Numerical Controller Virtual Axis for Non-Circular Cutting
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Solution Overview
Problem
Conventional cutting methods for non-circular workpieces, such as cam surfaces, require complex tool motion control and often result in poor surface quality, increased tool consumption, and labor-intensive tool re-dressing due to the inability to efficiently manage infeed and retract motions along multiple axes during C-X profile cutting.
Innovation Solution
A program writing method for numerical controllers that introduces a virtual axis to control multiple axes simultaneously, allowing for continuous and even infeed of the cutting tool along one axis, separate the tool from the workpiece, and adjust infeed speed to improve surface accuracy and reduce tool consumption by using user set programs to manage control amounts and infeed speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cutting methods are used for non-circular workpieces, then cutting operations can be performed, but surface quality deteriorates and tool consumption increases due to inability to efficiently manage infeed and retract motions
Solution Approach 1:
The patent segments the control of cutting tool motion into multiple independent user-set programs (PU1, PU2, PU3), each responsible for specific functions such as C-X profile motion, infeed motion, and retract motion. This segmentation allows precise control of each motion component separately, enabling continuous and even infeed while managing retract operations independently, thereby improving surface quality and reducing tool consumption.
Solution Approach 2:
The patent implements dynamic control of infeed and retract motions by allowing user-set programs to calculate control amounts in real-time based on workpiece geometry and cutting conditions. The numerical controller dynamically adjusts the cutting tool's position and motion speed during C-X profile cutting, maintaining optimal cutting parameters throughout the operation to improve surface quality and extend tool life.
2Adaptability or versatility
If multiple user-set programs control the same axis, then flexible control is achieved, but axis identification becomes ambiguous and control conflicts occur
Solution Approach 1:
The patent introduces a virtual axis (Y-axis) as an intermediary to resolve conflicts when multiple user-set programs need to control the same physical axis (X-axis). Each program can independently identify and control the virtual axis without interfering with others, while the numerical controller integrates all virtual axis control amounts into the corresponding physical axis driving program, eliminating identification conflicts while maintaining flexibility.
Solution Approach 2:
The patent adds a virtual dimension (Y-axis) to the control space to accommodate multiple independent control programs. By mapping multiple programs' control requirements to the virtual axis rather than having them directly control the same physical axis, the system resolves conflicts in the control domain while maintaining the ability to flexibly program complex multi-axis motions.
3Productivity
If infeed motion is performed during C-X profile cutting, then material removal efficiency improves, but surface accuracy deteriorates due to tool contact and load on the workpiece
Solution Approach 1:
The patent implements periodic alternation between infeed motion and retract motion during C-X profile cutting. User-set programs control the cutting tool to perform infeed motions to remove material efficiently, then retract motions to separate from the workpiece and reduce load. This periodic cycle of approaching and retracting allows continuous material removal while maintaining surface accuracy by minimizing sustained tool contact and workpiece deformation.
Solution Approach 2:
The patent performs preliminary positioning and speed adjustment before each infeed operation. User-set programs calculate and set the cutting tool's position and infeed speed in advance based on the workpiece geometry and desired surface quality, ensuring optimal cutting conditions are established before material removal begins, thereby maintaining both productivity and surface accuracy.
Data Source
AI summary
It is one object of the present invention to provide a program writing method of numerical controller, a numerical controller and a cutting machine controlled thereby, achieving the writing of a plurality of programs relating to one axis to perform a high efficiency in a lot of productions. A next or later user-set-program controlling a duplicated axis controlled by plural user set programs identifies a virtual axis virtually controlled by one user set program. A program is written to replace the duplicated axis with the virtual axis. A control amount calculated by the user set program identifying the virtual axis is added to a control amount inputted to a correspondent axis driving program as a control amount of the duplicated axis before replacing the virtual axis.