Numerical Controller Adaptive Synchronization Error for Rigid Tapping
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Solution Overview
Problem
Existing numerical controllers fail to maintain desired precision during rigid tapping on inclined surfaces due to uniformly set allowable synchronization error thresholds, which do not account for the component ratios of individual movement axes, leading to potential tool damage and thread collapse.
Innovation Solution
A numerical controller that automatically adjusts the allowable synchronization error threshold based on the component ratios of individual movement axes with respect to the movement distance in the tap direction, using a preprocessing unit to acquire the inclination angle and determine a new allowable synchronization error for precise machining on inclined surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If uniformly set allowable synchronization error thresholds are used for rigid tapping on inclined surfaces, then the control system remains simple and easy to operate, but the machining precision and reliability deteriorate due to inability to account for component ratios of individual movement axes
Solution Approach 1:
The allowable synchronization error thresholds are dynamically adjusted based on the inclination angle of the cutting surface. The control device calculates component ratios of individual movement axes relative to the tap direction and automatically modifies the thresholds accordingly, transforming the static uniform threshold system into a dynamic adaptive one that maintains precision without requiring complex manual intervention
Solution Approach 2:
The control device changes the parameter values of allowable synchronization error thresholds based on the inclination angle and component ratios. By automatically calculating and adjusting these parameters according to the specific machining conditions, the system adapts the error thresholds to match the geometric characteristics of the inclined surface, thereby maintaining machining precision
2Reliability
If uniformly set allowable synchronization error thresholds are applied in the machine coordinate system, then the control logic remains simple, but the ability to correctly determine desired precision on inclined surfaces deteriorates
Solution Approach 1:
The control device incorporates a feedback mechanism that continuously monitors the inclination angle of the cutting surface and automatically adjusts the allowable synchronization error thresholds based on calculated component ratios. This closed-loop approach ensures that the error thresholds accurately reflect the actual machining conditions, thereby maintaining reliable precision determination without requiring complex manual calibration
Solution Approach 2:
The control device performs self-adjustment of the allowable synchronization error thresholds by automatically calculating component ratios and modifying the thresholds according to the inclination angle. This self-service capability eliminates the need for manual intervention or complex external calibration procedures, thereby maintaining reliability while managing complexity through automation
Data Source
AI summary
The numerical controller controls a machine tool and performs rigid tapping on a cutting surface of a workpiece. The numerical controller determines, based on a first allowable synchronization error between a rotation of a spindle and movement of each axis of a workpiece coordinate system and an inclination angle of a cutting surface, a second allowable synchronization error between a spindle and a feed axis and monitors a synchronization error between the spindle and the feed axis based on a second allowable synchronization error that has been determined.