Ultimotion is a new software-based motion control system developed by Hurco, awarded four patents, that enhances CNC machining through superior motion planning and control. It optimizes trajectories with features like dynamic look-ahead, smoothing, and a robust control loop to improve cycle times and surface finishes, achieving impressive gains in efficiency for various industries. The system is particularly beneficial for applications requiring high-speed machining, accurate tapping, and smooth motion, resulting in significantly enhanced throughput and part quality.

1. UItiMotion
September 10, 2012
Paul J. Gray
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. Nominal Path – Centre of track

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

16. Nominal Path – Centre of track
Path Tolerance – Width of track
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
Y50 X60
X

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

21. • 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-Axis
Velocity
Velocity
Time Time
Sharp

22. • 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
Velocity
Velocity
Velocity
Time Time Time
Sharp Micro
radius

23. 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
Velocity
Velocity
Velocity
Time Time Time Time
Sharp Micro Rounded
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 X-Axis Y-Axis
Velocity
Time
Micro
radius

25. To improve cycle times and surface finish we need
Motion 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

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
Rally Race Stage Driver’s View

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. 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

45. 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

46. Customer
Testimonials

47. 3D Solutions
40% gain in throughput 1.4 parts for every 1 they were making before
UltiMotion Standard Motion
1 hours 40 min 2 hours 20 min

48. 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

49. 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

50. 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

51. Thank You