new brand template - cnc machining blog | hurco cnc … · · 2017-10-101 hours 40 min. american...
TRANSCRIPT
UItiMotion
Paul J. Gray, Ph.D.
Manager • Path Planning
• Front-End Design
• R&D
What is UltiMotion? • An entirely new software-based
motion control system
• Wholly owned by Hurco
• Awarded 4 patents
• Superior to Hurco Standard
Motion
Machining a part is a lot
like running a race
The Part Program is the
tool path map of the track
Interpret the Race Track
Race team generates the
strategy and pace notes
that describe the obstacles
and markers in the course
Program Interpreter 1. Load the part program instructions
(map)
2. Program Interpreter uses
• Part & tool setup
• Machine Kinematics
to generate machine-specific motion
data (pace notes)
3. The data is sent to the motion
system for real-time processing
Start the race by activating the
motion system
Start Cycle!
The Motion System Primary Components
Software and hardware that handle the physics of a CNC machine:
The Motion System 1. Motion Planning Co-Driver & Driver
2. Motion Control Driver
3. Servo Drives & Motors Race Car
Software and hardware that handle the physics of a CNC machine:
UltiMotion Components
A. Motion Planning
• Smoothing
• Look-Ahead & dynamic model
B. Control Loop
• Feed Forward
• Feedback
1. Motion Planning Co-Driver & Driver
2. Motion Control Driver
Motion Planning Smoothing & Look Ahead
Motion Planning Co-driver interprets pace notes
Calls out upcoming obstacles to the driver
Driver plans smoothest, fastest trajectory
within bounds of the track and vehicle limits
Motion Planning CNC Motion Planning includes:
1. Smoothing the path within machine
tolerances
2. Optimizing velocity and acceleration based
on the axes physical limits
Nominal Path – Centre of track
Nominal Path – Centre of track
Path Tolerance – Width of track
Nominal Path – Centre of track
Path Tolerance – Width of track
Optimal Path
Ultimotion Smoothing
• Patented curvature controlled
smoothing system
• Increases performance and
surface finish without sacrificing
part accuracy
Co-driver calls out the pace notes ahead of
obstacles
Driver anticipates the speed to navigate
obstacles based on vehicle performance
CNC Motion Controller
Anticipates acceleration and deceleration to
navigate an optimized trajectory
Based on measured characteristics of the
machine (dynamics of the axes)
What is Look Ahead?
Example
G01 X60 F2000
Y50
Y50
X
Y
X60
• Cannot accelerate & decelerate
instantaneously Y50
X
Y
X60
X-Axis
Time
Velo
city Y-Axis
• S-Curve velocity profile gives
smooth motion
• X stops before Y starts giving a
sharp corner
Y50
X
Y
X60
X-Axis
Time
Velo
city Y-Axis
Time
Velo
city X-Axis Y-Axis
Sharp
• Add small overlap
• Gives micro radius
• Cannot detect on part
• Significantly improves cycle times
Y50
X
Y
X60
X-Axis
Time
Velo
city Y-Axis Y-Axis
Time
Velo
city X-Axis
Time
Velo
city X-Axis Y-Axis
Sharp Micro
radius
Too much overlap will round corners Y50
X
Y
X60
X-Axis
Time
Velo
city Y-Axis Y-Axis
Time
Velo
city X-Axis Y-Axis
Time
Velo
city X-Axis
Time V
elo
city X-Axis Y-Axis
Sharp Micro
radius
Rounded
corner
To improve cycle times and surface finish we need
1. Smooth tool paths
2. Good control of velocity, acceleration, and Jerk
3. Robust control loop to handle real-time disturbances and
changing loads
Y-Axis
Time
Velo
city X-Axis
Micro
radius
Mo
tio
n P
lan
nin
g
To improve cycle times and surface finish we need
1. Smooth tool paths
2. Good control of velocity, acceleration, and Jerk
3. Robust control loop to handle real-time disturbances and
changing loads
Y-Axis
Time
Velo
city X-Axis
Micro
radius
The UltiMotion Motion Planning system generates optimal
trajectories to squeeze the most out of your machine
Driver’s View
How far to look?
Start
End
Co-driver calls out a few obstacles ahead of current position
Look Ahead plans the smoothest, fastest trajectory
Obstacles at the end are not relevant at the start
Rally Race Stage
More Speed Look Farther
How far to look?
Myth: High block look ahead is necessary for
high-speed machining
Truth: Larger look ahead doesn’t hurt, but
may not be needed
UltiMotion Dynamic Look-Ahead
Proprietary, patented system
Dynamic variable length
Looks as far as it needs to
Up to 10,000 blocks
Never runs out of data
The Control Loop Feed Forward and Feedback
The Control Loop Look-Ahead
Driver plans the trajectory, accelerations & decelerations
Motion Planning output is the input to the Control Loop
Feed Forward Driver executes the predicted steering, gas and braking
levels to navigate the race track obstacles
For CNC it is the predicted output gains to the axes
servo drives to follow the tool path
This is the primary output of the control system
In a perfect world, the
machine would follow
the output exactly
Feed Forward
Feedback Control Driver monitors and adjusts controls based on the actual
response of the car
CNC Machine has axes encoders to measure actual
position and velocity
Feedback control makes small adjustments to servo
gains to compensate for real-world conditions
The Control Loop Control Loop = Feed Forward + Feedback
Feed Forward provides major portion of controller output
Feedback only has to correct for small disturbances by
monitoring following error
The UltiMotion Control Loop
Dynamic velocity, acceleration,
and Jerk modeling and control
Advanced digital filters for
vibration control and smooth
motion
Summary Putting it all together
Putting it all together Start with the part program (map)
Putting it all together Generate machine-specific motion data using part & tool setup
and machine Kinematics (pace notes)
Start Cycle begins the race
Putting it all together
Motion Planning 1. Smooth the path within
tolerance
2. Look-Ahead:
Advanced dynamic velocity,
acceleration, and jerk modeling
and control
Output feeds the Control Loop
Putting it all together Control Loop 1. Feed Forward: Predict control gains /
gas, steering, brake input
2. Feedback:
Monitor vehicle trajectory, adjust
controls if off track
Control monitors encoders and adjusts
axes control gains
41
UltiMotion Features What can UltiMotion do for you?
Superior Tapping Tapping requires tight coordination spindle and linear axes
Only available with UltiMotion
1. True Master-Slave control
Linear axes are slave to the Spindle (master)
The Spindle feedback is the linear axes control loop input
More accurate tapping
1. True Master-Slave control
Example—Badly tuned spindle
1. True Master-Slave control
Example—Badly tuned spindle
Superior Tapping 2. High-Speed Tap Retract
Up to 1000% faster retract out of tapped hole for faster
throughput
Master-Slave control
ensures accuracy
3. Override and motion hold
during tapping
4. Power loss Tap Recovery
E-Stop Tap Recovery
E-Stop Tap Recovery
E-Stop & Power Loss Control
During power loss or E-stop event, Ultimotion can:
retract smoothly
or hold the controlled position until brake engages
even during Tapping
On subsequent power-up, UltiMotion can extract the tap from the
hole without damaging the thread
Customer Testimonials
3D Solutions
Standard Motion
2 hours 20 min
40% gain in throughput 1.4 parts for every 1 they were making before
UltiMotion
1 hours 40 min
American Precision Machining
Ultimotion Standard Motion
50 minutes 1 hour 15 minutes
50% gain in throughput 1.5 parts for every 1 they were making before
Wepco Example from customer states:
S7 tool steel
100 hour part down to 30 hours
Over 230% gain in throughput
3.3 parts for every 1 part they were making before
“With UltiMotion … We are achieving extremely high feed
rates up to 800 IMP. … And I don't have to polish the mold!
the finish is that good.”
Dave Parmlee
High-Speed Machining
UltiMotion Standard Motion
High-Speed Machining • Identical
programs
• 29% cycle time
reduction
• Better surface
finish
Who can benefit from UltiMotion? Virtually all industries and parts
Both Conversational and NC users
Particularly:
3- through 5-Axis contouring
Pocketing
High-Speed Machining
Because of:
1. Higher feed rates
2. Smoother motion
3. Better surface finish
4. Higher accuracy
Repetitive drilling due to smoother rapid motion
Repetitive tapping from High Speed Tap Retract
Thank You