Machine process controller

A method of adaptively controlling an automated machine having a tool for machining a workpiece, said method comprising:

• storing an air cut feed rate value in a memory for determining the machine feed rate when the tool is not in contact with the workpiece;
• storing an impact feed rate in a memory for determining the machine feed rate upon initial impact between the machine tool and workpiece;
• storing a selected adaptive power level in a memory for determining the desired machine power consumption during normal machine operation after impact;
• sensing the power consumed by the machine;
• comparing said machine power consumption with a preselected limit value;
• driving said machine at the air cut feed rate until the machine power consumption exceeds said limit value;
• driving said machine at said impact feed rate for a predetermined amount of time to stabilize machine operation once the power consumption has exceeded the limit value;
• and
• thereafter, driving said machine at a feed rate necessary to maintain the machine power consumption at the adaptive power level.

In a controller for a machine having a tool for machining a workpiece, said controller having at least one dedicated output line coupled to a switch for altering the machining operation upon occurrence of an alarm signal, the improvement comprising:

• means responsive to both external manual and internal machine-generated requests to force the output line to a reset condition;
• alarm means for generating an alarm signal when a machine parameter exceeds a predetermined limit;
• and
• individually programmable means operative in a first programmed condition to place the output line in a switch activating state only for so long as the alarm signal persists, and operative in a second programmed condition to place the output line in the switch activating state upon occurrence of the alarm signal and until reset by the means to force, whereby an operator may selectively choose, via the individually programmable means, a latching or nonlatching switch activating state of said output line to control the machine operation.

In a machine controller for adaptively controlling the relative feed rate of the machine as a function of the error between a preselected value of a parameter and the actual parameter generated by the machine, the improvement comprising:

• feed rate change means for generating a feed rate change value as a function of the error;
• means defining a nonreactive window for disabling said feed rate change means when the error is below a preselected value;
• and
• means for adjusting the nonreactive window to adapt the controller to different machining applications thereby insuring stability.

In a machine controller for adaptively controlling the relative feed rate of the machine as a function of error between a preselected value of a machine parameter and the actual value of the parameter generated by the machine, the improvement comprising:

• feed rate change means for generating a feed rate change value as a function of error;
• individually programmable means for selecting a response factor for affecting the controller response to the error;
• adjustment means for adjusting the feed rate change value as a function of the response factor;
• and
• means for altering the machine feed rate according to the value of the adjusted feed rate change value.

In a machine controller for controlling the relative feed rate of a machine having a motor for effecting the feed rate between a workpiece and a tool, the improvement comprising:

• means for generating a digital output signal whose contents is a function of the desired feed rate;
• means for sensing the maximum and minimum operating voltage levels of the motor;
• buffer means having a plurality of inputs for receiving said digital signal, and a plurality of outputs, operative to provide signals on its outputs at voltage levels which are a function of the contents of the digital signal and the operating voltage levels of the motor;
• wherein the output signals from the buffer are automatically referenced to the operating voltage levels of the motor so that they may be utilized to control the motor at the desired feed rate.

In a controller for an automated machine having the capability of performing a plurality of different machining operations, said controller having at least one dedicated output line coupled to the machine capable of altering the machining operation depending on the state of the output line, the improvement comprising:

• manually selectable means for selecting section parameters associated with each machining operation, said section parameters including (a) a first limit value defining a first extreme level of machine power consumption;
• (b) a second limit value defining a second extreme level of machine power consumption;
• (c) a first timer value defining a first delay time period associated with said first limit value;
• (d) a second timer value defining a second delay time period associated with said second limit value;
• and (e) a status control selection for latching or nonlatching the state of the controller dedicated output line when overlimit conditions are detected;
• manually selectable means for assigning each section with an identification tag;
• memory means for storing a plurality of different sections along with their respective identification tags in a memory;
• means in the machine for generating the appropriate section identification tag for each different machining operation such that the controller will utilize the identified section parameters for monitoring the particular machining operation to be performed;
• means for monitoring the power consumed by the machine;
• comparison means for comparing the machine power consumption with said first and second limit values, operative to change the state of the controller dedicated output line if either of said limit values have been continuously exceeded for their respective delay time periods;
• and
• means for maintaining the changed state of the dedicated controller output line regardless of subsequent sensed levels of machine power consumption if the status control selection indicates that the output line is to be latched, and otherwise returning the state of the output line to its original state when machine power consumption is again below said first and second limit values if the status control selection indicates a desired nonlatched condition.