Thread Whirling Motor Controller Synchronization
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Solution Overview
Problem
Conventional methods face challenges in efficiently performing turning during thread whirling, as increasing the rotational speed of the workpiece and thread whirling tool for faster machining results in inaccurate thread grooves, while reducing the movement speed of the thread whirling tool to ensure accuracy lowers the workpiece rotational speed below the required range for effective turning.
Innovation Solution
A numerical control apparatus that includes a thread-whirling motor controller to manage the movement and rotational speeds of the thread whirling tool and workpiece, using the thread lead, reference differential speed, number of tool blades, and workpiece spindle speed to synchronize and optimize the machining process, allowing for efficient screw formation by simultaneously performing thread whirling and turning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rotational speed of the workpiece and the movement speed of the thread whirling tool are increased to improve machining efficiency, then the productivity is improved, but the manufacturing precision of the thread groove deteriorates
Solution Approach 1:
The patent applies dynamics by making the movement speed of the thread whirling tool variable rather than constant. The control unit dynamically adjusts the movement speed based on the rotational speed of the workpiece, allowing the system to adapt to different operating conditions. This enables high-speed machining while maintaining accurate thread groove formation by optimizing the speed relationship between the tool and workpiece in real-time.
2Manufacturing precision
If the movement speed of the thread whirling tool is reduced to improve thread groove accuracy, then the manufacturing precision is improved, but the productivity deteriorates
Solution Approach 1:
The patent changes the parameter of movement speed from a fixed value to a variable that depends on the workpiece rotational speed. By establishing a functional relationship between these parameters through the control unit, the system can optimize the movement speed for each specific operating condition, achieving both high accuracy and high productivity without being constrained by fixed speed limits.
3Productivity
If the rotational speed of the workpiece is increased to enable effective turning, then the productivity is improved, but the movement speed of the thread whirling tool must also increase which deteriorates thread groove accuracy
Solution Approach 1:
The patent implements feedback control where the control unit continuously monitors the rotational speed of the workpiece and uses this information to adjust the movement speed of the thread whirling tool. This closed-loop control ensures that the movement speed is always appropriately matched to the rotational speed, maintaining thread groove accuracy even when operating at high speeds for improved productivity.
Data Source
AI summary
A numerical control apparatus includes: a thread-whirling motor controller controlling, based on a thread lead representing a movement amount of a thread whirling tool per rotation of a workpiece, a reference differential speed representing a difference between a predetermined reference rotational speed of the thread whirling tool and a rotational speed of the workpiece, the number of tool blades of the thread whirling tool, and a workpiece spindle speed representing the rotational speed of the workpiece, a first motor moving the thread whirling tool, a second motor rotating the thread whirling tool, and a third motor rotating the workpiece. The thread-whirling motor controller controls: the first motor based on the thread lead and the reference differential speed; the second motor based on the thread lead, the reference differential speed, the number of tool blades, and the workpiece spindle speed; and the third motor based on the workpiece spindle speed.