Numerical Controller Tool Direction Display for Five-Axis Machines
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Solution Overview
Problem
Existing numerical controllers for five-axis machines cannot intuitively display or calculate tool directions relative to a workpiece using rotation axis positions alone, especially in machines with inclined rotation axes, making it difficult to predict the behavior of the workpiece during rotation.
Innovation Solution
A numerical controller that calculates and displays tool directions using vector, roll-pitch-yaw angles, or Euler angles based on rotation axis positions, allowing for intuitive representation and manual movement commands, thereby facilitating better control of five-axis machines with table or tool head rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If rotation axis positions are used to represent tool direction, then the control system remains simple, but the tool direction cannot be intuitively understood relative to the workpiece
Solution Approach 1:
The patent introduces an intermediary coordinate transformation system that converts rotation axis positions into workpiece-relative tool direction representations (vectors, roll-pitch-yaw angles, or Euler angles). This intermediary layer maintains the simplicity of the control system while providing intuitive tool direction information relative to the workpiece coordinate system.
Solution Approach 2:
The patent transforms the representation parameters of tool direction from raw rotation axis positions to multiple alternative parameter sets including vectors, roll-pitch-yaw angles, and Euler angles. This parameter transformation enables intuitive understanding of tool direction relative to the workpiece without complicating the underlying control system.
2Measurement precision
If machine configuration calculation is performed to obtain tool direction, then accurate tool direction is obtained, but the calculation becomes complex especially with inclined rotation axes
Solution Approach 1:
The patent segments the tool direction representation into multiple independent coordinate systems (machine coordinate system and workpiece coordinate system). By separating these coordinate systems and providing transformation relationships, the patent enables accurate tool direction calculation while simplifying the overall computation through modular coordinate handling.
Solution Approach 2:
The patent creates a universal coordinate transformation framework that handles various machine configurations (including inclined rotation axes) through a unified mathematical approach. This multi-functional transformation system accommodates different machine types and configurations without requiring separate calculation methods for each case.
3Ease of operation
If manual rotation axis commands are issued, then the rotation axes can be controlled, but the workpiece behavior cannot be easily predicted
Solution Approach 1:
The patent implements a feedback mechanism that provides real-time information about workpiece behavior relative to the tool direction. By displaying tool direction in workpiece-relative coordinates (vectors, roll-pitch-yaw angles, or Euler angles), the system gives operators immediate feedback on how the workpiece will behave during manual rotation axis commands, enabling better prediction and control.
Data Source
AI summary
A numerical controller controls a five-axis machine which machines a workpiece mounted on a table by means of at least three linear axes and two rotation axes. The numerical controller calculates a tool direction relative to the workpiece as a tool direction vector, roll-pitch-yaw angles, or Euler angles, based on respective positions of the two rotation axes, and displays the tool direction relative to the workpiece on a display, based on the result of the calculation.