NC Machine Conservation Control for Load and Wear Reduction
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Solution Overview
Problem
Numerically controlled production machines face challenges in maintaining consistent production quality and extending maintenance intervals due to high mechanical and electrical loads, which lead to rapid wear and require lengthy run-up phases when stopped and restarted.
Innovation Solution
A method and numerical controller that allow variable reduction of acceleration and jolting within a limited part value range during a conservation operation, maintaining production quality while reducing mechanical and thermal loads, thereby extending machine component life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high mechanical and electrical loads are applied to production machine components to increase speed and productivity, then production efficiency is improved, but component wear increases and maintenance intervals decrease
Solution Approach 1:
The patent applies dynamics by making the load parameters variable rather than constant. The control system dynamically adjusts acceleration and jolting values based on operational context, allowing the machine to operate at high performance when needed while reducing loads during conservative operation modes to extend component life. This is achieved through variable parameter control within permissible ranges.
Solution Approach 2:
The patent changes operational parameters (acceleration and jolting values) from fixed maximum values to variable values within a permissible range. The control system selects appropriate parameter sets depending on whether conservative operation is activated, thereby adjusting mechanical and electrical loads to balance productivity with component durability.
2Reliability
If the production machine is stopped and restarted to reduce loads, then component wear is reduced, but lengthy run-up phases are required to restore processing accuracy
Solution Approach 1:
The patent applies preliminary action by maintaining continuous operation at reduced loads (conservative operation) instead of stopping and restarting. The control system proactively manages loads within permissible ranges to prevent excessive wear while keeping the machine continuously running, thereby avoiding the time-consuming run-up phases required after shutdowns.
Solution Approach 2:
The patent implements periodic alternation between normal operation and conservative operation modes. The control system switches between different operational states depending on production requirements and component condition, allowing the machine to periodically reduce loads without complete shutdown, thus extending service life while minimizing interruptions.
3Reliability
If acceleration and jolting values are reduced within a limited part value range during conservative operation, then mechanical and electrical loads are reduced, but production speed decreases
Solution Approach 1:
The patent applies partial action by reducing acceleration and jolting values only within a limited part value range during conservative operation, rather than eliminating them completely. This allows the machine to continue productive operation at reduced intensity, extending component life while maintaining some production speed. The control system activates conservative operation selectively based on production requirements.
Data Source
AI summary
A method for operating a numerically controlled production machine includes defining a permissible value range determined by the design and construction of the production machine in which, in a normal operation during production of a workpiece, values representing a mechanical or electrical load described by acceleration and/or jolting of at least one component of the numerically controlled production machine are variable, and activating, for producing the workpiece, with a control signal a conservation operation for reducing the mechanical or electrical loads, wherein in the conservation operation the values of acceleration and/or jolting of the at least one component are variable within a part value range that is limited in comparison to the permissible value range.