UItiMotion Paul J. Gray , Ph.D. Manager Path Planning Front-End - - PowerPoint PPT Presentation

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UItiMotion Paul J. Gray , Ph.D. Manager Path Planning Front-End - - PowerPoint PPT Presentation

Jan 21, 2024 579 likes •1.17k views

UItiMotion Paul J. Gray , Ph.D. 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

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SLIDE 1

UItiMotion

Paul J. Gray, Ph.D.

Manager • Path Planning

  • Front-End Design
  • R&D
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SLIDE 2

What is UltiMotion?

  • An entirely new software-based

motion control system

  • Wholly owned by Hurco
  • Awarded 4 patents
  • Superior to Hurco Standard

Motion

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SLIDE 3

Machining a part is a lot like running a race

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The Part Program is the tool path map of the track

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Interpret the Race Track

Race team generates the strategy and pace notes that describe the obstacles and markers in the course

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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

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 Start the race by activating the motion system

Start Cycle!

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The Motion System

Primary Components

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SLIDE 9

Software and hardware that handle the physics of a CNC machine:

The Motion System

1. Motion Planning  Co-Driver & Driver 2. Motion Control  Driver 3. Servo Drives & Motors  Race Car

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SLIDE 10

Software and hardware that handle the physics of a CNC machine:

UltiMotion Components

  • A. Motion Planning
  • Smoothing
  • Look-Ahead & dynamic model
  • B. Control Loop
  • Feed Forward
  • Feedback

1. Motion Planning  Co-Driver & Driver 2. Motion Control  Driver

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SLIDE 11

Motion Planning

Smoothing & Look Ahead

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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

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Motion Planning

CNC Motion Planning includes: 1. Smoothing the path within machine tolerances 2. Optimizing velocity and acceleration based

  • n the axes physical limits
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Nominal Path – Centre of track

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

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Nominal Path – Centre of track Path Tolerance – Width of track Optimal Path

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Ultimotion Smoothing

  • Patented curvature controlled

smoothing system

  • Increases performance and

surface finish without sacrificing part accuracy

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SLIDE 18
  • Co-driver calls out the pace notes ahead of
  • bstacles
  • Driver anticipates the speed to navigate
  • bstacles 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)

What is Look Ahead?

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SLIDE 19

Example G01 X60 F2000 Y50

Y50 X Y X60

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  • Cannot accelerate & decelerate

instantaneously

Y50 X Y X60

X-Axis

Time Velocity

Y-Axis

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SLIDE 21
  • S-Curve velocity profile gives

smooth motion

  • X stops before Y starts giving a

sharp corner

Y50 X Y X60

X-Axis

Time Velocity

Y-Axis

Time Velocity

X-Axis Y-Axis Sharp

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SLIDE 22
  • Add small overlap
  • Gives micro radius
  • Cannot detect on part
  • Significantly improves cycle times

Y50 X Y X60

X-Axis

Time Velocity

Y-Axis Y-Axis

Time Velocity

X-Axis

Time Velocity

X-Axis Y-Axis Sharp Micro radius

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SLIDE 23

Too much overlap will round corners

Y50 X Y X60

X-Axis

Time Velocity

Y-Axis Y-Axis

Time Velocity

X-Axis Y-Axis

Time Velocity

X-Axis

Time Velocity

X-Axis Y-Axis Sharp Micro radius Rounded corner

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SLIDE 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

Y-Axis

Time Velocity

X-Axis Micro radius

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SLIDE 25

Motion Planning

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

Y-Axis

Time Velocity

X-Axis Micro radius

The UltiMotion Motion Planning system generates optimal trajectories to squeeze the most out of your machine

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SLIDE 26

Driver’s View

How far to look?

Start End

  • 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

Rally Race Stage

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SLIDE 27

More Speed Look Farther

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SLIDE 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

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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

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The Control Loop

Feed Forward and Feedback

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The Control Loop

Look-Ahead

  • Driver plans the trajectory, accelerations & decelerations
  • Motion Planning output is the input to the Control Loop
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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
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SLIDE 33

In a perfect world, the machine would follow the output exactly

Feed Forward

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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

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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

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The UltiMotion Control Loop

  • Dynamic velocity, acceleration,

and Jerk modeling and control

  • Advanced digital filters for

vibration control and smooth motion

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Summary

Putting it all together

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Putting it all together

  • Start with the part program (map)
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SLIDE 39

Putting it all together

  • Generate machine-specific motion data using part & tool setup

and machine Kinematics (pace notes)

  • Start Cycle begins the race
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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
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SLIDE 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

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UltiMotion Features

What can UltiMotion do for you?

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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
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SLIDE 44
  • 1. True Master-Slave control

Example—Badly tuned spindle

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SLIDE 45
  • 1. True Master-Slave control

Example—Badly tuned spindle

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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
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SLIDE 47

E-Stop Tap Recovery

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SLIDE 48

E-Stop Tap Recovery

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E-Stop & Power Loss Control

During power loss or E-stop event, Ultimotion can:

  • retract smoothly
  • r 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

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Customer Testimonials

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3D Solutions

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

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American Precision Machining

Ultimotion Standard Motion 50 minutes 1 hour 15 minutes 50% gain in throughput 1.5 parts for every 1 they were making before

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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

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High-Speed Machining

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UltiMotion Standard Motion

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High-Speed Machining

  • Identical

programs

  • 29% cycle time

reduction

  • Better surface

finish

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Who can benefit from UltiMotion?

  • Virtually all industries and parts
  • Both Conversational and NC users

Particularly:

  • 3- through 5-Axis contouring
  • Pocketing
  • High-Speed Machining

Because of: 1. Higher feed rates 2. Smoother motion 3. Better surface finish 4. Higher accuracy

  • Repetitive drilling due to smoother rapid motion
  • Repetitive tapping from High Speed Tap Retract
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Thank You