Numerical Controller for Thermal-Aware Hole Machining Order
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Solution Overview
Problem
Existing numerical controllers for machining machines face challenges in determining optimal machining positions to avoid thermal deformation, particularly when dealing with varying hole shapes, as they often rely on manual operation, incomplete automation, and lack accurate heat influence evaluation, leading to potential thermal deformation issues.
Innovation Solution
A numerical controller equipped with a thermal influence calculation unit and machining position determination unit that calculates temporal heat distribution changes and determines optimal machining positions to avoid thermal deformation by considering elapsed time, heat distribution, and machining shape, using methods like the finite element method and measurement data to ensure accurate positioning and program generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual determination of machining order is used to avoid thermal deformation, then thermal deformation can be prevented, but operator time is significantly increased and productivity is reduced
Solution Approach 1:
The patent replaces the manual mechanical process of determining machining order with an automated computer-based system. The determination unit automatically calculates the optimal machining sequence by evaluating heat distribution data and thermal influence between holes, eliminating the need for manual operator intervention while maintaining thermal deformation prevention.
Solution Approach 2:
The system enables self-service by allowing the numerical controller to automatically determine its own machining order without external operator input. The determination unit uses pre-stored heat distribution data and thermal influence information to autonomously generate the optimal machining sequence, making the system self-sufficient in avoiding thermal deformation.
2Productivity
If automated schemes based on simple rules are used to determine machining order, then operator time is reduced, but thermal deformation may still occur due to lack of accurate heat influence evaluation
Solution Approach 1:
The patent implements feedback by using actual heat distribution data measured during machining operations to inform subsequent machining order decisions. The determination unit continuously evaluates thermal influence based on real or predicted heat distribution information, adjusting the machining sequence to prevent thermal deformation while maintaining automation.
Solution Approach 2:
The system performs preliminary action by pre-calculating and storing heat distribution data and thermal influence information before machining operations begin. This advance preparation enables the determination unit to quickly evaluate potential thermal deformation risks and optimize the machining order without real-time delays, maintaining both productivity and precision.
3Device complexity
If traditional schemes assume uniform hole shapes are machined, then calculation is simplified, but the system cannot handle varying hole shapes with different heat distributions
Solution Approach 1:
The patent applies local quality by recognizing that different holes have different thermal characteristics based on their specific shapes, sizes, and locations. The determination unit evaluates thermal influence individually for each hole pair combination, considering the unique heat distribution properties of each hole rather than applying uniform assumptions, thereby handling varying hole shapes effectively.
Solution Approach 2:
The system uses parameter changes by incorporating heat distribution data that varies with hole shape, size, and position. The determination unit adjusts thermal influence calculations based on specific hole parameters, allowing the system to adapt to different hole configurations while maintaining automated determination capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables automated determination of machining positions that prevent thermal deformation, reducing operator time and improving productivity, even for inexperienced operators, while handling varying hole shapes and shapes with different heat distributions effectively.
Implementation Method 1
The thermal influence calculation unit 101 calculates, for each machined hole, a temporal change in a heat distribution of the workpiece
Data Source
AI summary
A numerical controller that machines a workpiece to create multiple machined holes with a predetermined machining position and a predetermined machining shape in the workpiece includes a thermal influence calculation unit that determines a temporal change in a heat distribution of the workpiece for each of the machined holes when the machined hole having the machining shape is created at the machining position, a machining position determination unit that determines a next machined hole that does not cause thermal deformation of the workpiece on the basis of an elapsed time that elapses from creation of a previously machined hole to creation of a next machined hole and a heat distribution resulting from creation of the previously machined hole and the next machined hole, and a machining unit that creates the machined holes. The numerical controller can determine the machining positions taking the thermal deformation into account.