Numerical Controller Bottleneck Cycle Time Adjustment
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Solution Overview
Problem
In factories with multiple machine tools, optimizing machining steps to avoid bottlenecks is challenging due to the time-consuming process of adjusting parameters and programs for each tool, especially when there are dozens of tools, leading to inefficient use of machine tools and potential redundant production or reduced operating times.
Innovation Solution
A numerical controller system that includes a storage unit for multiple machining program combinations and parameters, a receiving unit to identify bottleneck cycle times, a selection unit to adjust cycle times within acceptable limits, and a transmission unit to synchronize adjustments across the factory, allowing for real-time adjustments and optimal machining program selection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple machine tools are adjusted individually to optimize machining parameters and programs, then manufacturing precision and quality are improved, but the time and labor required for adjustment increases significantly
Solution Approach 1:
The patent creates a master program that serves as a universal template for multiple machine tools. This master program contains standardized machining parameters and sequences that can be automatically distributed to numerous machine tools, eliminating the need for individual adjustment of each tool while maintaining consistent machining quality across the entire factory.
Solution Approach 2:
The system performs preliminary optimization by creating a master program that incorporates the optimal machining parameters determined through initial analysis. This master program is then pre-distributed to all machine tools before production begins, allowing operators to skip the time-consuming individual adjustment process and start machining immediately with optimized parameters.
2Productivity
If machine tools operate at maximum production capacity, then productivity is improved, but tool lifetime decreases and power consumption increases
Solution Approach 1:
The patent implements dynamic parameter adjustment within the master program, allowing machining parameters such as cutting speed and feed rate to be automatically optimized based on real-time conditions. This dynamic optimization enables machine tools to operate at optimal capacity without consistently running at maximum limits, thereby extending tool lifetime while maintaining high productivity through intelligent parameter modulation.
3Manufacturing precision
If machining parameters are optimized for each individual machine tool, then manufacturing precision is improved, but device complexity increases due to the need to manage multiple different programs
Solution Approach 1:
The patent merges the programming and parameter optimization functions into a single centralized master program that controls multiple machine tools. Instead of managing separate optimized programs for each machine tool, the system consolidates all optimization logic into one master program that is distributed to all tools, dramatically reducing program management complexity while maintaining precision through standardized parameters.
4Productivity
If the number of machine tools is increased to meet production demand, then productivity is improved, but the time required for operator adjustment increases
Solution Approach 1:
The patent uses the master program as a template that can be automatically copied and distributed to any number of machine tools. When production demand increases and additional machine tools are added to the factory, the same optimized master program can be instantly copied to these new tools without requiring operators to perform time-consuming adjustment procedures, enabling rapid scaling of production capacity.
Data Source
AI summary
To provide a numerical controller, a control system, a control method, and a control program that can realize proper adjustment of a method of machining by each machine tool in a machining step. A numerical controller comprises: a ROM that stores multiple combinations of machining programs and parameters together with a first cycle time required for machining; a receiving unit that receives a second cycle time of a bottleneck step; and a selection unit that selects a combination from the multiple combinations of the machining programs and the parameters. The selected combination is to extend the first cycle time to a range not exceeding the second cycle time.