Numerical Controller Power Saving via Non-Cutting Block Detection
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Solution Overview
Problem
Conventional numerical controllers consume excessive power during non-cutting states due to continuous operation of peripheral equipment, and existing power-saving techniques either increase cycle time, fail to address heat generation, or do not effectively reduce power consumption during short non-cutting periods.
Innovation Solution
A numerical controller with a program analysis unit that looks ahead in the machining program to detect non-cutting blocks and calculates the power consumption of shifting equipment to a power-saving state and back, creating an operation variation pattern to reduce power consumption without affecting cycle time or equipment state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If equipment is shifted to power saving state during non-cutting blocks, then power consumption is reduced, but cycle time increases due to acceleration and deceleration
Solution Approach 1:
The controller performs preliminary analysis of the machining program to identify non-cutting blocks before execution. By pre-calculating whether power saving operations are beneficial based on block duration and power consumption parameters, the system prepares optimal control strategies in advance, avoiding real-time decision delays and enabling proactive power management without affecting machining cycle time
Solution Approach 2:
The system dynamically adjusts equipment operation states based on real-time conditions. The controller continuously monitors whether the current block is cutting or non-cutting, and dynamically switches equipment between operative and power saving states. This dynamic control adapts to varying machining conditions, enabling power consumption optimization without fixed timing constraints that would increase cycle time
2Use of energy by moving object
If equipment is deactivated in non-cutting blocks, then power consumption is reduced, but equipment may generate abnormal heat or affect machining quality
Solution Approach 1:
The controller implements feedback mechanisms by continuously monitoring equipment state and machining conditions. Before deactivating equipment to save power, the system evaluates feedback information including whether the block is truly non-cutting, the duration of the block, and equipment thermal state. This feedback-driven decision-making ensures power saving actions are taken only when safe and beneficial, preventing abnormal heat generation and maintaining machining quality
Solution Approach 2:
The system changes operational parameters based on block characteristics. For short non-cutting blocks, the controller maintains equipment in operative state with adjusted parameters, while for sufficiently long non-cutting blocks, it transitions to power saving state. This parameter adjustment strategy, based on block duration and power consumption thresholds, optimizes power usage while preventing harmful effects from inappropriate deactivation
3Use of energy by moving object
If power operation codes are inserted into machining program, then power source can be deactivated, but number of program commands increases and cycle time increases
Solution Approach 1:
The controller performs self-service by autonomously analyzing the machining program and automatically determining optimal power saving opportunities without requiring program modifications. The system independently identifies non-cutting blocks, calculates power consumption benefits, and executes appropriate control actions, eliminating the need for additional power operation codes in the machining program and avoiding any increase in cycle time
Solution Approach 2:
The invention replaces the mechanical approach of inserting explicit power control commands into the program with an intelligent software-based solution. The controller uses program analysis and automated decision-making algorithms to substitute for manual power management commands, achieving power savings through smart control rather than through additional program instructions that would extend cycle time
Data Source
AI summary
A numerical controller looks ahead a machining program to detect consecutive non-cutting blocks. The numerical controller calculates first consumed power needed during an execution duration of the non-cutting blocks to shift equipment to a power saving state, operate the equipment in the power saving state, and restore the equipment to a state before the shifting to the power saving state, and second consumed power needed during the execution duration of the non-cutting blocks to operate the equipment without shifting the equipment to the power saving state. When a result of the calculation indicates that the first consumed power is lower than the second consumed power, the numerical controller creates an equipment operation variation pattern according to which the equipment is to be shifted to the power saving state, operated in the power saving state, and then restored to the state before the shifting to the power saving state.