Machine Tool Path Capture Using Feed-Rate Adaptation
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Solution Overview
Problem
Current machine tools face challenges in capturing accurate tool paths due to communication protocol limitations, leading to time delays and inaccuracies in data transmission, and existing CAM systems struggle to generate G-codes for advanced tool path formats, resulting in incomplete and biased tool path reconstruction.
Innovation Solution
A method and device that adjust the feed rate of a cutting tool based on the communication frequency of the machine tool's controller, using a communication-frequency analysis unit, cutting-speed control unit, and tool-path capture unit to synthesize a tool path file by obtaining and processing machine coordinates and G-codes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a typical controller of the conventional machine tool adopts a communication protocol unable to provide real-time data transmission, then the communication system is simple and easy to implement, but substantial time delay would be inevitable to result in incomplete or disconnected collection of coordinates
Solution Approach 1:
The system dynamically adjusts the feed rate of the cutting tool based on the communication frequency of the controller. By making the feed rate variable rather than fixed, the system adapts to the controller's data transmission capabilities, ensuring accurate tool path capture without requiring real-time transmission protocols.
Solution Approach 2:
The invention changes the parameter of feed rate according to the communication frequency. By reading G-codes to confirm the feed rate and adjusting it based on communication capabilities, the system optimizes the balance between measurement accuracy and time delay without modifying the communication protocol itself.
2Ease of manufacture
If a machining program is provided by a computer aided design (CAD) system through a computer aided manufacturing (CAM) simulation, then the path planning can be performed in advance, but practical machining of the machine tool can't be present in a real-time manner
Solution Approach 1:
The system implements feedback by continuously monitoring the actual machine coordinates during machining and comparing them with the planned path. This feedback mechanism allows the system to capture real-time machining data while maintaining the benefits of pre-planned paths, bridging the gap between simulation and actual machining.
Solution Approach 2:
The invention performs preliminary actions by pre-reading G-codes to determine appropriate feed rates before machining begins. This preliminary preparation enables the system to optimize machining parameters in advance while still capturing real-time coordinate data during actual machining operations.
3Extent of automation
If an interpreter is introduced to realize the G-codes, then the machining program can be executed, but following maintenance or service difficulty would be encountered due to singularity and incompleteness of the interpreter
Solution Approach 1:
The invention extracts only the essential feed rate information from the G-codes rather than relying on a complete interpreter to execute and analyze all G-code commands. By taking out only the necessary parameters (feed rates) and using them to control the machining process, the system reduces dependency on complex interpreters and simplifies maintenance.
Solution Approach 2:
Instead of using a singular interpreter that is difficult to maintain, the system creates multiple simple copying mechanisms that read G-codes to extract feed rate information. This approach replaces a complex, hard-to-maintain interpreter with simpler, more maintainable code reading operations.
4Adaptability or versatility
If the current CAM system may not produce G-codes for supporting the tool path file generally in an advanced packaging tool (APT) format, then the CAM system is compatible with standard formats, but inaccuracy would arise after tedious processes of analyzing coordinates, processing G-codes, and preparing macro instructions
Solution Approach 1:
Instead of converting tool paths from various formats into G-codes through tedious processing, the invention inverts the approach by directly capturing machine coordinates during machining and synthesizing the tool path file from these actual measurements. This eliminates the need for complex format conversions and macro instructions while improving accuracy.
Solution Approach 2:
The invention replaces the mechanical process of analyzing coordinates, processing G-codes, and preparing macro instructions with a direct coordinate capture and synthesis system. By substituting the complex software processing chain with direct measurement and synthesis, the system achieves higher accuracy without sacrificing format compatibility.
Data Source
AI summary
A method for capturing a tool path, applicable to a machine tool having a controller and furnished with a tooling, includes the steps of: obtaining a data update frequency of the controller; calculating a feed rate of the controller, determining whether or not the feed rate is obtained, going to next step if positive, and going to the previous step if negative; reading G-codes of the controller to confirm the feed rate; and, based on the confirmed feed rate, recording machine coordinates transmitted from the controller for synthesizing a tool path file. The tool path file is used for simulation and analysis of machining of the machine tool. In addition, a device for capturing the tool path is also provided.