Numerical Controller Swarf Discharge Timing
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Solution Overview
Problem
Existing numerical controllers for machine tools face challenges in accurately predicting swarf accumulation, leading to inefficient cutting fluid usage and potential machining defects due to improper timing of swarf discharge, as they rely on inaccurate predictions and fixed pressure and area settings.
Innovation Solution
A numerical controller that performs three-dimensional machining simulations to accurately calculate swarf accumulation based on machining program blocks, allowing for precise timing of swarf discharge and enabling operators to adjust discharge methods and pressures through automated insertion of M codes into the machining program.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cutting fluid is jetted continuously from the beginning to the end of the machining program, then the swarf is washed away effectively, but the cutting fluid and electric power are wasted
Solution Approach 1:
The system performs preliminary calculation of the swarf accumulation amount before actual machining based on the machining program. This allows the cutting fluid jetting to be activated only when swarf accumulation exceeds a threshold, rather than running continuously. The preliminary calculation uses machining parameters (depth, width, length, speed) to predict swarf volume in advance.
Solution Approach 2:
The system calculates the swarf accumulation amount during machining based on actual machining progress and compares it with a threshold value. This feedback mechanism dynamically controls the cutting fluid jetting operation, activating it only when necessary (when accumulation exceeds threshold) and stopping it when the threshold is not exceeded, thereby optimizing resource usage while maintaining effective swarf discharge.
2Reliability
If the cutting fluid is jetted early when predicted cutting volume exceeds threshold, then swarf is discharged timely, but cutting fluid is wasted in cases where actual swarf production is low
Solution Approach 1:
The system dynamically adjusts the swarf discharge control strategy by considering both calculated swarf accumulation and actual machining conditions. Rather than using a fixed threshold-based approach, the system continuously monitors actual swarf accumulation during machining and compares it with predicted values, allowing adaptive control of the cutting fluid jetting operation to match actual swarf production rates.
Solution Approach 2:
The system changes the control parameter from a simple predicted volume threshold to a dynamic comparison between calculated and actual swarf accumulation. By introducing the actual swarf accumulation measurement and comparing it with predictions, the system adjusts the jetting activation decision based on real-world conditions, reducing false positives where jetting would be activated unnecessarily.
3Ease of operation
If the pressure and area of cutting fluid jetting are fixed, then the system is simple to operate, but it cannot handle varying swarf accumulation statuses effectively
Solution Approach 1:
The system performs preliminary setup where the operator can designate multiple jetting areas in advance through graphical input on the display device. These predetermined areas are stored and automatically selected based on actual machining progress and swarf accumulation patterns during operation, combining simple operator input with adaptive system behavior.
Solution Approach 2:
The system dynamically switches between different predetermined jetting areas during machining based on the current machining status and calculated swarf accumulation. Rather than using a fixed jetting area, the system automatically selects from multiple pre-configured areas to match the actual swarf accumulation pattern, maintaining simplicity while achieving adaptability.
Data Source
AI summary
Provided is a numerical controller that is capable of determining a proper timing of swarf discharge and allows an operator to change a swarf discharge method and examine appropriateness of the timing of the swarf discharge on an as needed basis, the numerical controller including a simulation unit that executes a simulation in which a workpiece is machined based on a machining program, a rendered workpiece volume calculation unit that calculates the volume of a rendered workpiece representing the shape of the workpiece rendered by the simulation, and a swarf accumulation amount prediction unit that predicts, based on the volume of the initial rendered workpiece when execution of the simulation is started and the volume of the rendered workpiece when execution of each block included in the machining program is completed, a swarf accumulation amount when the execution of the block is completed.