NC Program Generation for 5-Axis Tool Posture Inversion Control
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Solution Overview
Problem
Machine tools with two rotation axes (B-axis and C-axis) face issues with singular solutions and multiple solution sets for tool posture, leading to restricted motion ranges and potential increases in machining time and surface quality deterioration due to the need to select between two sets of rotation angles.
Innovation Solution
An information processing device generates two NC programs by calculating initial and alternative rotational positions, counting inversions, and selecting the program with fewer inversions to optimize tool movement and reduce machining time and surface quality issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the postprocessor calculates rotational positions about the rotation axes based on tool posture, then the NC program can be generated, but two solutions are obtained requiring selection, which may lead to increased machining time or deterioration in machined surface quality when the motion range of the rotation axis is restricted
Solution Approach 1:
The patent applies preliminary action by calculating both possible rotational position solutions in advance during the NC program generation phase. The postprocessor computes both Solution 1 and Solution 2 for each tool posture, then evaluates which solution is more favorable based on motion range constraints and inversion counts before actual machining begins. This allows the optimal solution to be selected beforehand, avoiding suboptimal tool movements during machining that would increase machining time.
Solution Approach 2:
The patent applies dynamics by making the selection of rotational positions adaptive rather than fixed. The system dynamically evaluates both solutions against the specific machining context, including motion range constraints and the number of inversions required, and selects the most favorable solution for each tool posture. This dynamic selection process optimizes the NC program for each specific machining scenario, preventing excessive rotation axis movements that would deteriorate surface quality or extend machining time.
2Device complexity
If the postprocessor selects a solution based on positive rotational position or smaller movement amount, then the calculation is simplified, but the motion range of the rotation axis may be restricted causing unfavorable outcomes
Solution Approach 1:
The patent applies preliminary action by evaluating both solution options during the NC program generation phase. Instead of简单地 selecting based on positive rotational position or smaller movement amount, the system calculates both Solution 1 and Solution 2, then performs a comprehensive evaluation considering motion range constraints and the number of inversions. This preliminary evaluation ensures that the selected solution will not cause excessive rotation axis movements that would deteriorate surface quality.
Solution Approach 2:
The patent applies feedback by introducing an evaluation mechanism that counts the number of inversions for each solution. The postprocessor monitors the rotational position changes and compares both solutions against the motion range constraints and inversion criteria. This feedback loop allows the system to identify and select the more favorable solution, ensuring that the NC program produces high-quality machined surfaces without excessive rotation axis movements.
3Ease of operation
If the rotation axis moves greatly during actual machining, then the tool can reach the instructed position, but the machining time increases and surface quality deteriorates
Solution Approach 1:
The patent applies preliminary action by calculating and comparing both rotational position solutions during the NC program generation phase. The postprocessor determines the number of inversions for each solution and selects the one with fewer inversions before machining begins. This preliminary optimization ensures that the selected NC program minimizes rotation axis movements, thereby reducing machining time and improving surface quality while still achieving the required tool positioning.
Solution Approach 2:
The patent applies parameter changes by optimizing the rotational position parameters (B and C axis angles) during NC program generation. The system changes the selection criterion from simple positive position or minimal movement to a more sophisticated evaluation based on inversion counts and motion range constraints. This parameter optimization ensures that the tool reaches the instructed position with minimal rotation axis movement, reducing machining time and improving surface quality.
Data Source
AI summary
An information processing device includes a CL data acquiring unit for acquiring CL data including an instructed position of a tool leading end point and an instructed angle of a tool posture; and an NC program generating unit for calculating a movement position on the linear axis corresponding to the instructed position and a rotational position about the rotation axis corresponding to the instructed angle. The NC program generating unit generates (i) first instructed point data calculated with an initial value of the rotational position and (ii) second instructed point data, which is different from the first instructed point data, calculated with the initial value of the rotational position, and the NC program generating unit counts number of inversions of the rotational position for each of the first instructed point data and the second instructed point data and generates the NC program in which the number of inversions is smaller.