Numerical Controller Stroke Limit Test Mode
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Solution Overview
Problem
Operators face increased effort and time in verifying machining programs due to the risk of interference between machine tools and workpieces, especially when approaching movement prohibition boundaries, leading to a high burden and prolonged verification processes.
Innovation Solution
A numerical controller with a test mode that sets a neighboring distance from the movement prohibition boundary, temporarily stops axis movement, calculates a movable distance less than the boundary, and restricts movement within that range to prevent exceeding the prohibition boundary, thereby reducing operator burden and verification time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the operator manually verifies the machining program by gradually moving the tool near the movement prohibition boundary, then the safety of the operation is improved, but the verification time and operator burden increase significantly
Solution Approach 1:
The numerical controller automatically performs verification of the machining program by executing test operations with automatically adjusted movement amounts, eliminating the need for manual operation. The system self-verifies by detecting proximity to movement prohibition boundaries and autonomously reducing movement amounts to prevent interference, thereby reducing both verification time and operator burden while maintaining safety
Solution Approach 2:
The system continuously monitors the tool position relative to the movement prohibition boundary and provides feedback by automatically adjusting the movement amount in test operations. When the tool approaches the boundary, the controller reduces the movement amount to maintain a safe distance, creating a closed-loop control system that ensures safety without requiring manual intervention
2Reliability
If the operator reduces the override of movement speed to gradually move the tool, then the risk of interference is reduced, but the verification process becomes time-consuming and complex
Solution Approach 1:
The numerical controller automatically adjusts the movement amount in test operations based on the detected distance to the movement prohibition boundary, eliminating the need for the operator to manually reduce override or carefully control movement speed. The system autonomously manages the movement parameters to prevent interference while simplifying the verification process
Solution Approach 2:
The system dynamically changes the movement amount parameter in test operations based on the tool's proximity to the movement prohibition boundary. When approaching the boundary, the controller automatically reduces the movement amount to a safer value, thereby preventing interference without requiring complex manual speed adjustments
3Productivity
If automatic test operation is performed without stroke restriction, then the verification speed is improved, but the risk of interference near the stroke limit increases
Solution Approach 1:
The system dynamically adjusts the movement amount in test operations based on the real-time distance to the movement prohibition boundary. Instead of using a fixed movement amount, the controller modifies the movement parameter adaptively - using larger movements when safe and reducing movements when approaching the boundary - thereby maintaining both verification speed and safety
Solution Approach 2:
The numerical controller changes the movement amount parameter in test operations according to the detected position relative to the movement prohibition boundary. By automatically reducing the movement amount when the tool approaches the boundary, the system prevents interference while maintaining efficient verification speed in safer regions
Data Source
AI summary
A numerical controller has a test mode of a machining program, sets, for each axis, a neighboring distance from a movement prohibition boundary of a tool or a workpiece, and temporarily stops an axis movement at a boundary of a near region thereof. A movable distance in a direction approaching the movement prohibition boundary is obtained for each axis such that the movable distance is less than a distance to the movement prohibition boundary. Further, if an axis exceeding the movable distance is present, an axis movement is stopped by restricting a movement distance within a range not exceeding the movable distance.