1. Proposal of the problem
It is now common for CNC machine tools to maintain a constant feed rate during machining, which is preset by the machining program. In order to ensure the safety of production, the compiler must set the feed rate according to the maximum load condition, but in fact this condition may only account for 5% of the entire process. So how to improve the machining efficiency of CNC machine tools, optimize the tool feed, and automatically protect the spindle system of the machine tool and expensive tools without damage has become a concern of end users and machine tool manufacturers. In order to solve this problem, Israel OMAT has applied adaptive control technology to CNC machine tools and developed a mature product, the OMAT CNC machine tool adaptive system, which has been widely used in the world.
2, the working principle
The adaptive control technology is applied to CNC machining by detecting the load of the machine tool spindle, using the internal expert system to analyze the collected spindle load signal and the corresponding tool and workpiece material data, and calculate the optimal feed of the machine tool in real time. The rate is applied to the CNC machining process, which greatly increases the production efficiency, and controls the feed rate stably, continuously and automatically during the machining process, and realizes the dynamic tool protection function (as shown in Fig. 1).
Figure 1 Adjust the tool feed rate in real time according to the change of cutting conditions
In the process of processing, the adaptive control system can learn and re-learn according to the input and output data of the control object, continuously identify the model parameters and correct them. As the production process continues, the model becomes more and more accurate, closer to reality, and finally adjusts itself to an optimal working state to optimize the machining process.
3, the main function
1) Greatly improve processing efficiency
The OMAT adaptive control system samples the load change of the machine tool spindle in real time, increases the feed rate under the condition of small load, reduces the feed rate under the condition of large load, and achieves the purpose of shortening the processing cycle and improving the processing efficiency.
2) Protect tools, machine tools and workpieces from damage
Conventional machining tool breakage is undetectable and control, tool wear is manually monitored, and efficiency is low. Under the control of the adaptive control system, the machining parameters are automatically adapted to the tool load and cutting conditions in real time. If an unexpected event occurs during processing, such as an impact on the tool or workpiece, the diameter of the workpiece blank increases too much, etc., the adaptive control system automatically reduces the feed rate to the safety value allowed by the internal expert system. If necessary, force the machine to stop. When these emergencies pass, the system increases the feed rate to the maximum allowed by the internal expert system, thereby effectively protecting the tool, reducing tool wear and thus extending tool life.
The OMAT adaptive control system has the following protection features:
Milling cutter break protection (alarm and stop to prevent damage to workpiece and subsequent tools)
Deep hole drill prop break protection (alarm and stop)
Tool wear monitoring (digital display wear)
Spindle overload protection (alarm or shutdown)
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