Numerical Controller Reciprocal Turning Cycle Time Reduction
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Solution Overview
Problem
Existing numerical controllers for turning operations in machine tools face inefficiencies due to unidirectional movement, resulting in longer cycle times as tools need to return to the start point after each cycle, increasing overall processing time.
Innovation Solution
A numerical controller that employs two tools moving in opposite directions, with a tool switching unit allowing for reciprocal turning operations, minimizing tool movement and enabling simultaneous execution of turning operations in both directions, thereby reducing cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If a single tool performs turning in one direction only, then the tool path is simple and control is easy, but the cycle time increases due to unnecessary return movement to the start point
Solution Approach 1:
The turning operation is segmented into two independent tools: a first tool for forward turning and a second tool for reverse turning. This segmentation eliminates the need for the single tool to return to the start point, as the second tool is already positioned to perform turning in the opposite direction, thereby reducing cycle time while maintaining manageable system complexity through modular tool design
Solution Approach 2:
The system transitions from unidirectional tool movement to bidirectional simultaneous operation by introducing a second tool positioned in the opposite direction. This dimensional change allows both tools to operate concurrently in opposite directions along the workpiece, eliminating idle return movements and significantly reducing cycle time
2Productivity
If the tool returns to the start point after each turning cycle, then the tool can be reused for the next cycle, but time is wasted on the return movement
Solution Approach 1:
The second tool is pre-positioned in advance on the opposite side of the workpiece, ready to perform turning in the reverse direction immediately after the first tool completes its operation. This preliminary positioning eliminates the need for the tool to return to the start point, as the second tool is already in the optimal position to continue the turning operation without interruption
Solution Approach 2:
The turning operation maintains continuous useful action by having the second tool immediately follow the first tool's completion. While the first tool is performing forward turning, the second tool is positioned and ready to perform reverse turning, ensuring that there is no idle time or non-productive return movement, thus maximizing productivity
3Productivity
If two tools are used for reciprocal turning, then the cycle time is shortened, but the device complexity increases
Solution Approach 1:
The first tool and second tool are merged into a single tool holder assembly that can be rotated to bring either tool into the active cutting position. This merging approach allows the system to utilize two tools for reciprocal turning operations while maintaining a compact and manageable device structure, reducing the overall complexity compared to having completely separate tooling systems
Solution Approach 2:
The tool holder is designed as a universal component that can accommodate and switch between multiple tools (first tool and second tool) with different orientations. This multi-functional design allows a single device to perform both forward and reverse turning operations, reducing the need for multiple specialized devices and thereby managing device complexity while achieving shortened cycle time
Data Source
AI summary
A numerical controller controls a machine tool that performs a turning on a workpiece on the basis of a cycle instruction indicated by an NC program. The machine tool includes first and second cutter holders that are mutually coupled by a coupling member, and first and second tools are mounted on the cutter holders in mutually opposing fashion. The machine tool performs a turning according to a complex fixed cycle, in a reciprocal fashion rather than unidirectionally, using the first and second tools, and when the turning by the first tool has been completed and the first tool that has performed a turning is withdrawn, it is possible to perform a turning in the opposite direction by the second tool on the opposite side.