Machine Tool Thermal Displacement Compensation via Visual Operator Feedback
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Solution Overview
Problem
Existing thermal displacement compensation methods for machine tools are inadequate in accurately adjusting the thermal displacement compensation amount due to external factors like coolant and air temperature, leading to significant compensation errors and insufficient precision in matching the adjustment direction with the machining point's movement.
Innovation Solution
A thermal displacement compensation device that predicts thermal displacement amounts and adjusts the compensation amount by displaying an image on a controller's display device, allowing operators to move the image in the correct direction to determine whether to increase or decrease the compensation amount, thereby aligning the adjustment with the machining point's movement and reducing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the thermal displacement compensation amount is adjusted by calculating a new heat generation coefficient based on compensation error, then the compensation precision is improved, but the adjustment direction may be incorrect due to mismatch between thermal displacement amount and machining point movement direction
Solution Approach 1:
The patent introduces an image as an intermediary visual representation on the display device. This image serves as a mediator between the operator and the abstract thermal displacement data, allowing the operator to visually confirm the machining point movement direction and set the adjustment direction based on visual feedback rather than relying solely on numerical calculations that may be mismatched with actual movement directions.
Solution Approach 2:
The patent replaces the purely mechanical/mathematical adjustment method (calculating heat generation coefficients) with a visual interaction system. By using image display and operator visual judgment, the system substitutes automatic calculation with human visual perception and decision-making, ensuring the adjustment direction matches the actual machining point movement direction.
2Ease of operation
If the thermal displacement compensation amount is adjusted by adding or subtracting a fixed adjustment value, then the adjustment process is simplified, but the compensation error remains significant when external factors change
Solution Approach 1:
The patent makes the adjustment value dynamic by calculating it based on the compensation error and the machining point movement amount. Instead of using a fixed adjustment value, the system dynamically determines the adjustment magnitude proportionally to the actual error and movement, allowing the adjustment process to remain simple while achieving accurate compensation even when external factors change.
3Productivity
If the operator sets adjustment values without visual feedback on machining point movement, then the operation is faster, but wrong settings occur due to mismatch between thermal displacement and machining point movement directions
Solution Approach 1:
The patent uses visual display of the machining point position and movement direction on the display device. By presenting visual information about the machining point location and direction, the operator can quickly and accurately set the adjustment direction without confusion, maintaining high adjustment speed while eliminating wrong settings caused by directional mismatch.
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 approach enables accurate adjustment of thermal displacement compensation amounts, ensuring that the compensation amount is correctly increased or decreased based on the machining point's movement direction, thereby reducing compensation errors and improving precision.
Implementation Method 1
a function of predicting a thermal displacement amount from an operation of a machine tool or a temperature of each part
Data Source
AI summary
A position command value is compensated by predicting a thermal displacement amount of each part of a machine tool and adding a thermal displacement compensation amount which cancels the predicted thermal displacement amount to the position command value of a feed axis. This thermal displacement compensation amount is adjusted from the error amount between this compensated position command value and an actual machining point. Upon adjustment of this thermal displacement compensation amount, it is possible to determine whether to increase or decrease the thermal displacement amount based on a direction in which an operator moves a tool image or a workpiece image on a screen.