Machine Tool Threading Control for Phase-Accurate Faster Starts
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Solution Overview
Problem
Conventional machine tools require inefficient waiting times for spindle rotation signals to adjust the phase of the spiral track during multiple iterations of thread-cutting, leading to prolonged machining times and reduced work efficiency.
Innovation Solution
A controller system that dynamically determines a thread-cutting startable area based on the relative feed rate between the tool and workpiece, allowing for thread-cutting to commence when the tool is within this area, thereby optimizing the timing and reducing the cycle time for threading operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the tool waits for detection of a one-rotation signal of the spindle to start thread-cutting, then the phase of spiral track of the screw is adjusted accurately, but the cycle time for threading is prolonged and work efficiency is reduced
Solution Approach 1:
The controller pre-calculates the thread-cutting startable area range on the basis of the relative feed rate between the tool and workpiece before thread-cutting actually starts. This allows the system to determine in advance whether the current tool position falls within the startable area, eliminating the need to wait for spindle rotation signals and enabling phase-adjusted thread-cutting to commence immediately when conditions are met.
Solution Approach 2:
The invention transitions from a static waiting approach (fixed spindle rotation signal detection) to a dynamic determination approach. The thread-cutting startable area is dynamically calculated based on the real-time relative feed rate, allowing the thread-cutting start position to be flexibly determined within a calculated range, thus adapting to varying machining conditions while maintaining phase accuracy.
2Stability of the object's composition
If the tool repeatedly moves on the same track waiting for spindle signals, then phase consistency is maintained across multiple thread-cutting operations, but total machining time increases
Solution Approach 1:
The controller performs preliminary calculation of the thread-cutting startable area before each thread-cutting operation. By determining the valid start position range in advance based on feed rate parameters, the system eliminates repeated waiting for spindle signals while ensuring that thread-cutting starts within the calculated safe range, thereby maintaining phase consistency across multiple operations without sacrificing productivity.
Solution Approach 2:
The invention enables continuous thread-cutting operations by eliminating idle waiting time for spindle rotation signals. The tool can continuously move and start thread-cutting immediately when the tool position falls within the pre-calculated startable area, ensuring that the useful cutting action continues without interruption while maintaining phase accuracy through the calculated range constraints.
Data Source
AI summary
In a machine tool that performs threading, a thread-cutting startable area parallel to an X-axis of the machine tool is set based on a timing when a relative feed rate between a tool and a workpiece reaches a thread-cutting feed rate after the tool starts cutting feed. Then, movement of the tool in an X-axis direction is started first, and a rotation position of a spindle is monitored. When a thread-cutting start angle of the spindle is detected, cutting feed in a Z-axis direction of the tool is started if the tool travels in the thread-cutting startable area.