Numerical Controller Torque Maximization via Table Rotation
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Solution Overview
Problem
Conventional numerical controllers for machine tools are limited by the maximum torque specified for each axis, preventing the tool from achieving higher torque during cutting feeds, which restricts the depth of cut and cutting feedrate.
Innovation Solution
A numerical controller and movement control method that analyze programs to calculate and utilize synthetic torque by rotating the table to align the cutting feed direction with the synthetic feeding direction, allowing the tool to move with a torque higher than the upper limit movement torque of each axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the tool is moved by a higher torque to increase depth of cut and cutting feedrate, then productivity is improved, but the torque is limited to the maximum torque specified for each axis
Solution Approach 1:
The patent introduces a rotational dimension by tilting the table in addition to the conventional two-axis (X and Y) movement. This third dimension allows the tool to move along a synthetic feeding direction that combines X and Y axis movements, enabling the torque to be distributed across multiple axes simultaneously. The table tilt angle is calculated to maximize the synthetic torque, effectively utilizing the torque capacity of both X and Y axes together rather than being limited to the maximum torque of a single axis.
2Force
If the table is rotated to align with synthetic feeding direction, then torque utilization is optimized, but the control system complexity increases
Solution Approach 1:
The control system performs preliminary calculations to determine the optimal table tilt angle before executing the cutting operation. By pre-calculating the synthetic feeding direction and the required table rotation angle based on the start and end positions of the tool, the system prepares the optimal configuration in advance. This preliminary action simplifies the real-time control by reducing it to executing pre-determined rotation and movement commands rather than continuously calculating optimal angles during operation.
Data Source
AI summary
A numerical controller includes: a program analyzing unit to obtain an end point position of a tool; a first angle calculating unit to calculate an inclination angle of a synthetic feeding direction that maximizes a synthetic torque, based on an upper limit movement torque of the tool in each of the two axis directions; a second angle calculating unit to calculate an inclination angle of a cutting feed direction of the tool based on a start point position and the end point position of the tool; a rotation angle calculating unit to calculate a difference between the inclination angle of the synthetic feeding direction and the inclination angle of the cutting feed direction as a rotation angle of a table; and a servo motor control unit to control rotation of the table based on the rotation angle.