Numerical Control Tool-Direction Correction for Five-Axis Machining
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Solution Overview
Problem
Five-axis processing machines face challenges in maintaining smooth tool-direction vector changes, leading to unnecessary acceleration/deceleration and degraded surface quality due to large changes in tool-direction vectors, which can result in tool interference with the machine and extended processing times.
Innovation Solution
A numerical control device that includes a tool-direction instruction correction unit, which sets and corrects tool-direction instructions within predefined tolerances to ensure smooth vector changes, reducing correction amounts and unnecessary acceleration/deceleration, thereby improving surface quality and processing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the tool center point is controlled to follow the instructed movement path with large changes in tool-direction vector, then the tool center point can reach the instructed position, but the control point movement becomes non-smooth causing unnecessary acceleration/deceleration of servo motors
Solution Approach 1:
The patent applies preliminary action by correcting the tool-direction vector in advance before interpolation. The correction unit modifies the tool-direction vector so that the ratio between linear axis movement amount and tool-direction change amount becomes uniform, preventing non-smooth control point movement before it occurs during actual machining.
2Adaptability or versatility
If the tool-direction vector changes largely, then the tool can reach different orientations, but the control point movement becomes non-smooth extending processing time
Solution Approach 1:
The patent applies parameter changes by modifying the tool-direction vector parameters to achieve uniform ratio between linear axis movement and tool-direction change. This ensures smooth control point movement while maintaining the tool's ability to reach different orientations, thereby reducing unnecessary acceleration/deceleration and shortening processing time.
3Manufacturing precision
If the tool-direction instruction is directly corrected without direction control, then the tool direction can be adjusted, but the correction may increase in processing-surface normal direction causing excessive cutting
Solution Approach 1:
The patent applies local quality by making the correction behavior direction-dependent. Different correction amounts are applied in different directions: correction in the processing-surface normal direction is limited to prevent excessive cutting, while correction in other directions is allowed to maintain tool direction accuracy. This directional differentiation resolves the contradiction between accuracy and harmful material removal.
4Adaptability or versatility
If the correction amount increases in the direction with barrier such as machine, then the tool direction can be adjusted, but the tool and machine may interfere with each other
Solution Approach 1:
The patent applies local quality by implementing direction-specific correction limits. In directions where barriers such as the machine structure exist, the correction amount is restricted to prevent tool-machine interference. In other directions without barriers, full correction is applied to maintain tool direction adaptability. This resolves the contradiction between adjustment range and interference prevention.
Data Source
AI summary
A numerical control device for controlling a five-axis processing machine includes a tool-direction instruction correction unit, and corrects a tool-direction vector so that a tool direction of a processing program smoothly changes. The tool-direction instruction correction unit refers to a tool-direction correction tolerance set in advance by a tool-direction correction tolerance setting unit.