Sensor-based feed optimization

A method for feed speed optimization, said method comprising:

• collecting time-series data, by a machine controller, for a reference machining cycle performed by a machine tool, where the data includes a tool center point position along a tool path and axial acceleration data from an acceleration sensor mounted to the machine tool for a plurality of time steps, where the acceleration sensor is configured to measure axial acceleration in a direction parallel to a rotational axis of a spindle of the machine tool;
• computing time-series values for an acceleration parameter from the time-series axial acceleration data, including performing a double integral of the time-series axial acceleration data to produce intermediate time-series data, and then computing a moving average of the intermediate time-series data to produce the time-series values for the acceleration parameter;
• determining an acceleration parameter target value as a maximum value from the time-series values for the acceleration parameter over the reference machining cycle;
• computing an optimum feed speed profile including, for each time step in the time-series data, computing a new feed speed as an original feed speed from the reference machining cycle multiplied by a ratio of the acceleration parameter target value to the acceleration parameter for the time step, and pairing the new feed speed with the tool center point position in the optimum feed speed profile;
• and
• using a motion program created with the optimum feed speed profile, by the machine controller, to control the machine tool performing production machining operations.

A machine tool feed speed optimization system, said system comprising:

• a machine tool configured for performing an operation on a workpiece;
• an acceleration sensor mounted to the machine tool and configured to measure axial acceleration in a direction parallel to a rotational axis of a spindle of the machine tool;
• and
• a computing device in communication with the machine tool and the acceleration sensor, said computing device being configured to compute and use an optimum feed speed profile by performing steps including;
• collecting time-series data for a reference machining cycle performed by the machine tool, where the data includes a tool center point position along a tool path and axial acceleration data from the acceleration sensor for a plurality of time steps;
• computing time-series values for an acceleration parameter from the time-series axial acceleration data;
• determining an acceleration parameter target value from the time-series values for the acceleration parameter;
• computing an optimum feed speed profile including, for each time step in the time-series data, computing a new feed speed as an original feed speed from the reference machining cycle multiplied by a ratio of the acceleration parameter target value to the acceleration parameter for the time step, and pairing the new feed speed with the tool center point position in the optimum feed speed profile;
• and
• using a motion program created with the optimum feed speed profile to control the machine tool performing production machining operations.