Numerical Controller Dynamic Acceleration Adjustment
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Solution Overview
Problem
Conventional numerical controllers for machines fail to minimize mechanical shock and extend machine life by automatically adjusting acceleration and deceleration times, as they prioritize energy conservation over vibration suppression and do not consider cycle times required in machining processes.
Innovation Solution
A numerical controller with a program analysis unit, impact analysis unit, and acceleration/deceleration time constant adjustment mechanism that identifies and adjusts the time constants based on impact and motor load thresholds, ensuring machining time remains within tact times, thereby reducing mechanical stress and extending machine life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the acceleration and deceleration time is set as short as possible to minimize cycle time, then productivity is improved, but mechanical shock increases resulting in reduced machine life
Solution Approach 1:
The system dynamically adjusts the acceleration/deceleration time constant based on real-time impact sensor data and motor load currents, rather than using a fixed value. This allows the cycle time to be minimized when machine conditions permit, while automatically increasing acceleration time when impact thresholds are exceeded, thus resolving the contradiction between productivity and machine life
Solution Approach 2:
The system uses impact sensors and motor load current measurements to provide feedback on the actual mechanical shock being generated. This feedback is continuously monitored and used to adjust the acceleration/deceleration time constant, enabling the system to maintain high productivity when conditions are favorable while protecting machine life when shock levels become excessive
2Reliability
If the acceleration/deceleration time constant is increased to reduce mechanical shock, then machine life is improved, but cycle time increases reducing productivity
Solution Approach 1:
The acceleration/deceleration time constant is changed from a static, manually-set value to a dynamic parameter that is automatically adjusted based on real-time monitoring of impact sensor data and motor load currents. This enables the system to use shorter acceleration times (higher productivity) when machine conditions are favorable, and automatically extend acceleration time (protecting machine life) when impact thresholds are exceeded
Solution Approach 2:
The system performs self-adjustment of the acceleration/deceleration time constant without requiring manual intervention. The numerical controller automatically monitors impact sensor data and motor load currents, identifies when threshold exceedances occur, and autonomously modifies the time constant to protect the machine while maintaining productivity
3Reliability
If manual adjustment is used to increase acceleration/deceleration time constant to reduce mechanical shock, then machine life is improved, but ease of operation deteriorates due to difficulty of on-spot adjustment
Solution Approach 1:
The system eliminates the need for manual adjustment by implementing automatic monitoring and adjustment of the acceleration/deceleration time constant. The numerical controller continuously monitors impact sensor data and motor load currents, automatically identifies when threshold exceedances occur, and autonomously modifies the time constant, completely removing the burden of manual adjustment from the operator while protecting machine life
4Reliability
If feed speed is dynamically changed to suppress vibration and chattering, then machine life is improved, but cycle time may exceed tact time reducing productivity
Solution Approach 1:
The system uses impact sensors and motor load current measurements to provide real-time feedback on mechanical shock and vibration levels. This feedback is used to dynamically adjust the feed speed and acceleration/deceleration time constant, enabling vibration suppression when needed while maintaining high feed speeds when conditions permit, thus resolving the contradiction between machine life and productivity
Data Source
AI summary
A numerical controller obtains a maximum value of an impact produced in a machine during execution of a machining program, identifies an acceleration/deceleration time constant at a point where the maximum value of the impact is generated, based on command data, if the obtained value exceeds a threshold, changes the identified time constant, and recalculates a cycle time of the machining program based on the changed time constant. If the cycle time is within a preset tact time, the changed time constant is stored in advance in association with an identified command block so that it is referred to during the execution of the machining program.