Simulation Apparatus for Manual Machine Tool Operation
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Solution Overview
Problem
Existing manual operation methods for machine tools lack real-time interference checking, leading to potential tool-workpiece contact and defective products due to delayed movement initiation and interruption during machining.
Innovation Solution
A simulation apparatus that includes model data storage, a display controller, a manual operation signal generator, and an NC program generator, allowing for virtual machining simulation by checking interference between movable structures and displaying potential collisions, enabling safe manual operation by generating an NC program based on manual operation signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If interference prevention method with no-entry area calculation is used, then interference can be prevented, but movement of movable body cannot start until no-entry area is set causing time-lag
Solution Approach 1:
The system pre-calculates and stores no-entry area information before manual operation begins. When manual operation is initiated, the movable body can start moving immediately since the interference prevention data is already prepared, eliminating the time-lag while maintaining reliable interference prevention.
2Reliability
If operation is stopped due to predicted interference, then interference can be prevented, but machining mark may be left on workpiece causing defective product
Solution Approach 1:
The system performs interference checking and calculates no-entry areas before actual machining begins. By pre-identifying potential interference zones and adjusting the movement path in advance, the system prevents interference without causing interruptions during machining, thereby avoiding machining marks and ensuring workpiece quality.
3Ease of operation
If manual operation is performed without simulation, then operation can be performed freely, but interference cannot be detected in advance
Solution Approach 1:
The system creates a virtual copy (three-dimensional model) of the machine tool and performs simulation operations on this copy. This allows operators to freely test manual operations in the virtual model while the system automatically detects interference between the movable body and other structures, providing interference detection without restricting operational freedom.
Data Source
AI summary
A simulation apparatus 1 includes a touch panel 20, a display controller 11, a display screen data storage unit 12, an input control unit 13, an operation information storage unit 14, a model data storage 16, a simulation executor 15 and an NC program generator 17. The simulation executor 15 displays an image of a movable structure 12 to be operated on the touch panel 20, moves the image in accordance with a manual operation and checks occurrence of interference, and, in the case where interference occurs, stops the movement of the image and displays the occurrence of interference on the touch panel 20. Further, in the case where it is confirmed that no interference occurs, the NC program generator 17 generates an NC program based on manual operation information.