively simple.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the throughput and flexibility of multi-axis machine tools by accurately positioning the tool tip relative to the workpiece, reducing errors and improving processing efficiency across various axes.
Implementation Method 1
The at least one positioner includes at least one selected from the group consisting of an acousto-optic deflector (AOD) system
Implementation Method 2
The at least one positioner includes at least one selected from the group consisting of an acousto-optic deflector (AOD) system, a microelectromechanical systems (MEMS) mirror system
Implementation Method 3
a scan lens arranged and configured to focus the beam of laser light thereby producing a focused beam of laser light, wherein the focused beam of light has a beam waist
Data Source
AI summary
One embodiment of the present invention can be characterized as a method for controlling a multi-axis machine tool that includes obtaining a preliminary rotary actuator command (wherein the rotary actuator command has frequency content exceeding a bandwidth of a rotary actuator), generating a processed rotary actuator command based, at least in part, on the preliminary rotary actuator command, the processed rotary actuator command having frequency content within a bandwidth of the rotary actuator and generating a first linear actuator command and a second linear actuator command based, at least in part, on the processed rotary actuator command. The processed rotary actuator command can be output to the rotary actuator, the first linear actuator command can be output to a first linear actuator and the second linear actuator command can be output to a second linear actuator.