Numerical Controller Overlapping Press Axis Motions
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Solution Overview
Problem
Existing numerical controllers face challenges in achieving high-speed machining when the amount of movement of table axes is small, leading to synchronization issues and potential machining defects due to inadequate clearance, resulting in reduced hit rates and increased operational load.
Innovation Solution
A numerical controller with an axis motion control unit that starts the press axis motion at a first top dead center and, if conditions are met, at a second top dead center lower than the first, allowing for overlapping of press axis motions between blocks, while maintaining a minimum clearance to prevent defects, thereby enabling high-speed machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the press axis motion is overlapped to reduce machining time, then productivity is improved, but synchronization with table axes and clearance cannot be secured
Solution Approach 1:
The patent implements dynamic adjustment of the press axis starting position by introducing a variable offset parameter (α) that modifies the top dead center position. This dynamic parameter allows the system to adapt the press axis motion timing and position based on real-time table axis states, enabling overlap control that maintains both synchronization and adequate clearance while improving productivity
Solution Approach 2:
The patent changes the parameter of press axis starting position from a fixed top dead center to a variable position defined by offset α. This parameter change enables flexible adjustment of the press axis motion to achieve optimal overlap with table axis movements, securing both synchronization and clearance requirements while reducing machining time
2Manufacturing precision
If the clearance is increased to prevent machining defects, then manufacturing precision is improved, but machining time increases
Solution Approach 1:
The patent applies local quality by ensuring adequate clearance only at the critical moment when the press axis contacts the workpiece, rather than maintaining a large clearance throughout the entire motion cycle. The offset parameter α is dynamically adjusted to provide precise clearance control at the point of contact, preventing defects while minimizing impact on machining speed
3Manufacturing precision
If the set value of clearance is changed for each condition, then manufacturing precision is improved, but operational load increases
Solution Approach 1:
The patent creates a universal solution by implementing a single offset parameter α that works across different workpiece conditions (thickness, material, tool type). This universal parameter replaces the need for multiple clearance set values for different conditions, reducing operational complexity while maintaining manufacturing precision through adaptive adjustment
Data Source
AI summary
A numerical controller is provided with an axis motion control unit configured to control the motions of a table axis and a press axis according to a machining program. The axis motion control unit starts the motion of the press axis for a first block at a first top dead center, if the state of the table axis satisfies a condition adapted for the start of the motion of the press axis for the second block and if the motion of the press axis for the first block is not completed, and the axis motion control unit starts the motion of the press axis for a second block at a second top dead center lower than the first top dead center, thereby overlapping the motions of the press axis for the first and second blocks.