A Real-Time Collision Prevention System for Machine Tools

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1 Alble onlne Poced CIRP 7 (13 ) Foy Sxh CIRP Confeence on Mnufcung Syem 13 A Rel-Tme Collon Peenon Syem fo Mchne Tool Mco Schumnn*, Mco W, Phlpp Klmn Inue fo Mchne Tool nd Poducon Pocee, Chemnz Uney of Technology, Rechenhne Sße 7, 916 Chemnz, Gemny * Coepondng uho. Tel.: ; fx: E-ml dde: mco.chumnn@mb.u-chemnz.de. Abc Mnufcung pocee become moe nd moe complex. Theefoe collon whn he wokng e of he mchne ool occu moe ofen. Thoe collon ofen led o ool nd wok pece dmge. Epeclly when mchnng ey lge nd complex wok pece, e.g. n he Aeopce Induy, whee uch wok pece dmge ey expene. Addonlly, hee collon could cue he bekge of he whole mchne, whch wll led o downme nd hgh co; epeclly he commonng of he mchne ool nd he wok pece nole hgh k of collon cued by mnul mchnng. In ode o ole h poblem mnufcue offe dffeen peclzed ch poecon mechnm whch he cen conn o lck of genely. Whn h ppe we peen collon peenon yem bed on hull concep whch mono ll mchne xe egdng k of collon whou ung phycl eno. I necey o conde uffcen oppng dnce fo ll mong mchne p o od ch. Thee dnce cn be een hull ound he componen dependng on he mxmum peed nd deceleon lue. Conequenly, we peen n ppoch o cee hee hull, bed on he CAD d of he mchne ool, wok pece well he ool. Th led o ul collon model whch cn be ued npu d fo he collon peenon yem. The dnge well he cuen lmon of he noduced collon peenon yem e dcued bed on mchne ool n opeon. 13 The Auho. Publhed by by Elee B.V. B.V. Open cce unde CC BY-NC-ND lcene. Selecon nd/o pee-eew unde unde eponbly eponbly of Pofeo Pofeo Pedo Flpe Pedo do Flpe Cmo do Cunh Cmo Cunh Keywod: collon peenon; NC mchnng; el-me monong 1. Inoducon Inceng p complexy nd deceng poducon me eul n moe nd moe complex mnufcung pocee. Th led o ng equemen no only fo poce plnne bu lo fo mchne opeo [1]. Mnufcung pocee e uully plnned wh Whle CAM pogm uomclly genee complex mchnng pogm, he poce elf my ll be eoneou. Thee eo nge fom wong NC pogm fo pecfc NC conol un [], wong o mng condeon of he whole mchne ool o clmpng dece [] o opeo eo. Such eo my eul n collon of he mchne ool, wok pece o clmpng dece. Thee collon no only dmge he wok pece o he clmpng dece bu my lo led o dmge he mchne ool. The eulng co of uch collon, de fom eoneou wok pece, depend on he knd nd engh of he collon nd he followng co lke poducon downme. The f wo eo ouce (wong NC pogm, wong o mng condeon of mchne p) cn be peened by ung mchne mulon pogm po o he el poducon poce he el mchne ool wh dued conol un. Howee, opeo eo whch oell ncengly ppe he poce elf ge moe nd moe complex cnno be peened by mulon. The peened collon peenon yem oluon whch deec poenl collon uon dung he cuen wokng poce nd cn heefoe peen eo by he opeo.. Se of he A Fo he l decde lo of ege he been eeched nd mplemened o decee he mpc of collon on he mnufcung pocee (Fg. 1). Newly geneed NC pogm e uully eed hooughly wh mchne mulon pogm po o The Auho. Publhed by Elee B.V. Open cce unde CC BY-NC-ND lcene. Selecon nd pee-eew unde eponbly of Pofeo Pedo Flpe do Cmo Cunh do:1.116/.poc

2 33 Mco Schumnn e l. / Poced CIRP 7 ( 13 ) he el poducon poce he el mchne ool wh dued conol un. Thee mchne mulon pogm mule he whole mchne ool bed on 3D model of he el mchne. Some of hem lo ue Vul Rely o Augmened Rely o enhnce n effec cloe-o-ely [3, 4, 5]. An negon of he el NC conol un no he mulon enonmen lo poble [6, 7]. Thee mchne mulon pogm deec mo eo of he NC pogm. Howee, dung he el poducon poce on el mchne ool hee e ll lo of opeon h cnno be muled wh mchne mulon ofwe. Thee opeon e e.g. ll mnul ue opeon, eup of new wok pece o new ool nd chnge of he clmpng dece dung he poducon poce. Anohe ppoch o peen collon, een dung he opeon, ue exenl eno lke cme yem [8] o le yem [9] o mono he wokng pce. Thee yem e lmed o he eno deecon feld. To educe he mpc of collon on he poce nd heefoe o lm he co of ch, ome yem do no peen he collon elf bu decee he engh of he collon. One exmple of h knd of yem ed he cuen fom he mn pndle. In ce of ch he cuen of he pndle engne ncee nd op gnl wll be en uomclly o ll mong mchne xe [1]. Neehele, hee yem do no peen ch. Offlne Ph Plnnng Senole Poce Plnnng Eleconc Collon Poecon Sege Collon Peene Seno-Bed Wokpce Scnnng Dmge Peene / Dmge Reducng Seno-Bed Poce Accompnyng Senole Onlne Ph Plnnng Toque- Opeed Mechnc Fg. 1 Oeew of poece meue ccodng o [11] Seno-Bed Ph Coecon Foce- Opeed A el collon poecon yem need o know he dmenon nd poon of ll obec n he wokng e of he mchne ool well ll mong mchne xe, ncludng clmpng dece, wok pece, cully eleced ool nd he poge of he chppng poce. The ppoch peened n h ppe ue 3D model of ll mong p whn he wokng e, deec poble che n he 3D model nd op he el mchne ool befoe he el ch occu. 3. Pncple of he Collon Deecon Concep 3.1. Collon Deecon Sequence The peened ppoch con of eel ep whch wll be execued whn n endle loop. In ode o obn n oeew of he bc pocedue he followng enumeon expln he fou mn p of he lgohm: 1. obn lue fo x nd help fom NC conol un. nfom collon model wh hee lue 3. check fo collon dnge 4. end check eul o NC conol un. The coe of he lgohm he ecognon of he oncomng collon dnge (3). A hull-bed oluon popoed n he followng. 3.. Genel Hull Appoch Eey moeble p of he mchne ool poee mxmum peed nd mxmum deceleon lue. The moemen cn be eped no nlon nd oon. Bed on hee lue he mxmum oppng dnce cn be elued. Theefoe, hee dnce mu be clculed fo eey mong decon mchne p cn pefom ( mx n Fg., D cheme fo bee undendng) nd cn be een offe lue fo he CAD geomey whch exend he ognl componen. Th led o c hull ound eey moeble p whch encloe hem. Sc mchne p he nehe peed no oppng dnce nd heefoe need no hull. mx Fg. Moeble p wh offe If collon beween hull occu, he mchne ool h o be opped mmedely. Due o h condeed wy of oppng he collon wll be peened. A ddnge of h c hull concep he ecognon of wong collon uon. Eey me when mchne p moe nely de by de, he hull collon would op he mchne moemen. A ml ce he low moemen beween ne componen whch eul n ecognzed poenl dnge. Th led o unnecey op of he mchne ool und heefoe o unnecey co. One poble oluon fo h he noducon of mulple hull ned of one. The ue of n oue peededucng hull nd n nne op hull defue h poblem gnfcnly. If n oue hull deec collon, he oell peed mu be educed o pedefned lue (peed educon, ee uon n Fg. 3). Th low he mchne ool down, bu doe no op he poce.

3 Mco Schumnn e l. / Poced CIRP 7 ( 13 ) Only f he mlle nne hull collde, he peed wll be e o (ee uon 3 n Fg. 3, D cheme fo bee undendng). Howee, he nne hull much mlle becue of he lowe peed whch w foced by he oue hull. Theefoe, he pobbly of wongly ecognzed op lo much lowe. In heoy h hull concep cn be exended o deed numbe of hull. 1. no hull collon deeced (full peed llowed) componen oue hull 3. nne hull collon deeced (op ode) nne hull. oue hull collon deeced (peed educon) 4. mchne p opped ge peed cuen peed Fg. 3 Ce of collon beween moeble nd mmoeble p 3.3. Hull Clculon The followng deon e mde fo he wo-hull ucue nd mu be dped f nohe numbe of hull deed. The genel ppoch n econ 3. only conde he bekng dnce of he moeble p. Obnng he equed lue fom he NC conol un, clculng he collon e nd endng he eul bck o he NC conol un lo conume me nd mu be condeed when choong he ppope hull ze. Theefoe, econ me mu be noduced whn whch he mchne ool keep mong. Th led o oppng dnce whch he um of econ dnce nd deceleon dnce. The followng npu pmee e equed: mxmum feed e e f ndll mxmum deceleon econ me peed educe fco The educed peed defned f wh f (;1) (1) Tme nel e defned 1 (), (3) The econ me mu be condeed fo boh hull. Two n e poble fo kng no ccoun h ue Vn 1 If collon of he oue hull deeced, he mchne ool moemen dded no eel ep: 1. edy moon peed fo he lengh of econ me ([ ; 1 ] n Fg. 4). deceleed moon unl he educed peed eched nd he deceleon end ([ 1 ;,1 ] n Fg. 4). If he mong decon on collon coue, he nne hull wll lo collde, whch led o: 3. edy moon educed peed fo he lengh of econ me ([,1 ; 3,1 ] n Fg. 4) 4. deceleed moon unl he mchne op ([ 3,1 ; 4,1 ] n Fg. 4). 1 Fg. 4 --dgm fo n 1,1 4,1 3,1 4,1 The deceleon me fo he oue hull f ( 1),1 The deceleon me fo he nne hull e f 4 oppng dnce oue hull oppng dnce nne hull (4) (5) The econ dnce fo he oue hull 1 (6) The deceleon dnce fo he oue hull ( f 1),1, 1 (7) The econ dnce fo he nne hull f (8) 3 The deceleon dnce fo he oue hull ( f ) (9) Th led o n oue hull dnce of (1) The nne hull mu be

4 33 Mco Schumnn e l. / Poced CIRP 7 ( 13 ) (11) Vn If collon of he oue hull ecognzed, he mchne ool moemen wll be dded no eel p: 1. edy moon peed fo he lengh of econ me ([ ; 1 ] n Fg. 5). deceleed moon unl he educed peed eched ([ 1 ;, ] n Fg. 5). If he mong decon on collon coue, he nne hull wll lo collde, whch led o 3. deceleed moon unl he mchne op ([, ; 4, ] n Fg. 5). In con o n 1, he econd edy moon omed. Th cn be cheed by ung n nne hull whch gnl collon whle he mchne p ll n he oue deceleng e. Th men h he econ me ncluded n he me of deceleon fom peed o educed peed., 4 1 oppng dnce oue hull oppng dnce nne hull The econ nd deceleon dnce fo he nne hull 1 ( f ) (17) Th led o n oue hull dnce of 1 14 (18) The nne hull mu be 4 (19) Jek nd Secuy Dnce A he del oppng dnce ppled, he llued clculon led o of ouch of he componen when boh e mong owd ech ohe full peed. No fee pce condeed. Lkewe he ek no p of he clculon. Th led o nccuce. Theefoe, he nfluence of he ek w neged. The ek umed conn: h ( ) () The negon of he ek eul n he funcon fo he dnce: 3 3 ( ) h( ) d (1) 6 The me o ech he mxmum deceleon wh mxmum deceleon () 1, 3, 4, Fg. 5 --dgm fo n The dnce funcon whou ek ( ) (3) A f he peed lm equed whee he nne hull condeng he econ me: 1 f (1) The ene deceleon me 14 4, 1 (13) The educed-e deceleon me 1 f 4 4, 4 (14) The econ dnce fo he oue hull 1 (15) The ene deceleon dnce (16) The eo dnce hen defned d ( ) ( ) d h 6 3 (4) Becue of he edy moon he begnnng, cn be umed. Th led o 3 d (5) 3 The fomul how h he ek nfluence depend on he mxmum deceleon nd he ek elf. Tble 1 Jek nfluence exmple Deceleon n m - Jek n m- 3 Eo dffeence n m

5 Mco Schumnn e l. / Poced CIRP 7 ( 13 ) The eo dffeence mu be comped o he hull dnce o ge pope emen bou he nfluence. Inne hull e mll nd, heefoe, he eo dnce could be gnfcn. Addonlly o he ek he poducon nfluence of he mchne ool componen ply n mpon ole. E.g. hee mel houng cn he embly dffeence n he mllmee nge. Th fc mu be condeed o od collon. Theefoe, uggeed o ue ecuy dnce fo he clculed lue o ke he ek nfluence nd embly dffeence no ccoun. The moun of h offe depend on he clculed hull dnce nd he mchne ool nd e fom ce o ce Compon of he wo Vn Boh n e uble fo clculng he hull lengh n one x decon. Vn 1 eul n gee oue hull whch depend on he peed educon fco. Howee, he nne hull become mlle, whch n dnge. The oppoe pple fo n. The oue hull ndependen fom he peed educon fco nd mlle hn n n 1. Th beho cheed hough gee nne hull. Nomlly he mchne opeo doe no ue he mxmum peed of he mchne ool ey ofen. Addonlly, peed educon h le nfluence on he poce hn mchne op. Theefoe, uggeed o ue n 1 o chee mlle oppng hull wh he dwbck of lghly gee oue hull. 4. Pncple of he Vul Model nd Hull Modelng A hown n Chpe 3, he fundmenl b of he collon peenon yem le whn ul mchne model wh coec collon hull. Ceng wokng ul mchne model no only nclude he hull geneon elf bu lo n opmzed ul model bed on CAD d of he wokng mchne. The f ep o cee h model o opmze he hechy of he CAD d. Common CAD d of wokng mchne gouped ehe bed on p l o bed on poducon. Thee opmzon decbed n [3] e ofen ued fo ul mchne model o mp he coec knemc chn of he wokng mchne. Theefoe, mchne p mu be egouped n ode o goup ll componen whch e mong long mchne x ogehe. The followng xe, on mllng mchne, fo exmple, mu be nged n pen-chld elon o hey follow he moemen of he penl x bu cn be moed ddonlly. The coec ngemen n he hechy, whch mnly equed o epoduce coec knemc chn, epeclly ueful n ode o cee he collon hull n fuhe modelng. The me ue fo flenng of he hechy. All componen of mchne x cn be flened o one ngle p. Fo exmple he houng nd he uppo of mchne x cn be flened o one ngle p. The collon hull of ech flened mchne x cn be ceed epely nd ncluded n he complee ul mchne model fewd. The collon hull of mchne x mu ccoun fo ll moemen of he mchne x, ncludng poble moemen fom penl elon. Theefoe, clculng coec collon hull, hown n chpe 3, cn be que complex nd my be dffeen fo ll decon of he mchne x, dependng on he knemc chn of he wokng mchne. The nex ep fo ceng collon hull o mplfy he model of he mchne x. Th ep educe he numbe of polygon, whch wll educe he clculon me of he collon deecon nd lo ecommended fo ome opeon dung he hull geneon. If he CAD d conn feue (hole, beel o ndd p) my be ueful o educe he componen befoe unfcon. Afe combnng he componen of mchne x, fnl mplfcon hould be ced ou. Th mplfcon lo common ep o cee ul model, hown n [3]. Afe mplfyng nd flenng he mchne x o one ngle p, he l ep o cee he clculed hull. Thee e dffeen ppoche o cee he nceed hull of mchne x. A mple clng of he mchne x, howee, would led o n nccue collon hull. Sclng componen wh undecu, u -hped p, fo exmple, would cee coec oue edge, bu he nne edge of he u hpe would be ncoec hey e moed n he clng decon. Fg. 6 how cled u -hped p comped o boh poon of he mchne p he begnnng nd he end of he hull. A poble wy o cee coec hull would be o copy he p nd moe he p o he begnnng nd end poon of he hull dnce. Combnng he cope of he p cee he equed collon hull. Wh efeence o he exmple (Fg. 6, D cheme fo bee undendng), he dnce beween he coped p mu no be lge hn he wdh of he b o peen n eoneou collon hull. A oluon o cee coec hull wh lge dnce would be ddng ddonl cope beween he ng nd end poon. Howee, he oluon fo ceng he hull by copyng nd unfyng p, by Boolen opeon, fo exmple, ofen ll eoneou he quly nd een pobly of hee opeon e bed on p complexy nd numbe of opeon. Anohe poblem ung h mehod o cee collon hull he geneon of numeou fce, whch wll led o lo of polygon o be hndled fo he collon deecon.

6 334 Mco Schumnn e l. / Poced CIRP 7 ( 13 ) clng componen Fg. 6 Eo n hull ceon ncoec hull copyng Alhough copyng my ply cee coec collon hull, ung hee mehod uch clng nd copyng fo uomed o em-uomed mehod my cee eoneou hull. Th eque mnul hull ceon. Mnul hull ceon ue dffeen mehod lke exuon, cu o copy. In ode o cee coec hull necey o conde eey plne nd edge of mchne x. I my be dffcul nd me-conumng, dependng on he complexy of he componen. 5. Sofwe Demono The peened ppoch w elzed n C++ wndow pplcon. The equed NC-IPC couplng w elzed wh Pofbu. An nefce dele he x d fom ll poon meuemen yem n he mchne ool. Thee x d cn be ued o nfom he collon nd gphc model popely. Collon deecon well-known feld of eech n compue cence. Becue of he lmed me fme, f lgohm e needed o chee he el-me equemen. Appoche of ngle neecon e ey quckly lble n lge numbe. Specl echnque lke ocee o AABB ee llow he ue of hgh numbe of ngle [1]. Theefoe, nglebed oluon w ued o check he hull geomey fo collon. The ued e yem coned of moden mulcoe poceo wh 4 coe, 8GB RAM, n nvd 56 T gphc cd nd 64-b Wndow 7 openg yem. The eed hull model conned ppoxmely 17k o 137k ece nd 15k o 68k ngle. The ege me conumpon w ppoxmely 3-6 m fo ll defned collon e, nd hu ly unde he me lm of 1m (poon conol cycle me) egd he undelyng mchne ool. 6. Concluon nd Fuue Wok The peened yem w fully mplemened nd efed ung lhe. The funconly of he yem could be poed. By men of he peened clculon poble o cee pope hull ound he mchne ool geomey whch coe he equed deceleon dnce. If he mchne ool eche ccl e wll be lowed down o opped. Th peen collon dmge. The mpc on he mchnng poce depend on he knd of poce nd mu be fuhe eeched. The cuen yem h ome ddnge. The effo fo modelng he hull ey hgh nd he yem un on n IPC. Theefoe, he gol fo fuhe deelopmen e o fnd n lgohm fo n uomc hull ceon nd pong he collon peenon yem ono he NC conol compue. Anohe feld of eech le n he The geomey of he el wok pece chnge dynmclly dung he chppng poce. Th led o poblem when ung c hull model fo he ul wok pece. In he peened ppoch we elzed he geomey chnge of he ul wok pece hough eel collon model of he wok pece. Rel-me mel emol would be moe uffcen fo moe pece collon deecon. Refeence [1] ElMghy, H., AlGeddwy, T., Azb, A., ElMghy, W., 11. Chnge n Mnufcung Reech nd Indul Chllenge. Enblng Mnufcung Compeene nd Economc Sunbly, Poceedng of he 4h Inenonl Confeence on Chngeble, Agle, Reconfguble nd Vul poducon (CARV11), Monel, Cnd, Spnge-Velg Beln Hedelbeg, pp. -9. [] Smh, S., 9. Po-poceng hould no wok. Cung Tool Engneeng, Volume 61, Iue 8. [3] Neugebue, R., Klmn, P., Wock, V., 11. Vul-Rely- Bed Smulon of NC Pogm fo Mllng Mchne. Globl Poduc Deelopmen - Poceedng of he h CIRP Degn Confeence, Nne, Fnce, Spnge-Velg Beln Hedelbeg, pp [4] Pchow, G., Röck, S., 4. Hdwe n he Loop Smulon of Mchne Tool. Annl of he CIRP, 53, pp [5] Neugebue, R., Klmn, P., W, M., 1. Relc Mchne Smulon wh Vul Rely. Poced CIRP 45 h CIRP Confeence on Mnufcung Syem 1, ELSEVIER, 3/1 pp [6] Zhng, J., Ong, S.K., Nee, A.Y.C., 1. Degn nd Deelopmen of n n u Mchnng Smulon Syem Ung Augmened Rely Technology. Poced CIRP 45 h CIRP Confeence on Mnufcung Syem 1, ELSEVIER, 3/1, pp [7] Klmn, P., Püzel, F., Neugebue, R., Kuhl, M., Wock, V., 1. Feld of Applcon of Couplng Rel NC Conol Un wh Vul Rely Technology. ASME 1 Inenonl Degn Engneeng Techncl Confeence & Compue nd Infomon n Engneeng Confeence, Chcgo, IL, USA. [8] Tomono, A., 4. Collon peenon mehod fo mchne ool openg p. Jpn Pen [9] hp:// enon_y.hml, [1] Abele, E., Beche, C., Gell, S.C., H, A., Koff, D., 1. Sep owd poecon yem fo mchne ool mn pndle gn ch-cued dmge. Poducon Engneeng, Reech nd Deelopmen 1, WGP, Spnge, Volume 6, Iue 6, pp [11] Abele, E., Koff, D., 11. Aodnce of collon cued pndle dmge Chllenge, mehod nd oluon fo hgh dynmc mchne ool. CIRP Annl Mnufcung Technology, Elee, Mnchee, 6/1 pp [1] Akenne-Mölle, T., Hne, E., Hoffmnn, N., 8. Rel-Tme Rendeng Thd Edon. A K Pee, p