Servo Control for Oscillation Machining Without Unnecessary Cuts
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Solution Overview
Problem
Existing oscillation machining techniques generate unnecessary cuts during the machining process, which can lead to inefficiencies and inaccuracies, particularly when dealing with workpieces of tapered or arc shapes.
Innovation Solution
A servo controller system that includes an oscillation command generating unit, a deviation deducting unit using a high pass filter to remove steady-state position deviations, and a learning control unit to calculate compensation amounts, ensuring precise control and prevention of unnecessary cuts by generating an oscillation command that causes the workpiece and tool to oscillate effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If oscillation machining is performed using conventional methods, then chip shredding is achieved, but unnecessary cuts are generated during machining
Solution Approach 1:
The invention implements feedback control by calculating the actual position deviation between the tool and workpiece during oscillation machining, comparing it with the commanded position, and adjusting the oscillation parameters in real-time to prevent unnecessary cuts while maintaining chip shredding effectiveness
Solution Approach 2:
The invention replaces conventional mechanical oscillation control with a control system that uses position deviation calculation and deduction mechanisms to precisely manage tool-workpiece relative motion, substituting mechanical trial-and-error approaches with calculated compensation methods
2Productivity
If oscillation amplitude and frequency are increased to improve chip shredding, then chip removal efficiency is enhanced, but machining precision deteriorates
Solution Approach 1:
The invention applies dynamics by making the oscillation parameters (amplitude and frequency) variable rather than fixed, allowing the system to adapt oscillation intensity based on real-time position deviation feedback, thus optimizing both chip removal efficiency and surface finish quality during different stages of machining
Solution Approach 2:
The invention changes oscillation parameters dynamically by adjusting amplitude and frequency based on calculated position deviations, transforming static oscillation settings into adaptive parameters that respond to actual machining conditions to prevent unnecessary cuts
3Device complexity
If steady-state position deviation is not deducted from the control signal, then simple control is maintained, but unnecessary cuts occur during oscillation machining
Solution Approach 1:
The invention extracts and removes the steady-state position deviation component from the total position deviation signal, separating it from the dynamic oscillation control to prevent unnecessary cuts caused by sustained position offsets while maintaining the essential oscillation motion
Data Source
AI summary
Provided is a servo controller that can prevent an unnecessary cut from being generated during oscillation machining. A servo controller which controls a machine tool 10 that turns a workpiece W by cooperative operation of a plurality of axes includes: an oscillation command generating unit 23 that generates an oscillation command for causing the workpiece W and the tool 11 to relatively oscillate; a deviation deducting unit 31, 241 that applies the oscillation command to a position deviation based on a moving command for causing the workpiece W and the tool 11 to relatively move, and deducts a steady-state position deviation; and a learning control unit 27 that calculates a compensation amount from a position deviation based on the moving command after deducting the steady-state position deviation.