uitimotion
play

UItiMotion Paul J. Gray , Ph.D. Manager Path Planning Front-End - PowerPoint PPT Presentation

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


  1. UItiMotion Paul J. Gray , Ph.D. Manager • Path Planning • Front-End Design • R&D

  2. What is UltiMotion? • An entirely new software-based motion control system • Wholly owned by Hurco • Awarded 4 patents • Superior to Hurco Standard Motion

  3. Machining a part is a lot like running a race

  4. The Part Program is the tool path map of the track

  5. Interpret the Race Track Race team generates the strategy and pace notes that describe the obstacles and markers in the course

  6. 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

  7. Start Cycle!  Start the race by activating the motion system

  8. The Motion System Primary Components

  9. The Motion System Software and hardware that handle the physics of a CNC machine:  1. Motion Planning Co-Driver & Driver  2. Motion Control Driver  3. Servo Drives & Motors Race Car

  10. UltiMotion Components Software and hardware that handle the physics of a CNC machine:  1. Motion Planning Co-Driver & Driver  2. Motion Control Driver A. Motion Planning • Smoothing • Look-Ahead & dynamic model B. Control Loop • Feed Forward • Feedback

  11. Motion Planning Smoothing & Look Ahead

  12. 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

  13. Motion Planning CNC Motion Planning includes: 1. Smoothing the path within machine tolerances 2. Optimizing velocity and acceleration based on the axes physical limits

  14. – Centre of track Nominal Path

  15. – Centre of track Nominal Path – Width of track Path Tolerance

  16. – Centre of track Nominal Path – Width of track Path Tolerance Optimal Path

  17. Ultimotion Smoothing • Patented curvature controlled smoothing system • Increases performance and surface finish without sacrificing part accuracy

  18. What is Look Ahead?  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)

  19. Example Y Y50 G01 X60 F2000 X60 Y50 X

  20. • Cannot accelerate & decelerate Y Y50 instantaneously X60 X Y-Axis Velocity X-Axis Time

  21. • S-Curve velocity profile gives Y Y50 smooth motion • X stops before Y starts giving a X60 sharp corner X Y-Axis Velocity X-Axis Velocity X-Axis Y-Axis Time Time Sharp

  22. • Add small overlap Y Y50 • Gives micro radius X60 • Cannot detect on part • X Significantly improves cycle times Y-Axis Velocity X-Axis Velocity X-Axis Velocity X-Axis Y-Axis Y-Axis Time Time Time Micro Sharp radius

  23. Too much overlap will round corners Y Y50 X60 X Velocity X-Axis Y-Axis Velocity X-Axis Velocity X-Axis Y-Axis Y-Axis Velocity X-Axis Y-Axis Time Time Time Time Micro Rounded Sharp radius corner

  24. 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 Velocity X-Axis Y-Axis Time Micro radius

  25. Motion Planning 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 Velocity X-Axis Y-Axis Time Micro radius The UltiMotion Motion Planning system generates optimal trajectories to squeeze the most out of your machine

  26. How far to look?  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 Start End Driver’s View Rally Race Stage

  27. More Speed Look Farther

  28. 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

  29. 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

  30. The Control Loop Feed Forward and Feedback

  31. The Control Loop Look-Ahead  Driver plans the trajectory, accelerations & decelerations  Motion Planning output is the input to the Control Loop

  32. 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

  33. Feed Forward In a perfect world, the machine would follow the output exactly

  34. 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

  35. 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

  36. The UltiMotion Control Loop  Dynamic velocity, acceleration, and Jerk modeling and control  Advanced digital filters for vibration control and smooth motion

  37. Summary Putting it all together

  38. Putting it all together  Start with the part program ( map )

  39. Putting it all together  Generate machine-specific motion data using part & tool setup and machine Kinematics ( pace notes )  Start Cycle begins the race

  40. 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

  41. 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

  42. UltiMotion Features What can UltiMotion do for you?

  43. 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

  44. 1. True Master-Slave control Example — Badly tuned spindle

  45. 1. True Master-Slave control Example — Badly tuned spindle

  46. 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

  47. E-Stop Tap Recovery

  48. E-Stop Tap Recovery

  49. 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

  50. Customer Testimonials

  51. 3D Solutions 40% gain in throughput 1.4 parts for every 1 they were making before UltiMotion Standard Motion 2 hours 20 min 1 hours 40 min

  52. American Precision Machining 50% gain in throughput 1.5 parts for every 1 they were making before Ultimotion Standard Motion 50 minutes 1 hour 15 minutes

  53. 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

  54. High-Speed Machining

  55. UltiMotion Standard Motion

  56. High-Speed Machining • Identical programs • 29% cycle time reduction • Better surface finish

  57. Who can benefit from UltiMotion?  Virtually all industries and parts  Both Conversational and NC users Particularly: Because of:  3- through 5-Axis contouring 1. Higher feed rates  Pocketing 2. Smoother motion  High-Speed Machining 3. Better surface finish 4. Higher accuracy  Repetitive drilling due to smoother rapid motion  Repetitive tapping from High Speed Tap Retract

  58. Thank You

Recommend


More recommend