Real time machining process monitoring utilizing preprocess simulation

A method of monitoring operation of a machine tool, wherein operation of the machine tool causes a tool carried by the machine tool to move along a tool path, the tool path comprising a plurality of sequential tool positions, the method comprising:

• a. simulating operation of the machine tool on a computer;
• b. for at least one respective simulated operating condition corresponding to each respective one of a plurality of the plurality of sequential tool positions, determining during the simulating step at least one respective predicted value for each of the at least one simulated operating condition;
• c. determining at least one actual value of a respective operating condition experienced by said machine tool during operation while at an associated one of said plurality of sequential tool positions;
• d. comparing the at least one actual value to the at least one respective predicted value of the simulated operating condition corresponding to the respective operating condition associated with the at least one respective actual value;
• and
• e. adjusting operation of the machine tool if based on the comparison said at least one actual value is not within a range containing the respective predicted value.

A machining system comprising:

• a. a real machine tool, the real machine tool configured to provide, to a monitoring system, for each respective one of a plurality of sequential tool positions at least one respective actual value of each of at least one operating condition resulting from operation of the machine tool at that respective one of the plurality of sequential tool positions;
• b. a computer configured to:
• i. simulate operation of the machine tool by modeling the execution of a plurality of motion steps corresponding to a NC program;
• and
• ii. for at least one respective simulated operating condition corresponding to each respective one of a plurality of the plurality of motion steps, calculate at least one respective predicted value for each of the at least one simulated operating condition;
• c. the monitoring system configured to:
• i. compare each respective actual value to the predicted value of the corresponding simulated operating condition that corresponds to the operating condition of the respective actual value at the tool position that matches the motion step;
• and
• ii. send a command to the real machine tool if the compared respective actual value falls outside of a range which contains the predicted value;
• and
• d. the machine tool configured to act in response to said command, the act being selected from the group consisting of adjusting tool feed rate and stopping the operation of the tool.

A machining system comprising:

• a. a real machine tool comprising a machine tool controller, the real machine tool configured:
• i. to operate at least one tool to machine a workpiece;
• and
• ii. to provide at least one respective actual value of an associated operating condition experienced by said machine tool during operation;
• b. a computer configured to
• i. simulate a plurality of simulated operating conditions by simulating execution of instructions;
• and
• ii. determine, by simulating execution of the instructions, at least one respective predicted value corresponding to a respective one of the plurality of simulated operating conditions;
• c. a monitoring system configured to
• i. compare said at least one respective actual value to the respective predicted value of the simulated operating condition that corresponds to said associated operating condition;
• and
• ii. send a command to said machine controller if said at least one respective actual value is not within a range containing the respective predicted value for more than a predetermined period of time;
• and
• d. the machine tool controller configured to act in response to said command, the act comprising adjusting operation of the machine tool.

A machining system comprising:

• a. a real machine tool, the real machine tool configured to provide for each respective one of a plurality of sequential tool positions at least one respective actual value of each of at least one operating condition experienced by said machine tool during operation of the machine tool at that respective one of the plurality of sequential tool positions;
• b. a computer configured to
• i. simulate a plurality of simulated operating conditions by simulating execution of instructions;
• and
• ii. determine, by simulating execution of the instructions, at least one respective predicted value corresponding to a respective one of the plurality of simulated operating conditions;
• c. a monitoring system configured to compare said at least one respective actual value to the respective predicted value of the simulated operating condition that corresponds to said associated operating condition, and
• d. the machine tool configured to adjust operation of the machine based on an indication that said at least one actual value is not within a range containing the respective predicted value.