Numerical Controller Machining Time and Error Prediction
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Solution Overview
Problem
Existing numerical controllers cannot accurately predict machining time and machining error simultaneously by simulation, failing to meet user demands for minimizing machining time while maintaining precision within a preset error tolerance without trial machining.
Innovation Solution
A numerical controller equipped with a machining time prediction unit and a machining error prediction unit that determines predicted machining times and errors through simulation, using designated precision and speed data to calculate the shortest predicted machining time within a preset error tolerance by evaluating distances between command and servo position sequences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If machining speed is increased to reduce machining time, then productivity is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent applies preliminary action by performing simulation calculations before actual machining to predict both machining time and machining errors. The numerical controller calculates predicted machining time and predicted machining errors based on the machining program and machine tool characteristics, allowing users to determine optimal machining parameters in advance without trial machining, thus resolving the contradiction between speed and precision.
2Manufacturing precision
If trial machining is performed to ascertain appropriate machining parameters, then manufacturing precision is ensured, but loss of time increases
Solution Approach 1:
The patent applies copying by creating a virtual model of the machining process through simulation. The numerical controller calculates predicted machining time and predicted machining errors based on the machining program and machine tool characteristics, providing a copy of the actual machining results before physical machining occurs. This eliminates the need for trial machining while ensuring precision requirements are met.
3Productivity
If existing numerical controllers predict machining time, then productivity is improved, but measurement precision of machining errors deteriorates (cannot predict errors)
Solution Approach 1:
The patent applies merging by combining machining time prediction and machining error prediction into a single integrated simulation system. The numerical controller simultaneously calculates both predicted machining time and predicted machining errors based on the machining program and machine tool characteristics, providing comprehensive prediction information that addresses both productivity and precision measurement needs.
Data Source
AI summary
In connection with a machining program used in machining a workpiece by means of a machine tool controlled by a numerical controller, interpolation data, a command position point sequence, and a servo position point sequence for each processing period are determined by simulation by designating speed data for giving a machining speed and precision data for giving a machining precision. A predicted machining time for workpiece machining is determined based on the determined interpolation data, and a predicted machining error for workpiece machining is determined based on the determined command and servo position point sequences. Further, the precision data and the speed data are determined for the shortest predicted machining time within a preset machining error tolerance, based on a plurality of predicted machining times and a plurality of predicted machining errors.