Numerical Controller Overlap Control for Cycle Time Reduction
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Solution Overview
Problem
In existing numerical controllers using table format data for axis control, manually detecting and adjusting overlapping sites to minimize cycle time is labor-intensive and requires specialized CAM support, making it difficult for operators to optimize operation efficiency.
Innovation Solution
A numerical controller with readout units, distribution processing units, a travel holding unit, and an overlap control unit that detects and corrects overlapping travel quantities, calculating and applying post-correction travels to synchronize axis movements and minimize synthesized velocity below a specified threshold, thereby optimizing cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If manual detection and adjustment of overlapping sites is performed, then cycle time optimization can be achieved, but labor intensity increases and requires specialized CAM support
Solution Approach 1:
The numerical controller automatically detects overlapping sites and calculates corrected travel quantities without requiring manual intervention or specialized CAM support. The overlap control unit performs self-service by reading travel data, detecting overlaps where synthesized velocity falls below thresholds, and generating corrected travel quantities autonomously
Solution Approach 2:
The patent replaces the manual mechanical process of detecting and adjusting overlapping sites with an automated computational system. The overlap control unit uses synthesized velocity calculations and threshold comparisons to automatically identify and correct overlaps, substituting operator labor with algorithmic processing
2Productivity
If overlapping sites are detected and corrected automatically, then production efficiency improves, but device complexity increases
Solution Approach 1:
The overlap control unit performs multiple functions within a single component: reading travel data from the travel holding unit, calculating synthesized velocity, detecting overlapping sites by comparing velocity against thresholds, determining overlap quantities, and writing corrected travel quantities back to the holding unit. This multi-functionality improves productivity while minimizing the increase in device complexity
3Manufacturing precision
If manual adjustment of overlapping sites is performed, then machining accuracy can be optimized, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The system performs preliminary detection and correction of overlapping sites before actual machining operations begin. The overlap control unit reads and analyzes travel data, identifies all overlapping sites, and calculates corrected travel quantities in advance, eliminating the need for time-consuming manual adjustments during setup or operation
Data Source
AI summary
A numerical controller of the invention includes an overlap control unit that detects a reference value minimizing a synthesized velocity for a plurality of control axes calculated based on table format data in an overlap period in which the synthesized velocity is equal to or lower than a threshold set in advance, that finds an overlap quantity as an amount in the reference value of overlapping of travels of the control axes after the detected reference value with travels of the control axes before the detected reference value, that advances the travels of the control axes after the reference value minimizing the synthesized velocity by the overlap quantity, and that calculates post-correction travels resulting from superposition of the travels of the control axes after the reference value on the travels of the control axes before the reference value minimizing the synthesized velocity.