Numerical Controller Workpiece Setting Error Compensation
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Solution Overview
Problem
Conventional numerical controllers for multi-axis machine tools with three rotating axes struggle to compensate workpiece setting errors effectively, leading to large motions near singular points and machining errors, as existing techniques are not applicable due to the complexity of calculating multiple solutions for these configurations.
Innovation Solution
A numerical controller with a workpiece setting error compensation unit that calculates compensated tool positions and directions, and linear and rotating axis positions, using multiple solutions to avoid large motions near singular points by selecting appropriate axis movements based on evaluation values, ensuring accurate machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional workpiece setting error compensation techniques are applied to multi-axis machine tools with three rotating axes, then workpiece setting errors can be compensated, but large motions occur near singular points causing machining errors and degraded surface quality
Solution Approach 1:
The patent implements dynamic solution selection that adapts to the current machining state. The control unit calculates multiple possible solutions for rotating axis positions and dynamically selects the most appropriate solution based on real-time evaluation of motion amounts and proximity to singular points, rather than using a fixed compensation method
Solution Approach 2:
The patent changes the selection criteria parameters by introducing evaluation values that consider both the motion amounts of rotating axes and the proximity to singular points. This parameter-based evaluation system allows the system to adjust its behavior based on calculated values rather than following a predetermined path
2Ease of operation
If rotating axes are commanded to move over singular points to reach opposite sides, then positioning can be achieved, but machining time increases and surface quality degrades
Solution Approach 1:
The control unit performs preliminary calculation of multiple possible solutions for rotating axis positions before executing the motion. By evaluating all possible paths in advance and selecting the optimal one, the system avoids unnecessary large motions and reduces machining time
Solution Approach 2:
The patent enables the system to skip unnecessary intermediate positions near singular points by directly selecting solutions that achieve the target position more efficiently. This allows the rotating axes to reach the desired position without performing redundant motions that would increase machining time
3Adaptability or versatility
If multiple solutions exist for rotating axis positions, then flexibility in path selection is available, but determining the appropriate solution becomes complex
Solution Approach 1:
The control unit uses feedback mechanisms by calculating evaluation values based on the current state and selected solution, then adjusting subsequent solution selection based on this feedback. The system continuously monitors motion amounts and singular point proximity to make informed decisions about which solution to implement
Solution Approach 2:
The system performs self-evaluation of multiple solutions by automatically calculating motion amounts and proximity to singular points for each candidate solution. This self-service capability allows the control unit to independently determine the optimal solution without external intervention
Data Source
AI summary
A numerical controller for controlling a multi-axis machine tool for machining with three linear axes and three rotating axes has a function for compensating a setting error that arises when a workpiece is set. This numerical controller determines compensated linear axis positions of the three linear axes and compensated rotating axis positions of the three rotating axes by calculating compensated tool position and direction depending on the setting error such that the tool position and direction on the workpiece setting coordinate system are maintained on the workpiece having such a setting error, and drives and controls the axes according to the compensated linear axis positions and compensated rotating axis positions.