Numerical Controller DNC Switching via Dual Communication Lines
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Solution Overview
Problem
Conventional numerical controllers face issues with prolonged communication failures during DNC operations, leading to machining stoppages, cutter marks, and increased machining time, as they lack effective mechanisms to switch between communication paths when failures occur.
Innovation Solution
A numerical controller with multiple communication units using different paths to receive NC programs, featuring a reception data buffer and a reception management unit that switches the acquisition source when a communication failure is detected, ensuring continuous machining by supplying NC programs from alternative buffers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single communication line is used for DNC operation, then the device complexity is low, but the reliability deteriorates when communication failure occurs
Solution Approach 1:
The communication unit is segmented into multiple independent communication lines (first communication line and second communication line), each capable of independently receiving NC programs. This segmentation allows the system to switch between lines when one fails, improving reliability without requiring complete system redesign.
Solution Approach 2:
The system preliminarily establishes multiple communication lines and buffers before communication failure occurs. The buffers are pre-configured to store NC programs, and the switching mechanism is pre-established, enabling immediate failover when a communication line fails, thus maintaining DNC operation continuity.
2Reliability
If a buffer is provided in the communication unit, then the reliability improves for temporary communication failures, but the productivity deteriorates when the buffer is exhausted during prolonged failures
Solution Approach 1:
The buffer storage is segmented into multiple independent buffers (first buffer and second buffer), each associated with a different communication line. When one buffer is exhausted, the system can switch to another buffer through the switching mechanism, preventing machining stoppage and maintaining productivity during prolonged communication failures.
Solution Approach 2:
The system dynamically changes the operational state by switching between different communication lines and buffers based on their availability. This parameter change (switching active communication line and buffer) ensures continuous NC program supply to the numerical control unit, maintaining machining productivity.
3Reliability
If multiple communication lines are used with switching capability, then the reliability improves for prolonged communication failures, but the device complexity increases
Solution Approach 1:
The reception management unit is designed with multi-functionality, serving as both the control mechanism for switching between communication lines and the coordinator for buffer management. This universal component handles multiple functions (switching, buffer selection, communication coordination) without requiring separate dedicated components for each function, thus limiting the increase in overall device complexity.
Data Source
AI summary
A numerical controller includes a numerical control unit, a DNC operation management unit, and first and second communication units. The first and second communication units receive the same NC program from a host through corresponding communication paths. The DNC operation management unit acquires the NC program from a reception data buffer included in one of the communication units to transfer the NC program to the numerical control unit, and when a failure occurs in the communication path used by the communication unit, an acquisition destination of the NC program is switched to a reception data buffer of the other communication unit.