Numerical Control Device for Balance Cutting with Non-Aligned Tool Posts
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Solution Overview
Problem
Machine tools with non-aligned cutting shafts of upper and lower tool posts cannot achieve balance cutting, leading to uneven machining loads and reduced cylindricity in workpieces.
Innovation Solution
A numerical control device that includes memory storing angular difference information and a machining program with commands for an imaginary shaft, allowing the distribution and synchronization of movement commands to align cutting shafts, enabling balance cutting even in machines with non-aligned shafts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If balance cutting is performed with aligned cutting shafts, then machining loads are equal and cylindricity is improved, but machine tool configuration becomes restricted to aligned shafts only
Solution Approach 1:
The patent replaces the mechanical alignment requirement with a computational solution. The NC device calculates and distributes movement commands to imaginary shafts that represent the actual non-aligned cutting shafts, enabling balance cutting through numerical control rather than mechanical alignment. This substitution allows balance cutting on machine tools with non-aligned shafts by using computational geometry and coordinate transformation.
Solution Approach 2:
The patent introduces imaginary shafts as intermediaries between the actual non-aligned cutting shafts and the balance cutting process. These imaginary shafts serve as virtual reference frames that allow the NC device to coordinate the movement of actual cutting shafts with different orientations, enabling load balancing without direct mechanical alignment.
2Productivity
If cutting feed speed is doubled through balance cutting, then machining time is shortened, but machining loads must be equal which requires aligned shafts
Solution Approach 1:
The patent replaces the mechanical alignment system with a numerical control system that uses computational geometry. The NC device performs coordinate transformations and calculates movement commands for imaginary shafts, substituting complex mechanical alignment requirements with software-based solutions that can handle non-aligned configurations while maintaining doubled feed speed capability.
3Manufacturing precision
If movement commands are distributed to multiple cutting shafts, then balance cutting is achieved, but control complexity increases
Solution Approach 1:
The patent introduces imaginary shafts as intermediary control elements that simplify the distribution of movement commands. Instead of directly coordinating multiple physically non-aligned shafts, the NC device issues commands to imaginary shafts that represent idealized reference frames, and the system automatically transforms these into coordinated movements of actual cutting shafts, reducing control complexity.
Solution Approach 2:
The imaginary shafts serve multiple functions: they act as reference frames for movement commands, as intermediaries for coordinate transformation, and as simplifying abstractions for control logic. This multi-functionality allows a single control mechanism to handle the complexity of coordinating non-aligned shafts while maintaining load balance.
Data Source
AI summary
A numerical control device includes: a memory storing in advance angular difference information between each of first cutting shafts formed for an upper tool post and a second cutting shaft of a lower tool post and a machining program including a movement command for the upper tool post to move an imaginary shaft, which moves along the same line as the second cutting shaft and performs cutting from a direction opposite to the second cutting shaft with respect to the main shaft; a shaft-command distribution processing unit distributing the movement command to move the imaginary shaft to the first cutting shaft components based on the angular difference information; and a shaft-synchronization processing unit driving the first cutting shafts based on the movement command distributed to the first cutting shaft components and driving the second cutting shaft by the movement amount same as that in the direction of the imaginary shaft.