Tapping Controller Adaptive Acceleration Motor Temperature
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Solution Overview
Problem
Machine tools experience overheating and reduced machining efficiency due to excessive acceleration and deceleration of motors, leading to potential tool breakage and decreased precision, especially during tapping operations with small diameters, and existing solutions vary acceleration without considering the specific requirements of the machining task.
Innovation Solution
A controller that identifies the tap size using an identifier unit, detects motor temperature, and calculates a new acceleration by multiplying the initial acceleration with a temperature-dependent rate, allowing for adaptive acceleration settings based on the tap size and temperature to prevent overheating and ensure optimal machining precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If acceleration and deceleration rates are increased to shorten machining time, then productivity is improved, but the driving device generates excessive heat leading to overheating
Solution Approach 1:
The patent applies dynamics by making the acceleration rate variable rather than fixed. The acceleration rate is dynamically adjusted based on real-time temperature feedback from the driving device. When temperature exceeds thresholds, the acceleration rate is reduced; when temperature is acceptable, the acceleration rate can be increased. This dynamic adaptation resolves the contradiction by allowing high productivity when conditions permit while preventing overheating when temperature rises.
Solution Approach 2:
The patent implements a feedback control mechanism where the temperature of the driving device is continuously monitored and used to adjust the acceleration rate. The temperature detection unit provides real-time temperature data to the control unit, which then modifies the acceleration rate accordingly. This closed-loop feedback system enables the system to automatically balance productivity and temperature control, resolving the contradiction between fast machining and heat generation.
2Temperature
If acceleration rate is reduced to prevent overheating, then temperature control is improved, but machining efficiency decreases
Solution Approach 1:
The system dynamically adjusts the acceleration rate based on actual temperature conditions rather than using a fixed conservative rate. When temperature is within acceptable ranges, the acceleration rate is increased to maintain high productivity. When temperature approaches critical thresholds, the acceleration rate is temporarily reduced. This dynamic approach prevents unnecessary reduction in machining efficiency while still ensuring temperature control.
Solution Approach 2:
The patent changes the acceleration rate parameter in response to temperature parameter changes. By establishing temperature thresholds and corresponding acceleration rate adjustments, the system adapts its operating parameters to balance temperature control and productivity. This parameter-based control allows the system to maintain optimal machining efficiency under normal conditions while preventing overheating when necessary.
3Temperature
If acceleration is varied based on temperature and acceleration frequency, then overheating is prevented, but machining precision varies irrespective of machining content
Solution Approach 1:
The patent applies local quality by differentiating acceleration rates based on specific machining conditions rather than using a uniform approach. The control unit identifies the type of machining operation (e.g., tapping, drilling, milling) and applies appropriate acceleration rates from different storage areas corresponding to each operation type. This allows the system to maintain high precision for precision-requiring operations while enabling faster acceleration for operations where precision is less critical, all while preventing overheating.
Solution Approach 2:
The system dynamically selects and adjusts acceleration rates based on both temperature conditions and machining operation types. The control unit continuously monitors temperature and combines this information with the identified machining operation to select the most appropriate acceleration rate. This dynamic, context-aware adjustment ensures that machining precision is maintained for specific operations while still preventing overheating through adaptive temperature management.
4Productivity
If acceleration is increased for efficient tapping, then productivity is improved, but tool breakage risk increases for small diameter taps
Solution Approach 1:
The patent applies local quality by storing and selecting different acceleration rates based on tap diameter specifications. The control unit identifies the tap diameter and retrieves the appropriate acceleration rate from a dedicated storage area. For small diameter taps, lower acceleration rates are automatically selected to prevent tool breakage. For larger diameter taps, higher acceleration rates can be used to maintain productivity. This localized, specification-based approach resolves the contradiction between tapping efficiency and tool durability.
Data Source
AI summary
A controller (10) for a machine tool (18) for tapping by a main shaft and a feed shaft, comprising an identifier unit (12) for identifying an index of the size of the tap, a temperature detector unit (19b) for detecting the temperature of a motor (19a) for the main shaft, an acceleration storage unit (21) for storing the acceleration of the main shaft corresponding to the index of the size of the tap, a rate storage unit (22) for storing the rate of varying the acceleration of the main shaft depending upon the temperature of the motor, and an acceleration calculation unit (16) for calculating a new acceleration of the main shaft by multiplying an acceleration determined from the index of the size of the tap and from the acceleration storage unit by a rate determined from the detected temperature and from the rate storage unit.