Numerical Control System Fault Detection via CAD-I/O Mapping
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Solution Overview
Problem
Existing numerical control systems face challenges in accurately detecting and locating defects, such as cable disconnection or power interruptions, within the control panel of a machine tool, as conventional methods require reference to circuit or mounting diagrams, which are time-consuming to prepare and may not clearly specify the fault location.
Innovation Solution
A numerical control system that reads CAD data for control panel design, associates it with I/O assignment data, and uses a fault detection mechanism to display the defect occurrence region on a panel image, allowing operators to identify fault locations without needing circuit or mounting diagrams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional fault detection methods are used, then fault causes can be discriminated, but fault locations cannot be easily identified without checking circuit or mounting diagrams
Solution Approach 1:
The system pre-stores the mounting positions of all I/O units in the control panel during the design phase. When a fault occurs, this pre-stored location information is immediately retrieved and displayed on the screen, eliminating the need for operators to manually check circuit or mounting diagrams during fault diagnosis.
Solution Approach 2:
The system creates a visual copy (display image) of the control panel layout showing the actual positions of I/O units. This graphical representation allows operators to quickly identify fault locations by viewing the displayed panel layout rather than consulting physical diagrams, providing an immediate visual reference.
2Ease of operation
If screen display applications are prepared for each individual machine, then fault locations can be visually displayed, but the preparation process becomes time-consuming
Solution Approach 1:
The system uses a standardized display template that can be universally applied to different machine tools. By storing I/O unit position information in a uniform format and using a generic panel layout display application, the same screen program can display fault locations for various machines without requiring individual customization, thus reducing preparation time.
Solution Approach 2:
The mounting position information of I/O units is pre-stored in the control device during the design phase. This pre-prepared data allows the system to quickly generate appropriate display information when faults occur, eliminating the need for time-consuming screen preparation for each individual machine.
Data Source
AI summary
A numerical control system includes a computer aided design (CAD) data storage means for storing CAD data, an input/output (I/O) assignment data storage means for storing I/O assignment data, and a relevant information storage means for recording relevant information between the I/O assignment data and mounting information included in CAD data of each of the I/O units, and displays a defect occurrence region on a shape image of a control panel.