Oscillation Cutting Waveform Display for Swarf Shredding Assessment
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Solution Overview
Problem
Operators face difficulty in determining whether swarf shredding is possible during oscillation cutting in machine tools, as existing display methods do not effectively visualize the change in command and actual position data of feed axes, affecting production efficiency and workpiece quality.
Innovation Solution
A display device that acquires position and rotation information, generates waveform data representing changes over time or rotation, and displays this data to help operators visually assess the feasibility of swarf shredding by oscillating the tool and workpiece relative to each other.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If operators use conventional waveform display devices to monitor command and actual position data during oscillation cutting, then they can observe the time change of data, but they cannot easily determine whether swarf shredding is possible
Solution Approach 1:
The patent transforms the conventional time-based waveform display into a spatial representation by plotting command position and actual position on the vertical axis against oscillation cycle on the horizontal axis. This dimensional transformation allows operators to visually assess swarf shredding feasibility through the overlap pattern of waveforms, converting temporal data into a spatial pattern that directly indicates cutting effectiveness.
Solution Approach 2:
The patent uses different display colors or patterns to represent command position and actual position waveforms, making it easier to distinguish between the two data sets. This visual differentiation helps operators quickly identify overlap regions where swarf shredding occurs, enhancing the visibility of critical information without increasing device complexity.
2Productivity
If operators manually adjust machining conditions and parameters in the numerical control device to determine oscillation frequency and amplitude, then they can control the cutting process, but they cannot efficiently assess whether swarf shredding will occur
Solution Approach 1:
The patent implements a feedback mechanism by displaying both command position and actual position data simultaneously in a comparative waveform format. This allows operators to immediately assess whether the oscillation parameters are achieving the desired swarf shredding effect, enabling rapid adjustment of machining conditions without time-consuming trial and error, thus improving production efficiency.
Solution Approach 2:
The patent enables operators to predict swarf shredding effectiveness before actual cutting by analyzing the waveform overlap pattern. The display shows whether the oscillation parameters will achieve proper swarf breakdown, allowing preliminary assessment and adjustment of parameters before committing to full production runs, thereby improving overall productivity.
3Productivity
If swarf is continuously generated during machining, then material is removed from the workpiece, but the swarf becomes entangled with the cutting tool requiring stops for removal
Solution Approach 1:
The patent monitors and optimizes periodic oscillation cutting parameters to ensure swarf is continuously shredded and evacuated. By displaying waveform overlap patterns, it helps operators maintain oscillation frequency and amplitude that prevent swarf entanglement, enabling continuous material removal without stopping for swarf clearance, thus improving productivity and reducing time loss.
4Productivity
If oscillation cutting is implemented to shred swarf, then production efficiency can be improved, but it requires precise control of feed axis position and spindle rotation
Solution Approach 1:
The patent displays both command position (what the system should do) and actual position (what the system actually does) waveforms simultaneously. This feedback mechanism allows operators to verify that the feed axis and spindle are maintaining the precise coordination required for oscillation cutting, ensuring reliable swarf shredding while enabling quick correction of any control deviations that might affect productivity.
Data Source
AI summary
A display device includes a position information acquisition part, a rotation information acquisition part, a first waveform generation part, a second waveform generation part, and a waveform display part, which displays plural second waveform data. The position information acquisition part acquires position information of a feed axis. The rotation information acquisition part acquires the rotation speed of a workpiece as rotation information of a spindle. The first waveform generation part generates first waveform data representing a change of the position information over time from time series position information of the feed axis. The second waveform generation part generates plural second waveform data by obtaining a time per rotation from the rotation speed, dividing the first waveform data into partial waveform data for time per rotation, and sequentially shifting each partial waveform data in the time axis direction so as to match a start point of the first waveform data.