Multi-Spindle CNC Synchronization for Collision-Safe Tool Paths
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Solution Overview
Problem
Multi spindle machine tools face challenges in minimizing the risk of collisions between tool spindles due to mechanical offsets, zero point displacements, and different dynamic restrictions, which can lead to asynchronicity and reduced productivity in processing nominally identical workpieces with varying tool dimensions.
Innovation Solution
A method for Computerized Numerical Control (CNC) of multi spindle machine tools, where the same parts program is processed in synchronized manner in two processing channels, allowing the first and second tool spindles to be moved differently to compensate for tool dimension differences, with the control apparatus adjusting the average track speeds and dynamic axis variables to ensure synchronized movement and minimize time differences between reaching the end of the tool tracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the mechanical offset between tool spindles is minimized to enable compact construction, then the working space is reduced and machine size is decreased, but the risk of collisions between spindles increases due to asynchronicity from different tool dimensions and dynamic restrictions
Solution Approach 1:
The control system dynamically adjusts the movement parameters of each tool spindle independently based on real-time synchronization status. The control apparatus modifies axis variables, speeds, and trajectories on-the-fly to maintain synchronization despite mechanical offsets and tool dimension variations, transforming a static mechanical constraint into a dynamically controllable parameter
Solution Approach 2:
The system changes operational parameters (speed, acceleration, position) of individual tool spindles to compensate for mechanical offsets and tool wear. By varying these parameters within allowable dynamic restrictions, the system maintains synchronization without requiring identical mechanical configurations, thus enabling compact design while preventing collisions
2Adaptability or versatility
If tool spindles are controlled independently to compensate for different tool dimensions, then manufacturing flexibility and adaptability are improved, but asynchronicity increases leading to higher collision risk
Solution Approach 1:
The control apparatus continuously monitors the position and movement status of each tool spindle and uses this feedback to adjust control commands in real-time. This closed-loop control ensures that independent tool spindles remain synchronized despite variations in tool dimensions, wear, or dynamic restrictions
Solution Approach 2:
The system pre-calculates and pre-adjusts movement trajectories and speed profiles for tool spindles based on known tool dimensions and mechanical offsets. By preparing synchronization compensation in advance, the system prevents asynchronicity before it occurs, maintaining reliability while allowing independent control
3Productivity
If the same parts program is processed in synchronized manner in multiple processing channels, then productivity is improved through parallel processing, but the complexity of control increases to manage synchronization
Solution Approach 1:
The control apparatus is designed as a universal system that can manage multiple processing channels simultaneously using the same control logic and algorithms. This multi-functional control unit handles synchronization, trajectory planning, and parameter adjustment for all spindles through a unified interface, reducing overall system complexity despite parallel processing demands
Data Source
AI summary
For control of a multi spindle machine tool (1), which has a first tool spindle (2a, 2b) and a second tool spindle (2a, 2b) able to be controlled independently thereof, a first workpiece (5a, 5b) and a second workpiece (5a, 5b) are processed by a parts program synchronized in two processing channels being processed. The processing of the parts program includes an activation of first machine axes for guidance of the first tool spindle (2a, 2b) in accordance with a first tool track and the processing of the parts program includes an activation of second machine axes for guidance of the second tool spindle (2a, 2b) in accordance with a second tool track. A processing result of the first workpiece (5a, 5b) at an end of the first tool track is the same as a processing result of the second workpiece (5a, 5b) at an end of the second tool track. The first machine axes and the second machine axes are activated in such a way that a difference in time between reaching the end of the first tool track and reaching the end of the second tool track is less than or equal to a predetermined limit value.