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UltiMotion Motion Control | Hurco IMTS 2012
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UltiMotion Motion Control | Hurco IMTS 2012

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Hurco's UltiMotion patented motion control technology provides faster cycle times and smoother finishes.

Hurco's UltiMotion patented motion control technology provides faster cycle times and smoother finishes.

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UltiMotion Motion Control | Hurco IMTS 2012 UltiMotion Motion Control | Hurco IMTS 2012 Presentation Transcript

  • UItiMotionSeptember 10, 2012 Paul J. Gray 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 thetool 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 Cycle! Start the race by activating the motion system
  • The Motion SystemPrimary Components
  • The Motion SystemSoftware and hardware that handle the physics of a CNC machine:1. Motion Planning  Co-Driver & Driver2. Motion Control  Driver3. Servo Drives & Motors  Race Car
  • UltiMotion ComponentsSoftware and hardware that handle the physics of a CNC machine:1. Motion Planning  Co-Driver & Driver2. Motion Control  DriverA. Motion Planning • Smoothing • Look-Ahead & dynamic modelB. Control Loop • Feed Forward • Feedback
  • Motion PlanningSmoothing & 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 PlanningCNC Motion Planning includes:1. Smoothing the path within machine tolerances2. Optimizing velocity and acceleration based on the axes physical limits
  • Nominal Path – Centre of track
  • Nominal Path – Centre of trackPath Tolerance – Width of track
  • Nominal Path – Centre of trackPath Tolerance – Width of trackOptimal Path
  • Ultimotion Smoothing• Patented curvature controlled smoothing system• Increases performance and surface finish without sacrificing part accuracy
  • 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)
  • Example Y Y50G01 X60 F2000Y50 X60 X
  • • Cannot accelerate & decelerate Y Y50 instantaneously X60 X X-Axis Y-AxisVelocity Time
  • • S-Curve velocity profile gives Y Y50 smooth motion • X stops before Y starts giving a X60 sharp corner X X-Axis Y-Axis X-Axis Y-AxisVelocity Velocity Time Time Sharp
  • • Add small overlap Y Y50 • Gives micro radius • Cannot detect on part X60 • Significantly improves cycle times X X-Axis Y-Axis X-Axis Y-Axis X-Axis Y-Axis VelocityVelocity Velocity Time Time Time Sharp Micro radius
  • Too much overlap will round corners Y Y50 X60 X X-Axis Y-Axis X-Axis Y-Axis X-Axis Y-Axis X-Axis Y-Axis Velocity VelocityVelocity Velocity Time Time Time Time Sharp Micro Rounded radius 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 X-Axis Y-Axis Velocity Time Micro radius
  • To improve cycle times and surface finish we needMotion Planning 1. Smooth tool paths 2. Good control of velocity, acceleration, and Jerk 3. Robust control loop to handle real-time disturbances and changing loads X-Axis Y-Axis Velocity Time Micro radius The UltiMotion Motion Planning system generates optimal trajectories to squeeze the most out of your machine
  • 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 startStart End Rally Race Stage Driver’s View
  • More Speed Look Farther
  • How far to look?Myth: High block look ahead is necessary for high-speed machiningTruth: 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 LoopFeed Forward and Feedback
  • The Control LoopLook-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
  • Feed ForwardIn a perfect world, themachine would followthe output exactly
  • 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
  • SummaryPutting 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 togetherMotion Planning1. Smooth the path within tolerance2. Look-Ahead: Advanced dynamic velocity, acceleration, and jerk modeling and control Output feeds the Control Loop
  • Putting it all togetherControl Loop1. Feed Forward: Predict control gains / gas, steering, brake input2. Feedback:  Monitor vehicle trajectory, adjust controls if off track  Control monitors encoders and adjusts axes control gains
  • UltiMotion FeaturesWhat can UltiMotion do for you?
  • Superior Tapping Tapping requires tight coordination spindle and linear axesOnly available with UltiMotion1. 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
  • Superior Tapping2. High-Speed Tap Retract  Up to 1000% faster retract out of tapped hole for faster throughput  Master-Slave control ensures accuracy3. Override and motion hold during tapping4. Power loss Tap Recovery
  • E-Stop Tap Recovery
  • E-Stop & Power Loss ControlDuring power loss or E-stop event, Ultimotion can: retract smoothly or hold the controlled position until brake engages even during TappingOn subsequent power-up, UltiMotion can extract the tap from the hole without damaging the thread
  • CustomerTestimonials
  • 3D Solutions40% gain in throughput 1.4 parts for every 1 they were making before UltiMotion Standard Motion 1 hours 40 min 2 hours 20 min
  • American Precision Machining50% gain in throughput 1.5 parts for every 1 they were making before Ultimotion Standard Motion 50 minutes 1 hour 15 minutes
  • WepcoExample 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 dont have to polish the mold! the finish is that good.”Dave Parmlee
  • 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: 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
  • Thank You