Numerical Controller Gentle Mode for Component Wear Reduction
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Solution Overview
Problem
Manufacturing machines face challenges in maintaining consistent manufacturing quality and extending the intervals for maintenance and replacement of machine components due to high mechanical and electrical stresses, which are exacerbated by frequent start-stop operations and high dynamic loads, leading to rapid wear and potential accuracy issues.
Innovation Solution
A method for operating numerically controlled manufacturing machines that varies acceleration and jerk values within a partial range, reducing mechanical and thermal stress by activating a gentle operation mode based on specific manufacturing process requirements, thus maintaining consistent temperature and avoiding downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high dynamic loads and frequent start-stop operations are used to reduce machining time, then productivity is improved, but mechanical and electrical components experience rapid wear and reach thermal limits
Solution Approach 1:
The patent implements dynamic operation modes that adapt acceleration and jerk values based on real-time component status. The control system dynamically switches between normal operation mode (higher acceleration/jerk for productivity) and gentle operation mode (lower acceleration/jerk for component protection), making the system flexible rather than static in its operational parameters
Solution Approach 2:
The patent changes operational parameters (acceleration and jerk values) based on component utilization and status. By adjusting these parameters dynamically - using higher values during normal operation to maintain productivity and lower values during gentle operation to reduce wear - the system optimizes both productivity and component service life
2Strength
If production is stopped or started arbitrarily to protect machine components, then mechanical stress is reduced, but manufacturing accuracy deteriorates due to temperature changes
Solution Approach 1:
The patent applies preliminary action by activating gentle operation mode before critical stress thresholds are reached. The control system proactively reduces acceleration and jerk values when component utilization approaches predefined thresholds, preventing excessive wear and thermal stress before they occur, rather than waiting for damage to accumulate
Solution Approach 2:
The patent ensures continuous operation of the manufacturing machine by maintaining productive speeds even when gentle operation mode is activated. The system continuously processes workpieces without stopping, but at reduced acceleration and jerk rates that still achieve manufacturing goals while protecting components from excessive stress
3Device complexity
If electrical components are designed to be as small as possible to reduce costs and heat dissipation, then device complexity is reduced, but they reach thermal limits during high-speed operations
Solution Approach 1:
The patent applies partial action by using reduced acceleration and jerk values during gentle operation mode, which consequently reduces the thermal load on electrical components. This partial reduction in operational intensity allows compact electrical components to operate within their thermal limits without requiring larger, more expensive components with better heat dissipation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach extends the service life of machine components by reducing wear and maintaining manufacturing accuracy without requiring warm-up phases, while allowing continuous operation within optimal conditions.
Implementation Method 1
the acceleration and/or jerk values of the at least one component are variable within a partial range of values, wherein the partial range of values is limited compared to the permissible range of values
Data Source
Figure 1~2
AI summary
The invention relates to a method for operating a numerically controlled production machine (2, 4) comprising at least one component (12A, 12B), which, during production of a workpiece (5), is exposed to mechanical and/or electrical loads. The loads are described by values of acceleration and/or jolting of the at least one component (12A, 12B), the values being variable within a permissible value range (LIMIT1) during normal operation. The permissible value range (LIMIT1) is determined by the design and construction of the production machine. For production of the workpiece (5), a preservation mode for reducing the mechanical and/or electrical loads is activated in a manner triggered by at least one control signal (30, 32, 34, 36). In the preservation mode, the values of acceleration and/or jolting of the at least one component (12A, 12B) are variable within a partial value range (LIMIT2), the partial value range (LIMIT2) being limited as compared to the permissible value range (LIMIT1).