Numerical Controller Work Error Correction for Five-Axis Machining
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Solution Overview
Problem
Existing numerical controllers for five-axis machine tools cannot accurately account for errors caused by changes in the workpiece, such as shape changes or different work types, leading to inaccuracies in tool center point positioning during machining.
Innovation Solution
A numerical controller that sets correction amounts at measurable lattice points within a work lattice region, calculates a translation correction amount for the tool center point, and adds it to the commanded linear axis position, enabling precise positioning of the tool center point by considering both machine-caused and work-caused errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If correction amounts are set only for machine-caused errors at lattice points, then machine positioning accuracy is improved, but work-caused errors (shape changes, different work types) cannot be corrected
Solution Approach 1:
The correction amount setting unit is designed to handle multiple types of errors (machine-caused and work-caused) through a unified correction framework. The system stores and applies correction amounts for both machine positioning errors and workpiece-induced errors, making the correction mechanism universally applicable to various error sources without requiring separate correction systems.
Solution Approach 2:
Correction amounts for work-caused errors are measured and stored in advance at lattice points before actual machining operations. By pre-measuring and storing correction data for different work types and shapes, the system is prepared to automatically apply appropriate corrections when machining begins, eliminating the need for real-time error calculation during machining.
2Manufacturing precision
If correction amounts are measured and stored at multiple lattice points covering the work region, then work-caused error correction capability is improved, but system complexity and measurement time increase
Solution Approach 1:
The work region is divided into a lattice structure with discrete lattice points, allowing correction amounts to be measured and stored at specific locations rather than continuously across the entire workspace. This segmentation approach simplifies the measurement and storage process while maintaining comprehensive coverage of the work region.
Solution Approach 2:
Correction amounts are specifically measured and stored at lattice points within the work neighboring region, focusing measurement efforts only where corrections are actually needed. This local approach avoids unnecessary measurements in areas outside the work region, reducing overall system complexity while maintaining high machining precision within the relevant workspace.
3Measurement precision
If correction amounts are calculated and applied for tool center point positioning, then positioning accuracy is improved, but calculation and processing time increase
Solution Approach 1:
Correction amounts are calculated and stored in advance at lattice points before machining operations begin. By pre-calculating correction values based on measured errors at lattice points, the system eliminates the need for real-time calculation during machining, reducing processing time while maintaining high positioning accuracy.
Data Source
AI summary
A numerical controller uses a work lattice region setting unit and a rotation axis work lattice region setting unit to form lattice points for error correction and uses a work-caused translation correction amount setting unit to set a correction amount of a work-caused translation error. A work-caused translation correction amount calculation unit calculates a correction amount at a tool center point position, and a correction section of the numerical controller adds the work-caused translation correction amount to positions of three commanded linear axes for error correction.