Numerical Controller Tool Path Smoothing
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Solution Overview
Problem
In table format data-based operations for machine tools, abrupt changes in velocity can lead to shocks and irregularities on the finished surface, requiring users to manually correct path table data to achieve a smooth surface, which is inefficient and time-consuming.
Innovation Solution
A numerical controller with a smoothing function that automatically corrects tool paths by detecting velocity changing points, designating a correction range, calculating boundary positions, and connecting them with smooth curved paths using multidimensional functions, thereby maintaining synchronization with reference values and preventing shocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If table format data is used for machine tool operation, then machining accuracy and synchronization are improved, but velocity changes abruptly causing shocks and surface irregularities
Solution Approach 1:
The patent applies curvature by replacing abrupt linear velocity changes with smooth curved transitions. Specifically, it uses quadratic functions to generate smoothed velocity profiles that connect discrete command positions, eliminating sharp corners and abrupt changes in the tool path that cause shocks and surface irregularities while maintaining the overall machining accuracy.
Solution Approach 2:
The patent changes the velocity parameter by introducing a smoothing function that modifies the velocity profile between command positions. The system calculates smoothed command positions using quadratic interpolation, which transforms the velocity characteristics from abrupt step changes to continuous smooth transitions, thereby eliminating shocks while preserving positioning accuracy.
2Manufacturing precision
If users manually correct path table data to achieve smooth surfaces, then surface quality is improved, but time consumption and operational complexity increase
Solution Approach 1:
The patent implements self-service by enabling the numerical controller to automatically smooth the tool path without requiring user intervention. The smoothing function is built into the controller, which automatically calculates smoothed command positions using quadratic interpolation of the path table data, eliminating the need for users to manually correct data while ensuring consistent surface quality.
Solution Approach 2:
The patent applies preliminary action by pre-calculating and storing smoothed command positions in the path table before execution. The quadratic smoothing function is applied in advance to generate optimized velocity profiles, so that when the machine tool executes the program, the smooth tool path is already prepared, eliminating the need for real-time manual adjustments and reducing operational time.
3Productivity
If velocity is increased to reduce machining time, then productivity is improved, but shocks and vibrations increase causing surface irregularities
Solution Approach 1:
The patent uses curved transition paths instead of straight linear movements to enable higher velocities without causing shocks. By applying quadratic interpolation to generate smooth velocity profiles, the system allows the machine tool to maintain high speed while following curved paths that eliminate abrupt directional changes, thereby preventing vibrations and surface irregularities even at increased machining speeds.
Solution Approach 2:
The patent applies dynamics by making the velocity profile adaptive and continuous rather than static and discrete. The quadratic smoothing function dynamically adjusts the velocity at each command position based on the geometry of the tool path, allowing the system to optimize speed while maintaining smooth transitions that prevent shocks and vibrations, thus improving productivity without sacrificing surface quality.
Data Source
AI summary
Positions to be synchronized with a reference value are stored as command data in table format. Velocity changing points of a tool path designated by the table format data are calculated. Two intersection points between the tool path and a circle or a sphere having a designated radius and centered on the velocity changing point are connected by a smooth curved tool path according to a multidimensional function or the like. In this way, the table format data is corrected.