Polygon Machining Phase Control for Faster Axis Alignment
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Solution Overview
Problem
Existing polygon machining technologies require a significant amount of time for phase alignment between the workpiece axis and the tool axis, especially when a large phase difference needs to be corrected, which can lead to inefficiencies in machining processes.
Innovation Solution
A controller system that includes a machining setting storage unit, current phase calculation unit, machining-allowing phase calculation unit, optimum phase calculation unit, and phase alignment control unit, which calculates and adjusts the phases of the workpiece and tool axes to minimize the time required for phase alignment by determining an optimal phase command value.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If phase alignment is performed by stopping the tool at a predetermined position, then phase alignment between workpiece axis and tool axis is achieved, but machining time is increased due to temporary stopping
Solution Approach 1:
The system calculates the optimal phase command value in advance based on the current phase difference, number of cutting tools, and machining program requirements. This preliminary calculation allows the system to plan the phase adjustment trajectory before execution, enabling continuous operation without stopping while achieving accurate phase alignment.
Solution Approach 2:
The system dynamically adjusts the phase command value during machining operations based on real-time phase measurements and calculated optimal values. The phase alignment control unit continuously modifies rotation phases while maintaining continuous rotation, transforming the static stopping-based alignment into a dynamic continuous adjustment process.
2Manufacturing precision
If phase alignment is performed by accelerating or decelerating the workpiece axis or tool axis, then phase difference is corrected, but a large phase difference requires large phase shift and long alignment time
Solution Approach 1:
The system changes the phase command value parameter based on the number of cutting tools and current phase difference. By calculating multiple possible phase command values and selecting the optimal one, the system can achieve phase alignment with minimal phase shift regardless of the initial phase difference magnitude, thereby reducing alignment time.
Solution Approach 2:
The system replaces the mechanical approach of large-phase-shift acceleration/deceleration with a computational approach. The phase alignment control unit calculates optimal phase adjustments and executes them through control signals, substituting brute-force mechanical phase correction with intelligent control algorithms that minimize adjustment time.
3Manufacturing precision
If the number of cutting tools and rotation ratio are adjusted to achieve desired polygonal shape, then machining precision is improved, but phase alignment complexity increases
Solution Approach 1:
The system automatically calculates the optimal phase command value based on the number of cutting tools, current phase difference, and machining program requirements. The phase alignment control unit self-adjusts the phase without requiring external intervention or complex manual coordination, simplifying the control process while maintaining high precision for various polygonal shapes.
Solution Approach 2:
The system measures the current phase of the workpiece axis and tool axis, compares it with the calculated optimal phase command value, and adjusts the phases accordingly. This feedback mechanism automatically handles the complexity of phase alignment for different cutting tool configurations and rotation ratios, maintaining precision without increasing operational complexity.
Data Source
AI summary
A time necessary for phase alignment is shortened in a polygon machining device having a plurality of cutting tools. In phase alignment of polygon machining, a phase RCURRENT of the workpiece axis and tool axis before phase alignment and a machining-allowing phase command value RNEW(n) are calculated, a new phase command value R′NEW is calculated while considering restrictions such as a phase alignment method and a maximum rotation speed. By adjusting a phase to the new phase command value R′NEW, a time necessary for phase alignment can be shortened.