UItiMotion September 10, 2012 Paul J. Gray Manager • Path Planning • Front-End Design • R&D
UItiMotionSeptember 10, 2012
Paul J. GrayManager • 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 the tool 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 Interpreter1. Load the part program instructions
(map)
2. Program Interpreter uses• Part & tool setup• Machine Kinematicsto generate machine-specific motion data (pace notes)
3. The data is sent to the motion system for real-time processing
Start the race by activating the motion system
Start Cycle!
The Motion SystemPrimary Components
Software and hardware that handle the physics of a CNC machine:The Motion System
1. Motion Planning Co-Driver & Driver2. Motion Control Driver3. Servo Drives & Motors Race Car
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 & Driver2. Motion Control Driver
Motion PlanningSmoothing & Look Ahead
Motion PlanningCo-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 tolerances
2. 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
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)
What is Look Ahead?
ExampleG01 X60 F2000Y50
Y50
X
Y
X60
• Cannot accelerate & decelerate instantaneously
Y50
X
Y
X60
X-Axis
Time
Velo
city Y-Axis
• S-Curve velocity profile gives smooth motion
• X stops before Y starts giving a sharp corner
Y50
X
Y
X60
X-Axis
Time
Velo
city Y-Axis
TimeVe
loci
ty X-Axis Y-Axis
Sharp
• Add small overlap• Gives micro radius• Cannot detect on part• Significantly improves cycle times
Y50
X
Y
X60
X-Axis
Time
Velo
city Y-Axis Y-Axis
Time
Velo
city X-Axis
TimeVe
loci
ty X-Axis Y-Axis
Sharp Microradius
Too much overlap will round corners Y50
X
Y
X60
X-Axis
Time
Velo
city Y-Axis Y-Axis
Time
Velo
city X-Axis Y-Axis
Time
Velo
city X-Axis
TimeVe
loci
ty X-Axis Y-Axis
Sharp Microradius
Roundedcorner
To improve cycle times and surface finish we need1. Smooth tool paths2. Good control of velocity, acceleration, and Jerk3. Robust control loop to handle real-time disturbances and
changing loads Y-Axis
Time
Velo
city X-Axis
Microradius
Mo
tio
n Pl
anni
ngTo improve cycle times and surface finish we need
1. Smooth tool paths2. Good control of velocity, acceleration, and Jerk3. Robust control loop to handle real-time disturbances and
changing loads Y-Axis
Time
Vel
ocity X-Axis
Microradius
The UltiMotion Motion Planning system generates optimal trajectories to squeeze the most out of your machine
Driver’s View
How far to look?
Start
End
Co-driver calls out a few obstacles ahead of current positionLook Ahead plans the smoothest, fastest trajectoryObstacles at the end are not relevant at the start
Rally Race Stage
More Speed Look Farther
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
UltiMotion Dynamic Look-Ahead
Proprietary, patented systemDynamic variable length Looks as far as it needs toUp to 10,000 blocksNever runs out of data
The Control LoopFeed Forward and Feedback
The Control LoopLook-Ahead
Driver plans the trajectory, accelerations & decelerationsMotion Planning output is the input to the Control Loop
Feed ForwardDriver 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
In a perfect world, the machine would follow the output exactly
Feed Forward
Feedback ControlDriver 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 LoopControl 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 togetherStart with the part program (map)
Putting it all togetherGenerate 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
tolerance
2. Look-Ahead: Advanced dynamic velocity, acceleration, and jerk modeling and controlOutput feeds the Control Loop
Putting it all togetherControl Loop1. Feed Forward: Predict control gains /
gas, steering, brake input
2. Feedback: Monitor vehicle trajectory, adjust controls if off trackControl monitors encoders and adjusts axes control gains
UltiMotion FeaturesWhat can UltiMotion do for you?
Superior TappingTapping requires tight coordination spindle and linear axes
Only available with UltiMotion1. True Master-Slave control
Linear axes are slave to the Spindle (master)The Spindle feedback is the linear axes control loop inputMore accurate tapping
Superior Tapping2. High-Speed Tap Retract
Up to 1000% faster retract out of tapped hole for faster throughputMaster-Slave control ensures accuracy
3. Override and motion hold during tapping
4. Power loss Tap Recovery
E-Stop & Power Loss Control
During power loss or E-stop event, Ultimotion can:retract smoothlyor hold the controlled position until brake engageseven during Tapping
On subsequent power-up, UltiMotion can extract the tap from the hole without damaging the thread
CustomerTestimonials
3D Solutions
Standard Motion2 hours 20 min
40% gain in throughput 1.4 parts for every 1 they were making before
UltiMotion1 hours 40 min
American Precision Machining
Ultimotion Standard Motion50 minutes 1 hour 15 minutes
50% gain in throughput 1.5 parts for every 1 they were making before
WepcoExample from customer states:
S7 tool steel 100 hour part down to 30 hoursOver 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
Who can benefit from UltiMotion?Virtually all industries and partsBoth Conversational and NC users
Particularly:3- through 5-Axis contouringPocketingHigh-Speed Machining
Because of:1. Higher feed rates2. Smoother motion3. Better surface finish4. Higher accuracy
Repetitive drilling due to smoother rapid motionRepetitive tapping from High Speed Tap Retract
Thank You