Real-Time Jerk Limited Feedrate Profiling and Interpolation for Linear Motor Multiaxis Machines Using NURBS Toolpaths

In this article, a NURBS toolpath feedrate profile generation algorithm for a biaxial linear motor control system is presented. High achievable velocities and accelerations of linear motor machines present new computational challenges in implementing feedrate generation and toolpath interpolation algorithms in real-time controllers. The proposed algorithm is capable of online generation of the feedrate profile with axial acceleration and jerk constraints. Each stage of the feedrate profiling algorithm is described with attention being given to both performance and implementation aspects. Furthermore, an alternative to the commonly used Taylor series interpolation method is also tested to ensure minimal interpolation errors. The feedrate profiling and interpolation algorithms’ implementation in a PC-based controller with real-time Linux kernel is described. Experimental results are presented that confirm that the algorithm is capable of limiting acceleration and jerk in the machine’s axes and it is low computation time enables real-time on-line operation in a PC-based CNC controller

Modelling and optimization of multi-axis machining process considering CNC motion limitations

The importance of multi-axis machining processes is increased over the years, especially for industries such as automotive, aerospace, dies and molds, biomedical where the parts have complex surfaces. As the demand for products is increased from these industries, it became crucial to minimize the cycle time to overcome the demand and also reduce the production costs while maintaining or enhancing the part quality. In order to achieve this the dimensional tolerances and a desired surface quality should be inside the acceptance limit while increasing productivity. The properties of the machine tool such as its own structure, axis drives, drivetrain, axis control limits and axis motor maximum capabilities can be regarded as boundary conditions of the process. The limits for the drives cannot be used at full capacity constantly as the machining process is a highly variable and flexible operation. For instance, sharp maneuvers on the tool path may not be realized at high feedrate values. In some cases, the required motion exceeds the motion capability of the axis drives, i.e. jerk, acceleration and velocity limitations. In those cases, the CNC unit slows down the motion to synchronize machine axes to keep up within geometrical limits of the required tool path. On the other hand, sometimes the commanded feed rate may not be achieved at some instances of a cycle involving short distances due to limited jerk and acceleration of the axes. These problems reduce the productivity of the operation as well as the quality of the final product. This thesis presents a new feed-rate optimization algorithm which re-adjusts the rotary axis motions to stay in the acceleration and jerk limits as well as to obtain a better surface quality for the final product in multi-axis machining. All measured velocity, acceleration and jerk limits are given to the algorithm to re-calculate the tool axis vector, such as lead and tilt angles, for minimizing the cycle time and enhancing part surface quality. As the current studies do not rely on the drive limits for choosing the tool orientation in multi-axis machining, for the first time, the algorithm represented in this thesis optimizes the tool’s lead and tilt angles at each Cutter Location (CL) point. The technique used in the study optimizes the tool orientation vector for minimizing the cycle time by observing the acceleration and jerk limits of the axis drives of the machine tool. The unnecessary motions between CL points generated by commercial software can be eliminated by the algorithm and this increases the productivity of the process. The feasibility of the algorithm and the models in this thesis is presented on an industrial part geometry where the productivity and machined surface quality improvements are demonstrated

A real-time interpolator for parametric curves

Driven by the ever increasing need for the high-speed high-accuracy machining of freeform surfaces, the interpolators for parametric curves become highly desirable, as they can eliminate the feedrate and acceleration fluctuation due to the discontinuity in the first derivatives along the linear tool path. The interpolation for parametric curves is essentially an optimization problem, and it is extremely difficult to get the time-optimal solution. This paper presents a novel real-time interpolator for parametric curves (RTIPC), which provides a near time-optimal solution. It limits the machine dynamics (axial velocities, axial accelerations and jerk) and contour error through feedrate lookahead and acceleration lookahead operations, meanwhile, the feedrate is maintained as high as possible with minimum fluctuation. The lookahead length is dynamically adjusted to minimize the computation load. And the numerical integration error is considered during the lookahead calculation. Two typical parametric curves are selected for both numerical simulation and experimental validation, a cubic phase plate freeform surface is also machined. The numerical simulation is performed using the software (open access information is in the Acknowledgment section) that implements the proposed RTIPC, the results demonstrate the effectiveness of the RTIPC. The real-time performance of the RTIPC is tested on the in-house developed controller, which shows satisfactory efficiency. Finally, machining trials are carried out in comparison with the industrial standard linear interpolator and the state-of-the-art Position-Velocity-Time (PVT) interpolator, the results show the significant advantages of the RTIPC in coding, productivity and motion smoothness

Novel control approaches for the next generation computer numerical control (CNC) system for hybrid micro-machines

It is well-recognised that micro-machining is a key enabling technology for manufacturing high value-added 3D micro-products, such as optics, moulds/dies and biomedical implants etc. These products are usually made of a wide range of engineering materials and possess complex freeform surfaces with tight tolerance on form accuracy and surface finish.In recent years, hybrid micro-machining technology has been developed to integrate several machining processes on one platform to tackle the manufacturing challenges for the aforementioned micro-products. However, the complexity of system integration and ever increasing demand for further enhanced productivity impose great challenges on current CNC systems. This thesis develops, implements and evaluates three novel control approaches to overcome the identified three major challenges, i.e. system integration, parametric interpolation and toolpath smoothing. These new control approaches provide solid foundation for the development of next generation CNC system for hybrid micro-machines.There is a growing trend for hybrid micro-machines to integrate more functional modules. Machine developers tend to choose modules from different vendors to satisfy the performance and cost requirements. However, those modules often possess proprietary hardware and software interfaces and the lack of plug-and-play solutions lead to tremendous difficulty in system integration. This thesis proposes a novel three-layer control architecture with component-based approach for system integration. The interaction of hardware is encapsulated into software components, while the data flow among different components is standardised. This approach therefore can significantly enhance the system flexibility. It has been successfully verified through the integration of a six-axis hybrid micro-machine. Parametric curves have been proven to be the optimal toolpath representation method for machining 3D micro-products with freeform surfaces, as they can eliminate the high-frequency fluctuation of feedrate and acceleration caused by the discontinuity in the first derivatives along linear or circular segmented toolpath. The interpolation for parametric curves is essentially an optimization problem, which is extremely difficult to get the time-optimal solution. This thesis develops a novel real-time interpolator for parametric curves (RTIPC), which provides a near time-optimal solution. It limits the machine dynamics (axial velocities, axial accelerations and jerk) and contour error through feedrate lookahead and acceleration lookahead operations. Experiments show that the RTIPC can simplify the coding significantly, and achieve up to ten times productivity than the industry standard linear interpolator. Furthermore, it is as efficient as the state-of-the-art Position-Velocity-Time (PVT) interpolator, while achieving much smoother motion profiles.Despite the fact that parametric curves have huge advantage in toolpath continuity, linear segmented toolpath is still dominantly used on the factory floor due to its straightforward coding and excellent compatibility with various CNC systems. This thesis presents a new real-time global toolpath smoothing algorithm, which bridges the gap in toolpath representation for CNC systems. This approach uses a cubic B-spline to approximate a sequence of linear segments. The approximation deviation is controlled by inserting and moving new control points on the control polygon. Experiments show that the proposed approach can increase the productivity by more than three times than the standard toolpath traversing algorithm, and 40% than the state-of-the-art corner blending algorithm, while achieving excellent surface finish.Finally, some further improvements for CNC systems, such as adaptive cutting force control and on-line machining parameters adjustment with metrology, are discussed in the future work section.It is well-recognised that micro-machining is a key enabling technology for manufacturing high value-added 3D micro-products, such as optics, moulds/dies and biomedical implants etc. These products are usually made of a wide range of engineering materials and possess complex freeform surfaces with tight tolerance on form accuracy and surface finish.In recent years, hybrid micro-machining technology has been developed to integrate several machining processes on one platform to tackle the manufacturing challenges for the aforementioned micro-products. However, the complexity of system integration and ever increasing demand for further enhanced productivity impose great challenges on current CNC systems. This thesis develops, implements and evaluates three novel control approaches to overcome the identified three major challenges, i.e. system integration, parametric interpolation and toolpath smoothing. These new control approaches provide solid foundation for the development of next generation CNC system for hybrid micro-machines.There is a growing trend for hybrid micro-machines to integrate more functional modules. Machine developers tend to choose modules from different vendors to satisfy the performance and cost requirements. However, those modules often possess proprietary hardware and software interfaces and the lack of plug-and-play solutions lead to tremendous difficulty in system integration. This thesis proposes a novel three-layer control architecture with component-based approach for system integration. The interaction of hardware is encapsulated into software components, while the data flow among different components is standardised. This approach therefore can significantly enhance the system flexibility. It has been successfully verified through the integration of a six-axis hybrid micro-machine. Parametric curves have been proven to be the optimal toolpath representation method for machining 3D micro-products with freeform surfaces, as they can eliminate the high-frequency fluctuation of feedrate and acceleration caused by the discontinuity in the first derivatives along linear or circular segmented toolpath. The interpolation for parametric curves is essentially an optimization problem, which is extremely difficult to get the time-optimal solution. This thesis develops a novel real-time interpolator for parametric curves (RTIPC), which provides a near time-optimal solution. It limits the machine dynamics (axial velocities, axial accelerations and jerk) and contour error through feedrate lookahead and acceleration lookahead operations. Experiments show that the RTIPC can simplify the coding significantly, and achieve up to ten times productivity than the industry standard linear interpolator. Furthermore, it is as efficient as the state-of-the-art Position-Velocity-Time (PVT) interpolator, while achieving much smoother motion profiles.Despite the fact that parametric curves have huge advantage in toolpath continuity, linear segmented toolpath is still dominantly used on the factory floor due to its straightforward coding and excellent compatibility with various CNC systems. This thesis presents a new real-time global toolpath smoothing algorithm, which bridges the gap in toolpath representation for CNC systems. This approach uses a cubic B-spline to approximate a sequence of linear segments. The approximation deviation is controlled by inserting and moving new control points on the control polygon. Experiments show that the proposed approach can increase the productivity by more than three times than the standard toolpath traversing algorithm, and 40% than the state-of-the-art corner blending algorithm, while achieving excellent surface finish.Finally, some further improvements for CNC systems, such as adaptive cutting force control and on-line machining parameters adjustment with metrology, are discussed in the future work section

Reparameterization of ruled surfaces: toward generating smooth jerk-minimized toolpaths for multi-axis flank CNC milling

This paper presents a novel jerk minimization algorithm in the context of multi-axis flank CNC machining. The toolpath of the milling axis in a flank milling process, a ruled surface, is reparameterized by a B-spline function, whose control points and knot vector are unknowns in an optimization-based framework. The total jerk of the tool's motion is minimized, implying the tool is moving as smooth as possible, without changing the geometry of the given toolpath. Our initialization stage stems from measuring the ruling distance metric (RDM) of the ruled surface. We show on several examples that this initialization reliably finds close initial guesses of jerk-minimizers and is also computationally efficient. The applicability of the presented approach is illustrated by some practical case studies.RYC-2017-2264

A review of dynamics design methods for high-speed and high-precision CNC machine tool feed systems

With the development of CNC machine tools toward high speed and high precision, the traditional static design methods can hardly meet the demand. Hence, in this paper, the dynamics matching design methods of existing CNC machine tool feed systems were investigated and analyzed. Further, sub-system coupling mechanisms and optimization design studies were carried out for each sub-system. First, the required kinematic indexes must be achieved when designing the feed system dynamics of high-speed, high-precision CNC machine tools. Second, the CNC machine tool feed systems generally have four sub-systems: motion process, control system, motor, and mechanical structure. The coupling effect between the sub-systems should also be considered in the design. Based on the dynamics design, each sub-system should be optimized to maximize the system dynamic performance with minimum resource allocation. Finally, based on the review, future research directions within the field were detected

Toolpath interpolation and smoothing for computer numerical control machining of freeform surfaces : a review

Driven by the ever increasing demand in function integration, more and more next generation high value-added products, such as head-up displays, solar concentrators and intra-ocular-lens, etc., are designed to possess freeform (i.e., non-rotational symmetric) surfaces. The toolpath, composed of high density of short linear and circular segments, is generally used in computer numerical control (CNC) systems to machine those products. However, the discontinuity between toolpath segments leads to high-frequency fluctuation of feedrate and acceleration, which will decrease the machining efficiency and product surface finish. Driven by the ever-increasing need for high-speed high-precision machining of those products, many novel toolpath interpolation and smoothing approaches have been proposed in both academia and industry, aiming to alleviate the issues caused by the conventional toolpath representation and interpolation methods. This paper provides a comprehensive review of the state-of-the-art toolpath interpolation and smoothing approaches with systematic classifications. The advantages and disadvantages of these approaches are discussed. Possible future research directions are also offered

Investigation of the Required Discreteness of Interpolation Movement Parameters in Cyber-physical Systems

Improving the accuracy, reliability, and performance of cyber-physical systems such as high-speed machining, laser cutting, welding and cladding etc. is one of the most pressing challenges in modern industry. CNC system carries out data processing and significantly affect on accuracy of operation such equipment. The paper considers the problem of controlled axes motion differential characteristics data processing in the internal representation of the discrete space of the CNC system. Equations for determining the required discreteness of the differential characteristics position and resolution, such as the speed, acceleration, and jerk are proposed. For the most widely used CNC equipment specific discreteness and resolution values have been determined

PSO based feedrate optimization with contour error constraints for NURBS toolpaths

Paper presented at MMAR 2016 conference (Międzyzdroje, Poland, 29 Aug.-1 Sept. 2016)Generation of a time-optimal feedrate profile for CNC machines has received significant attention in recent years. Most methods focus on achieving maximum allowable feedrate with constrained axial acceleration and jerk without considering manufacturing precision. Manufacturing precision is often defined as contour error which is the distance between desired and actual toolpaths. This paper presents a method of determining the maximum feedrate for NURBS toolpaths while constraining velocity, acceleration, jerk and contour error. Contour error is predicted during optimization by using an artificial neural-network. Optimization is performed by Particle Swarm Optimization with Augmented Lagrangian constraint handling technique. Results of a time-optimal feedrate profile generated for an example toolpath are presented to illustrate the capabilities of the proposed method