NC Tool Path Offsetting for Safe 5-Axis Test Runs
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Solution Overview
Problem
Existing numerical control devices face challenges in reliably preventing tool interference with the workpiece during test running, especially in complex machining operations like 5-axis machining, due to limitations in setting and maintaining the correct tool length settings.
Innovation Solution
A numerical control device that includes an offset setting unit to determine the offset direction and amount based on the tool's orientation, a test-running path calculation unit to calculate a safe movement path, and an operating mode selection unit to switch between machining and test-running modes, ensuring the tool does not interfere with the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the longest distance among movement amounts in the Z axis is defined as the offset amount, then the test running can be performed, but the tool may still interfere with the workpiece in complex 5-axis machining operations
Solution Approach 1:
The patent extends the offset calculation from a single Z-axis dimension to a multi-dimensional approach considering all tool movement paths and orientations. The control device calculates offset amounts in multiple directions (X, Y, Z axes) and determines the appropriate offset direction based on tool orientation, transforming a one-dimensional problem into a comprehensive multi-dimensional solution that prevents tool interference in complex 5-axis machining operations.
Solution Approach 2:
The system dynamically changes the offset parameters (offset amount and offset direction) based on the specific machining conditions, tool orientation, and movement path. Instead of using a fixed Z-axis offset, the control device calculates and applies appropriate offset values in different directions, adapting the offset parameters to each specific machining scenario to ensure reliable tool clearance.
2Reliability
If the tool length setting value is changed to avoid tool interference, then the tool can be retracted from the workpiece, but the setting value must be returned to the correct value after test running which may be forgotten or set incorrectly
Solution Approach 1:
The control device automatically manages the offset settings without requiring manual intervention. The system self-calculates the appropriate offset amounts and directions based on the machining program and tool parameters, then automatically applies these offsets during test running. This eliminates the need for operators to manually change tool length settings and remember to restore them, making the system self-sufficient in managing test running safety.
Solution Approach 2:
The control device introduces an intermediary offset mechanism between the machining program and the actual tool movement. Instead of directly changing the tool length setting, the system calculates offset amounts and applies them as an intermediate layer, allowing test running to be performed safely without modifying the original tool length parameters. This intermediary approach preserves the original settings while enabling safe test operations.
3Ease of operation
If a fixed Z-axis offset is used for test running, then the operation is simple, but it is not reliable for complex machining operations where tool orientation varies
Solution Approach 1:
The patent transforms the static fixed Z-axis offset into a dynamic offset system that adapts to varying tool orientations and movement paths. The control device continuously calculates offset amounts and directions based on the current tool position, orientation, and machining program requirements. This dynamic approach maintains operational simplicity while ensuring manufacturing precision by adjusting offsets in real-time according to the specific machining conditions.
Data Source
AI summary
A numerical control device according to an aspect of the present disclosure controls a machine tool that machines a workpiece by way of a tool in accordance with a machining program, and includes: an offset setting unit which decides an offset direction and an offset amount with an orientation of the tool as a reference, for every tool; a test-running path calculation unit which calculates a test-running movement path of the tool obtained by offsetting by the offset amount in the offset direction from a machining movement path of the tool designated by the machining program; and an operating mode selection unit which selects either one of a machining operation mode of causing the tool to move following the machining movement path, and a test-run mode of causing the tool to move following the test-running movement path.