Numerical Controller Axis Distribution for Parallel Axes
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Solution Overview
Problem
Creating NC programs for machining centers with multiple parallel axes is complex and time-consuming, limiting the frequent use of these axes due to the need for precise coordination of axis movements to avoid stroke limits and ensure machining precision and speed.
Innovation Solution
A numerical controller that automatically selects axes for control based on machining precision and speed, allowing movement commands for a virtual axis to distribute movement between parallel axes, minimizing the need for complex programming and optimizing axis usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If NC programs are created with precise coordination of axis movements to avoid stroke limits and ensure machining precision, then manufacturing precision is improved, but device complexity and programming time increase
Solution Approach 1:
The numerical controller automatically determines axis movement distribution and coordinates parallel axes without operator intervention. The controller reads cutting feed commands, determines fast feed start points, and automatically distributes movement amounts between parallel axes based on stroke limits and machining requirements, making the system self-organizing and eliminating complex manual programming.
Solution Approach 2:
The system dynamically changes control parameters by switching between different axis control modes (individual axis control vs. parallel axis coordination). The numerical controller adjusts movement distribution ratios and selects which axis to move based on real-time stroke limit parameters and machining conditions, optimizing both precision and simplicity automatically.
2Productivity
If parallel axes are coordinated to maximize stroke utilization, then productivity is improved, but programming time and complexity increase
Solution Approach 1:
The numerical controller automatically determines optimal axis coordination strategies to maximize stroke utilization. It reads cutting feed commands, determines fast feed start points, and automatically distributes movement amounts between parallel axes based on stroke limits, eliminating the need for operators to manually calculate and coordinate axis movements to maximize productivity.
Solution Approach 2:
The system performs preliminary determination of fast feed start points and axis movement distribution before actual machining operations. By pre-calculating optimal axis coordination based on upcoming cutting feed commands and stroke limits, the system prepares the most efficient path in advance, maximizing productivity without increasing programming time.
3Productivity
If the W axis is moved frequently to utilize its stroke, then productivity is improved, but machining speed decreases due to W axis movement limitations
Solution Approach 1:
The numerical controller continuously monitors the positions and stroke limits of parallel axes, using this feedback information to dynamically determine which axis should move next. Based on real-time axis position feedback and upcoming cutting feed commands, the controller selects the optimal axis (W or Z) to maintain high machining speed while maximizing overall stroke utilization.
Solution Approach 2:
The system dynamically switches between controlling the W axis and Z axis based on real-time conditions. Rather than following a fixed axis movement pattern, the numerical controller adaptively selects which parallel axis to move for each cutting feed command, optimizing both productivity and machining speed by keeping the faster Z axis moving whenever possible while still utilizing W axis stroke capacity.
Data Source
AI summary
A numerical controller performs cross-rail axis control that distributes moving amount to a first and second axes based on a command to a virtual axis. If a block of a program that is read out contains a fast feed command to the virtual axis for moving a tool to a cutting feed start point, the numerical controller distributes a moving amount commanded by the fast feed command to the first axis and the second axis. Further, the moving amount commanded by the fast feed command is distributed to the first axis and the second axis so that movement of the virtual axis commanded by a cutting feed command that follows the fast feed command in the program can be achieved by movement of only the first axis.