Tapping Motion Control With Overlapped Retraction and Positioning
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Solution Overview
Problem
Existing machining device control methods for tapping operations are inefficient in terms of cycle time, as they require separate steps for tapping, retracting, and positioning, leading to unnecessary pauses and increased processing time.
Innovation Solution
A controller for machining devices that coordinates the movement of a tapping tool between retracted and predetermined depth positions, synchronizes the rotation direction and speed of the tool, and optimizes the relative movement of the workpiece and tool by overlapping movement phases, allowing continuous and smooth path movement between tapping positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate steps for tapping, retracting, and positioning are used, then each operation can be completed accurately, but the cycle time increases due to unnecessary pauses
Solution Approach 1:
The patent merges the retracting step and positioning step into a single continuous motion sequence. The tool retracts from the workpiece while simultaneously positioning for the next tapping location, eliminating the pause between operations. This is achieved by coordinating the Z-axis motion (retraction) with the X-axis motion (positioning) in a synchronized manner, allowing both operations to occur concurrently without compromising tapping precision.
Solution Approach 2:
The invention maintains continuous tool motion by eliminating idle pauses between tapping, retracting, and positioning operations. The control system generates smooth continuous paths that keep the tool in constant motion, transitioning seamlessly from one operation to the next. This continuous action reduces cycle time while maintaining operational accuracy through coordinated multi-axis movement.
2Productivity
If the tool moves quickly between positions, then productivity increases, but the movement path may interfere with workpiece edges
Solution Approach 1:
The patent employs circular-arc-shaped movement paths instead of straight-line or angular transitions. The tool follows a curved trajectory during retraction and positioning, which naturally avoids sharp corners and prevents interference with workpiece edges. This curved path geometry allows the tool to move quickly and smoothly between positions while maintaining safe clearance from the workpiece boundaries.
Solution Approach 2:
The invention utilizes multi-dimensional coordinated motion by simultaneously moving the tool in both Z-axis (vertical retraction) and X-axis (horizontal positioning) directions. This three-dimensional motion approach allows the tool to clear the workpiece area more efficiently by moving upward and sideways in combination, avoiding interference that would occur with simple two-dimensional planar movements.
3Measurement precision
If the tool stops between tapping operations, then positioning accuracy improves, but power consumption and heat generation increase
Solution Approach 1:
The patent eliminates stopping between tapping operations by implementing continuous tool motion. The control system coordinates feed motors and spindle rotation to maintain constant movement through the sequence of tapping, retracting, and positioning. This continuous operation reduces energy consumption associated with repeated starts and stops, while positioning accuracy is maintained through precise motion control and coordinated multi-axis synchronization.
Solution Approach 2:
The invention employs dynamic motion control where the tool velocity and acceleration are continuously adjusted during the operation sequence. Rather than static positioning with complete stops, the system uses dynamic trajectory generation that maintains optimal speed while achieving precise positioning. This dynamic approach reduces energy waste from frequent acceleration and deceleration cycles while maintaining positioning accuracy through real-time control adjustments.
Data Source
AI summary
A controller for a machining-device includes a control-unit. The control-unit sequentially repeats a tapping step of tapping at a tapping-position by moving a tool from a retracted-position to a depth-position while rotating the tool in a normal direction, a retracting step of retracting the tool by moving from the depth-position to the retracted-position while rotating the tool in a reverse direction, and a positioning step of positioning a subsequent tapping-position. The control-unit performs a process including starting the positioning step at the same time as when the tool passes a reference-position in the retracting step, completing the positioning step at the same time as when the tool passes the reference-position in the tapping step, and controlling a timing at which acceleration of a workpiece and the tool finishes in the tapping step and a timing at which deceleration of the workpiece and the tool starts in the retracting step.