UItiMotion. Paul J. Gray, Ph.D. Manager Path Planning Front-End Design R&D

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1 UItiMotion Paul J. Gray, Ph.D. 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 Co-driver interprets pace notes Motion Planning Calls out upcoming obstacles to the driver Driver plans smoothest, fastest trajectory within bounds of the track and vehicle limits

13 CNC Motion Planning includes: Motion Planning 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 Path Tolerance Centre of track Width of track

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

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 G01 X60 F2000 Y50 Y X60 X Y50

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

21 Velocity Velocity S-Curve velocity profile gives smooth motion Y Y50 X stops before Y starts giving a sharp corner X60 X X-Axis Y-Axis X-Axis Y-Axis Time Time Sharp

22 Velocity Velocity Velocity Add small overlap Gives micro radius Y Y50 Cannot detect on part X60 Significantly improves cycle times X X-Axis Y-Axis X-Axis Y-Axis X-Axis Y-Axis Time Time Time Sharp Micro radius

23 Velocity Velocity Velocity Velocity 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 Time Time Time Time Sharp Micro radius Rounded corner

24 Velocity 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 Time Micro radius

25 Motion Planning Velocity 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 Time Micro radius The UltiMotion Motion Planning system generates optimal trajectories to squeeze the most out of your machine

26 Start 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 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 In a perfect world, the machine would follow the output exactly Feed Forward

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 Control Loop Putting it all together 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 1. True Master-Slave control Example Badly tuned spindle

45 1. True Master-Slave control Example Badly tuned spindle

46 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

47 E-Stop Tap Recovery

48 E-Stop Tap Recovery

49 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

50 Customer Testimonials

51 3D Solutions 40% gain in throughput 1.4 parts for every 1 they were making before UltiMotion 1 hours 40 min Standard Motion 2 hours 20 min

52 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

53 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

54 High-Speed Machining

55 UltiMotion Standard Motion

56 High-Speed Machining Identical programs 29% cycle time reduction Better surface finish

57 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

58 Thank You

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