Feedrate planning for machining with industrial six-axis robots

The authors want to thank Stäubli for providing the necessary information of the controller, Dynalog for its contribution to the experimental validations and X. Helle for its material contributions.Nowadays, the adaptation of industrial robots to carry out high-speed machining operations is strongly required by the manufacturing industry. This new technology machining process demands the improvement of the overall performances of robots to achieve an accuracy level close to that realized by machine-tools. This paper presents a method of trajectory planning adapted for continuous machining by robot. The methodology used is based on a parametric interpolation of the geometry in the operational space. FIR filters properties are exploited to generate the tool feedrate with limited jerk. This planning method is validated experimentally on an industrial robot

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

High-performance NC for high-speed machining by means of polynomial trajectories

International audienceThis paper summarises works carried out for defining tool trajectory formats well adapted to High Speed Machining (HSM). Advantages in using native polynomial formats, calculated directly from the CAD model, are highlighted. In particular, polynomial surface formats are presented as a generic format for tool trajectory. Illustrations show that surface formats represent a good compromise between smoothness machining time, and surface quality

Feedrate planning for machining with industrial six-axis robots

The authors want to thank Stäubli for providing the necessary information of the controller, Dynalog for its contribution to the experimental validations and X. Helle for its material contributions.International audienceNowadays, the adaptation of industrial robots to carry out high-speed machining operations is strongly required by the manufacturing industry. This new technology machining process demands the improvement of the overall performances of robots to achieve an accuracy level close to that realized by machine-tools. This paper presents a method of trajectory planning adapted for continuous machining by robot. The methodology used is based on a parametric interpolation of the geometry in the operational space. FIR filters properties are exploited to generate the tool feedrate with limited jerk. This planning method is validated experimentally on an industrial robot

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

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

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