Numerical Control Device Vibration Synchronization
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Solution Overview
Problem
Existing numerical control devices face challenges in creating data tables for synchronizing and feeding cutting tools in multiple axial directions at low frequencies, requiring significant time and effort, and are unable to perform machining without pre-defined rotational speeds or tool vibration conditions.
Innovation Solution
A numerical control device that includes an analysis processing unit to generate movement commands and vibration conditions, a command-movement-amount calculation unit, a vibrational-movement-amount calculation unit, and a movement-amount combining unit to calculate combined movement amounts, allowing machining to be performed along a machining path with vibrations without the need for a pre-defined table of tool vibration conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a table of tool vibration conditions is created for each rotational speed or feed amount, then machining can be performed with synchronized tool vibration, but considerable time and effort are required to create the table
Solution Approach 1:
The patent replaces the mechanical approach of pre-defining vibration conditions in lookup tables with a computational approach. The control device calculates tool vibration conditions in real-time based on the movement commands from the machining program, eliminating the need for manual table creation while ensuring accurate synchronization between tool vibration and workpiece rotation.
2Reliability
If a table of tool vibration conditions is created for each rotational speed or feed amount, then machining can be performed with synchronized tool vibration, but the system cannot handle rotational speeds or feed amounts not included in the table
Solution Approach 1:
The patent implements a dynamic calculation system that adapts to any rotational speed or feed amount specified in the machining program. Instead of relying on static pre-defined tables, the control device dynamically computes the appropriate tool vibration conditions based on the actual movement commands, enabling the system to handle any machining condition without limitation.
3Manufacturing precision
If tool vibration conditions are pre-defined in a table, then low frequency vibration cutting can be achieved, but the system is limited to frequencies of 25 Hz or higher
Solution Approach 1:
The patent enables dynamic adjustment of vibration frequency parameters through real-time calculation. By computing vibration conditions based on actual movement commands rather than relying on pre-defined tables with minimum frequency constraints, the system can achieve effective vibration cutting across a broader frequency range, including lower frequencies that were previously inaccessible.
4Productivity
If the control system uses a lookup table for vibration conditions, then processing is simple when conditions match, but the system lacks flexibility for custom machining conditions
Solution Approach 1:
The patent replaces the lookup table mechanism with a real-time computational system that calculates vibration conditions directly from machining program commands. This substitution maintains processing efficiency through automated calculation while dramatically improving operational flexibility, allowing the system to handle any custom machining condition without requiring pre-programmed tables.
Data Source
AI summary
To include an analysis processing unit that obtains a movement command for moving on a movement path in a machining program, and vibration conditions for vibrating along the movement path, a command-movement-amount calculation unit that calculates a command-movement amount per unit time, a vibrational-movement-amount calculation unit that uses the vibration conditions to calculate a vibrational-movement amount per unit time at a time corresponding to the movement command, and a movement-amount combining unit that combines the command-movement amount with the vibrational-movement amount to calculate a combined movement amount, and that acquires a movement amount within the unit time such that a position, which has moved from a reference position for calculating the combined movement amount by the combined movement amount, is located on the movement path.