Vibration Cutting Diagnostic Device for Non-Round Shapes
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Solution Overview
Problem
Conventional vibration cutting processes face challenges in maintaining machining accuracy due to high-frequency components in position command signals, which can cause machine resonance and require trial-and-error adjustments of feeding speed and main shaft revolution, leading to reduced accuracy and increased steps in determining optimal command conditions.
Innovation Solution
A vibration cutting process diagnostic device that includes a frequency analyzer to calculate frequency components in position command signals based on machining shape data and speed settings, and a process diagnosis executor to assess the propriety of the machining process, allowing for pre-process diagnosis of vibration cutting under specified speed conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the feeding speed is set higher to increase the throughput rate, then productivity is improved, but machine resonance is caused and machining accuracy is lowered
Solution Approach 1:
The patent performs preliminary frequency analysis on the position command signal before actual machining to identify resonance frequencies. This allows pre-determination of safe feeding speeds that avoid resonance, enabling high-speed machining without sacrificing accuracy. The frequency analysis unit calculates frequency components in advance, and the process diagnosis executor determines propriety before the process, preventing resonance issues rather than reacting to them.
Solution Approach 2:
The patent implements a feedback mechanism where the frequency analysis results are used to adjust and optimize the position command signal. By continuously analyzing the frequency components and comparing them with machine resonance characteristics, the system can dynamically adjust feeding speeds to maintain machining accuracy while maximizing productivity.
2Manufacturing precision
If the control gain is set higher to improve the accuracy, then manufacturing precision is improved, but machine natural vibration is excited and machine resonance is caused
Solution Approach 1:
The system performs preliminary frequency analysis to identify resonance frequencies before high-gain control is applied. This allows the control gain to be set high for accuracy while avoiding frequencies that would excite resonance, thus maintaining system stability. The frequency component calculation is performed in advance to guide control parameter selection.
Solution Approach 2:
The patent changes control parameters (feeding speed, main shaft revolution) based on frequency analysis results to avoid resonance frequencies. By adjusting these parameters within safe ranges identified through frequency analysis, the system achieves high control accuracy without exciting machine natural vibration.
3Stability of the object's composition
If a filter is used to remove machine natural vibration, then stability is improved, but frequency components in the position command signal may be attenuated leading to reduced machining accuracy
Solution Approach 1:
The patent extracts and analyzes the frequency components of the position command signal separately from the main control loop. By identifying the frequency content in advance through frequency analysis, the system can determine whether filtering is necessary without blindly applying filters that might attenuate useful high-frequency components needed for accurate machining.
Solution Approach 2:
The system adjusts filtering parameters based on the actual frequency components identified in the position command signal. Rather than using fixed filter settings, the filter characteristics are optimized according to the specific frequency content of each machining operation, preserving necessary high-frequency components while removing harmful resonance frequencies.
4Manufacturing precision
If trial-and-error adjustments are performed to determine optimal command conditions, then manufacturing precision is improved, but loss of time increases due to multiple adjustment steps
Solution Approach 1:
The patent performs frequency analysis and process diagnosis in advance before actual machining to determine optimal command conditions. This preliminary determination of feasible speed ranges and optimal parameters eliminates the need for time-consuming trial-and-error adjustments during production, significantly reducing setup time while ensuring machining accuracy.
Solution Approach 2:
The system automatically performs frequency analysis and determines optimal machining parameters without requiring operator intervention for trial-and-error adjustments. The process diagnosis executor autonomously evaluates the position command signal and recommends or sets optimal feeding speeds and main shaft revolutions, reducing both time loss and human effort.
Data Source
AI summary
A vibration cutting process diagnostic device diagnoses the propriety of a vibration cutting process to machine the sectional shape of a working object into a non-complete round shape by reciprocating a movable shaft. This device includes a frequency analyzer to calculate a frequency component contained in a position command signal for the movable shaft on the basis of shape data, which is machining shape data on a workpiece treated as the working object, and a machining speed set value; and a process diagnosis executor to diagnose the propriety of machining the shape data under the machining speed set value on the basis of the frequency component and a movable shaft parameter of the movable shaft.