Numerical Controller for Predicting Constant-Load Machining Time
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Solution Overview
Problem
It is challenging to predict machining time when controlling the feed rate of a spindle to maintain a constant load, as the feed rate changes accordingly, making it difficult to anticipate the machining time.
Innovation Solution
A numerical controller is developed with a spindle load detection unit, a target load setting unit, and a machining time prediction unit that uses time-series data to predict machining time before adjusting the spindle's feed rate to match a target load, allowing for accurate output of the predicted machining time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If the feed rate of the spindle is controlled so that the load on the spindle remains constant, then the lifetime of the tool is extended, but the machining time becomes difficult to predict
Solution Approach 1:
The patent applies preliminary action by predicting the machining time before actually executing the constant load control machining. The prediction is made by analyzing time-series load data from preliminary machining tests, allowing the system to estimate the machining time in advance without actually performing the full machining operation under constant load conditions.
Solution Approach 2:
The patent uses copying by creating a virtual model of the machining process through data analysis. Instead of directly measuring the machining time of the actual workpiece under constant load control, the system copies the load characteristics from preliminary test data and uses this copied information to predict the machining time for the actual machining operation.
2Reliability
If the feed rate is adjusted to maintain constant spindle load, then tool wear is reduced, but the machining process becomes more complex to manage
Solution Approach 1:
The patent introduces an intermediary element - the machining time prediction function - that mediates between the constant load control system and the operator. This intermediary analyzes the complex time-series load data and provides a simple predicted machining time value, allowing operators to manage the machining process without directly dealing with the complexity of real-time load monitoring and feed rate adjustment.
Solution Approach 2:
The system applies self-service by automatically analyzing the time-series load data and generating the machining time prediction without requiring manual intervention. The prediction unit autonomously processes the collected data, calculates the predicted machining time, and presents it to the operator, eliminating the need for manual calculation or complex operator judgment.
Data Source
AI summary
A numerical controller includes: a spindle load detection unit that detects time-series data on a load on a spindle when a workpiece is machined; a target load setting unit that sets a target load on the spindle; a machining time prediction unit that, based on the time-series data, predicts a machining time taken when a feed rate of the spindle is controlled so that a load on the spindle matches the target load; and a machining time output unit that outputs data on the predicted machining time.