Numerical Controller for Safe Tool Reverse Movement
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Solution Overview
Problem
Conventional machine tools require manual operator intervention to ensure the tool does not contact the workpiece during reversing, increasing operation time and potentially lowering productivity.
Innovation Solution
A numerical controller that extracts non-machining sections from a tool path using sensor information, sets an end position for reverse movement, and controls the tool to automatically avoid contact with the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the operator manually checks the machining program to identify non-contact sections during reversing, then the tool can be safely returned to a safe position, but the operation time increases and productivity decreases
Solution Approach 1:
The system automatically identifies non-machining sections and determines safe end positions for reverse movement without requiring operator intervention. The numerical controller autonomously processes the machining program, detects non-machining sections, and calculates appropriate end positions, allowing the system to serve itself rather than relying on manual operator checks.
Solution Approach 2:
The manual visual inspection and manual positioning process is replaced by an automated computational system. The numerical controller uses program analysis and sensor information to automatically determine safe reverse movement end positions, substituting the mechanical/visual checking process with an automated information processing system.
2Reliability
If the operator visually checks tool movement to ensure no contact during reversing, then the tool can be safely positioned, but the operation time increases
Solution Approach 1:
The system performs preliminary analysis of the machining program before reverse movement begins, identifying all non-machining sections and determining safe end positions in advance. This preliminary action eliminates the need for time-consuming visual checks during the actual reversing operation, as the safe position has already been calculated and verified.
Solution Approach 2:
The system uses sensor information as feedback to verify and refine the identification of non-machining sections. By incorporating real-time sensor data, the system can confirm the tool's position and status during reverse movement, providing automated feedback that replaces manual visual monitoring.
3Device complexity
If the reversing function is used without automated non-machining section detection, then the system remains simple, but the operator workload and time consumption increase
Solution Approach 1:
The numerical controller is enhanced to perform multiple functions: it not only controls the basic reversing operation but also automatically analyzes the machining program, detects non-machining sections using sensor information, and determines safe end positions. This multi-functionality allows the system to handle both the control and the safety analysis tasks without requiring separate dedicated devices.
Data Source
AI summary
A numerical controller includes an extraction unit configured to extract at least one non-machining section from a tool path based on sensor information indicating a physical quantity detected by a sensor, a tool moving along the tool path, and the tool and a workpiece not coming into contact with each other in the non-machining section, a setting unit configured to set an end position of reverse movement in one non-machining section among the at least one non-machining section extracted by the extraction unit, the tool reversing along the tool path in the reverse movement, and a control unit configured to control the reverse movement.