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