Numerical Controller Dynamic Overlap Time for Punch Press Dead Time
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Solution Overview
Problem
Conventional punch press machine tools experience dead time when the press operation starts from a position higher than the rising edge, leading to increased stroke and inefficient machining due to the overlap of X/Y axis movement and press operation.
Innovation Solution
A numerical controller is developed with a function to determine the difference between the start position of the press operation and the rising edge, automatically adjusting the overlap time to prevent dead time by recalculating the overlap time based on the position of the punch head during the press operation, ensuring timely contact with the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If press operation starts from a position higher than the rising edge, then the stroke increases allowing for tool exchange or obstacle avoidance, but dead time is generated reducing machining efficiency
Solution Approach 1:
The overlap time is made dynamic and adjustable based on the actual press start position. The system automatically calculates and sets the overlap time according to the difference between the press start position and the rising edge position, allowing the timing parameters to adapt to different operational conditions rather than using fixed values
Solution Approach 2:
The overlap time parameter is changed based on the press start position. When the press starts from a position higher than the rising edge, the system increases the overlap time to compensate for the extended stroke, ensuring the X/Y axis movement completes before the punch tool contacts the workpiece
2Manufacturing precision
If overlap time is set for normal rising edge press, then punch tool contacts workpiece at correct timing, but dead time occurs when press stroke increases
Solution Approach 1:
The system uses feedback from the press start position detection to automatically adjust the overlap time. The position detection unit provides information about where the press starts, and this feedback is used by the overlap time setting unit to calculate the appropriate overlap time, creating a closed-loop control system that maintains timing accuracy
Solution Approach 2:
The overlap time is preliminarily calculated and set before the press operation begins. By determining the required overlap time in advance based on the press start position, the system ensures that the X/Y axis movement will complete before the press operation starts, preventing dead time without requiring real-time adjustments during operation
Data Source
AI summary
A numerical controller generates movement command data, and performs an interpolation process based on the generated movement command data to generate and output interpolation data. Further, in the case of a state in which a press operation in punch press machining is started from a different position from a position of a preset rising edge, an overlap time is calculated based on a position of a punch head when the press operation is started, and an output timing of interpolation data related to an axis controlling the press operation is controlled based on the calculated overlap time. In this way, even when there is a change in press stroke, a dead time may be prevented from being generated.