Multi-Toolhead NC Programming for Collision-Free Shared Workspaces
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Solution Overview
Problem
Automated manufacturing systems with multiple toolheads face challenges in preventing collisions and ensuring independent operation over the same work area, leading to inefficiencies and inflexibility, as existing solutions either limit toolheads to fixed portions or require complex simulations for collision detection.
Innovation Solution
The system employs a bed platform with X and Y linear motion axes and a rotational axis, combined with a second toolhead mounted on a linear R axis offset from the first, ensuring that toolheads can operate independently and simultaneously without collision, using a combination of linear and rotary motion axes to position both toolheads within the work area without interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple toolheads are mounted to the same motion gantry at a fixed offset, then toolheads can operate simultaneously, but the system cannot move toolheads independently and is only useful for creating multiple copies of the same part
Solution Approach 1:
The system divides the motion control into separate independent gantries, each controlling one toolhead. This segmentation allows each toolhead to be positioned and moved independently across the entire work area, rather than being constrained to fixed offsets on a shared gantry. Each gantry-toolhead pair operates as an independent unit, enabling versatile manufacturing operations on single parts while maintaining simultaneous operation capability.
2Reliability
If the work area is partitioned into fixed portions for each toolhead, then collision is prevented, but toolheads will be idle for long periods and the system is inflexible
Solution Approach 1:
The system employs software simulations and closed-loop control systems that continuously monitor the positions and trajectories of multiple toolheads. This feedback mechanism allows dynamic adjustment of toolhead paths and speeds, enabling toolheads to safely access any position in the work area while preventing collisions through real-time coordination, rather than relying on static fixed partitions that cause idle time.
Solution Approach 2:
The system uses dynamic motion planning and control that adapts toolhead trajectories in real-time based on the current states of all toolheads. This dynamic coordination allows toolheads to flexibly share the entire work area, optimizing path utilization and minimizing idle time while maintaining collision-free operation, unlike static fixed partitions.
3Reliability
If software simulations and sensors are used for collision detection, then crash occurrence is greatly reduced, but it remains very difficult to prevent crashing in systems with two or more toolheads operating simultaneously
Solution Approach 1:
The system introduces an intermediary computational layer that performs software simulations of toolhead trajectories before execution. This intermediary simulation environment acts as a mediator, allowing the system to predict and prevent potential collisions by analyzing the combined motion paths of multiple independent toolheads, thereby enhancing safety without requiring overly complex sensor arrays.
Data Source
AI summary
An automated manufacturing system includes two simultaneous and independently operating toolheads accessing any location within the same work volume, with the exception of locations in proximity to each other. The system includes a bed platform connected with X and Y linear axes. A θ rotational axis rotates the bed and its linear axes as a unit. A first toolhead has a fixed position relative to the θ axis, and a second toolhead is coupled with a linear R axis parallel to the bed. The bed X and Y axes move the bed relative to the first toolhead, enabling the first toolhead to reach any portion of the bed. The R linear axis and θ rotational axis allow the second toolhead to move almost anywhere in a circular area that is always centered near the first toolhead. The system's kinematics ensure that it is impossible for the toolheads to collide.