5-Axis Numerical Controller for Singular Point Rotary Axis Switching
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Solution Overview
Problem
In 5-axis machine tools, the sudden change in the angle of the rotary axis near a singular point can lead to deteriorated workpiece surface quality, and existing technologies either fail to address this issue or are limited to specific machine configurations.
Innovation Solution
A numerical controller that calculates singular point distances for each rotary axis and extracts a control rotary axis based on these distances, using a pulse generation unit to drive the control rotary axis and prevent sudden angle changes near singular points, while being compatible with any machine configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional tool posture control is used in 5-axis machine tools, then machining commands can be executed, but the rotary axis angle changes extremely greatly near singular points causing sudden rotation and acceleration increases that deteriorate workpiece surface quality
Solution Approach 1:
The numerical controller performs preliminary detection of singular points based on the machining program before actual machining begins. It calculates the tool center line trajectory and identifies singular point positions in advance, then prepares appropriate handling strategies (such as axis substitution or trajectory adjustment) to prevent sudden rotary axis changes during machining, thereby maintaining surface quality while avoiding excessive rotation speeds and accelerations near singular points
Solution Approach 2:
The system dynamically adjusts the control strategy based on the machine tool's specific configuration and the current machining state. It selectively applies different singular point handling methods depending on which rotary axis is approaching a singular point, the type of machining operation, and the tool orientation requirements, allowing flexible adaptation to maintain precision without being constrained by a single control approach
2Measurement precision
If existing error compensation techniques are applied, then tool posture accuracy can be improved, but they are limited to specific machine configurations and cannot compensate errors around specific rotary axes universally
Solution Approach 1:
The numerical controller implements a universal error compensation method that works across different 5-axis machine tool configurations (whether rotary axes are on the tool side or workpiece side). The system detects singular points and applies compensation strategies that are adaptable to various machine architectures, enabling tool posture accuracy improvement without being restricted to a specific machine type, thus achieving both precision and versatility
Solution Approach 2:
The system changes control parameters dynamically based on the detected machine configuration and machining conditions. It adjusts the singular point detection thresholds, axis substitution strategies, and compensation amounts according to the specific machine tool setup, allowing the same compensation methodology to be effectively applied across different configurations while maintaining high tool posture accuracy
Data Source
AI summary
Provided is a numerical controller that can suppress a sudden change in the angle of a rotary axis in the vicinity of a singular point and can also be compatible with any machine configuration. A numerical controller for numerically controlling a designated direction of an axis of a movement axis member by two or more rotary axes. The numerical controller comprises a singular point distance calculation unit for calculating each singular point distance from a rotary axis direction of each of the two or more rotary axes and the designated direction based on an operation command, a rotary axis extraction unit for extracting a control rotary axis for controlling the designated direction based on the singular point distance calculated by the singular point distance calculation unit, and a pulse generation unit for generating a pulse for driving the control rotary axis based on the control rotary axis extracted by the rotary axis extraction unit. The rotary axis extraction unit compares the singular point distances with a preset threshold to extract, as the control rotary axis, the rotary axis exceeding the threshold, or comparing the singular point distances with each other to extract the rotary axis having a larger singular point distance as the control rotary axis.