Numerical Controller Signal Synchronization for Machine Tool Pitch Error Correction
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Solution Overview
Problem
Current high-precision machining systems require complex and costly signal branching devices to synchronize measurement signals from on-machine measuring devices with position detection signals from machine tool axes, leading to increased costs and processing time, and are prone to pitch errors due to mounting errors.
Innovation Solution
A machine tool with a numerical controller that receives and synchronizes axial position detection signals and measurement signals through integrated interfaces, eliminating the need for independent signal branching devices, and includes storage and transfer means to transmit data to an external device, allowing for real-time shape analysis and corrective machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If signal branching devices are used to synchronize measurement signals with position detection signals, then signal synchronization is achieved, but device complexity and cost increase significantly
Solution Approach 1:
The patent merges the functions of signal reception and synchronization into a single interface unit integrated within the numerical controller. Instead of using separate signal branching devices for different axes, the interface unit consolidates all position detection signals and measurement signals into one centralized processing point, eliminating the need for multiple branching devices and reducing overall system complexity while maintaining synchronization reliability
Solution Approach 2:
The interface unit serves multiple functions simultaneously: it receives position detection signals from all moving axes, receives measurement signals from the on-machine measuring device, performs synchronization processing, and outputs corrected position information. This multi-functional design replaces what would traditionally require multiple dedicated signal branching devices, one for each axis, thereby reducing device complexity while maintaining comprehensive signal synchronization
2Reliability
If independent signal branching devices are mounted for each moving axis, then complete signal coverage is achieved, but the number of cables and wire arrangement becomes complicated
Solution Approach 1:
The interface unit consolidates signal reception for all moving axes into a single location within the numerical controller. Instead of having separate signal branching devices distributed across different axes requiring extensive cable routing, all position detection signals from X, Y, Z, B, and C axes are routed to this single interface unit, dramatically simplifying the wire arrangement while ensuring complete signal coverage through centralized processing
3Reliability
If signal branching devices are used, then all position detection signals can be accessed, but dedicated position detector substrates and power sources are required
Solution Approach 1:
The interface unit consolidates the power supply function for all signal processing operations into a single integrated power source within the numerical controller. Instead of requiring separate power sources for each signal branching device, the interface unit receives power through a single supply line and distributes it internally to all processing functions, thereby maintaining complete signal access capability while eliminating the need for multiple external power sources and associated complexity
4Measurement precision
If branched signals with uncorrected pitch errors are used, then raw measurement data is obtained, but separate pitch error correction processing is required
Solution Approach 1:
The interface unit performs pitch error correction as a preliminary action during the signal reception and synchronization process itself, before the data is output to the external device. Instead of obtaining raw uncorrected signals and requiring separate correction processing later, the interface unit proactively corrects pitch errors inherent in position detection signals by utilizing stored correction values, thereby delivering already-corrected position information and eliminating subsequent error correction processing steps
Data Source
AI summary
A machine tool is fitted with a position detector for detecting a position of a moving axis of the machine tool and an on-machine measuring device for measurement on the machine tool. An axial position detection signal output from the position detector and a measurement signal output from the on-machine measuring device are received through interfaces by a numerical controller that controls the machine tool. These interfaces are designed so that the numerical controller receives the axial position detection signal and the measurement signal with the same timing.