Method, system, and apparatus for on-demand integrated adaptive control of machining operations

Abstract

A method, system, and apparatus for an adaptive controller for controlling a machining operation on a workpiece by a machining tool are provided. The system includes a sensor for measuring a present value of a spindle load on a spindle drive, and an adaptive controller for comparing the present value of the spindle load to a present value of a target spindle load. The adaptive controller includes a computing element configured to determine a first feed rate value of a machining tool, and a number generator configured to generate a first feed rate dither adjustment value used for adding noise to the first feed rate value. The adaptive controller is configured to control the feed rate of the machining tool relative to the workpiece to maintain the present value of the spindle load approximately equal to the present value of the target spindle load using one or more of the first feed rate value, the first feed rate dither adjustment value, and the second feed rate dither adjustment value.

1 . An adaptive controller for controlling a machining operation on a workpiece by a machining tool, said adaptive controller comprising:
 a computing element configured to determine a first feed rate value of a machining tool;   a number generator communicatively coupled to said computing element, said number generator configured to generate a first feed rate dither adjustment value, the first feed rate dither adjustment value used for adding noise to the first feed rate value, said number generator configured to receive a second feed rate dither adjustment value, wherein the second feed rate dither adjustment value is a previously generated feed rate dither adjustment value;   said adaptive controller configured to control a feed rate of the machining tool to maintain a present value of a spindle load approximately equal to a present value of the target spindle load using one or more of the first feed rate value, the first feed rate dither adjustment value, and the second feed rate dither adjustment value.   
     
     
         2 . An adaptive controller according to  claim 1 , wherein said adaptive controller is configured to receive the present value of the target spindle load from one or more of a user and a control system communicatively coupled to the adaptive controller. 
     
     
         3 . An adaptive controller according to  claim 2 , wherein said adaptive controller is configured to be activated only after the present value of the spindle load exceeds a threshold spindle load value, said adaptive controller configured to receive the threshold spindle load value from one or more of a user and a control system communicatively coupled to the adaptive controller. 
     
     
         4 . An adaptive controller according to  claim 3 , wherein said adaptive controller is configured to adjust the present value of the target spindle load using a spindle load scaling parameter that, one or more of increases and decreases the present value of the target spindle load, said adaptive controller is further configured to receive the spindle load scaling parameter from one or more of a user and a control system communicatively coupled to the adaptive controller. 
     
     
         5 . An adaptive controller according to  claim 4 , wherein said adaptive controller is configured to pause the feed rate of the machining tool relative to the workpiece by setting the first feed rate value to zero while the present value of the target spindle load, after being adjusted with the spindle load scaling parameter, is less than the threshold spindle load value. 
     
     
         6 . An adaptive controller according to  claim 1 , wherein said number generator generates one or more of a random and pseudo-random first feed rate dither adjustment value from within a range of values having a minimum value and a maximum value, said number generator configured to receive the minimum value and the maximum value from one or more of a user and a control system communicatively coupled to the adaptive controller. 
     
     
         7 . An adaptive controller according to  claim 6 , wherein said number generator is configured to generate a first feed rate dither adjustment value only after a predetermined time period has elapsed after a previous second feed rate dither adjustment value was generated by said number generator, said number generator configured to receive the time period value from one or more of a user and a control system communicatively coupled to the adaptive controller. 
     
     
         8 . An adaptive control system for controlling a machining operation on a workpiece by a machining tool, said system comprises:
 a sensor for measuring a present value of a spindle load on a spindle drive; and   an adaptive controller for comparing the present value of the spindle load to a present value of a target spindle load, said adaptive controller includes:   a computing element configured to determine a first feed rate value of a machining tool, and   a number generator configured to generate a first feed rate dither adjustment value, the first feed rate dither adjustment value used for adding noise to the first feed rate value;   said adaptive controller configured to control the feed rate of the machining tool relative to the workpiece to maintain the present value of the spindle load approximately equal to the present value of the target spindle load using one or more of the first feed rate value, the first feed rate dither adjustment value, and the second feed rate dither adjustment value.   
     
     
         9 . An adaptive control system according to  claim 8 , wherein said adaptive controller is configured to receive the present value of the target spindle load from one or more of a user and a control system communicatively coupled to the adaptive controller. 
     
     
         10 . An adaptive control system according to  claim 9 , wherein said adaptive controller is configured to be activated only after the present value of the spindle load exceeds a threshold spindle load value, said adaptive controller configured to receive the threshold spindle load value from one or more of a user and a control system communicatively coupled to the adaptive controller. 
     
     
         11 . An adaptive control system according to  claim 10 , wherein said adaptive controller is configured to adjust the present value of the target spindle load with a spindle load scaling parameter that, one or more of, increases and decreases the present value of the target spindle load, said adaptive controller is configured to receive the spindle load scaling parameter from one or more of a user and a control system communicatively coupled to the adaptive controller. 
     
     
         12 . An adaptive control system according to  claim 11 , wherein said adaptive controller is configured to pause the feed rate of the machining tool relative to the workpiece by adjusting the feed rate to zero while the present value of the target spindle load, after being adjusted with the spindle load scaling parameter, is less than the threshold spindle load value. 
     
     
         13 . An adaptive control system according to  claim 8 , wherein said number generator generates the first feed rate dither adjustment value from within a range of values having a minimum value and a maximum value, said number generator configured to receive the minimum value and the maximum value from one or more of a user and a control system communicatively coupled to the adaptive controller. 
     
     
         14 . An adaptive control system according to  claim 13 , wherein said number generator generates a new, first feed rate dither adjustment value only after a predetermined time period has elapsed after a previous, second feed rate dither adjustment value was generated by said number generator, said number generator configured to receive the time period value from one or more of a user and a control system communicatively coupled to the adaptive controller. 
     
     
         15 . A method of controlling a machining operation on a workpiece by a machining tool, said method comprises:
 measuring a present value of a spindle load developed by a spindle drive rotating a machining tool;   comparing the present value of the spindle load to a present value of a target spindle load;   determining a first feed rate value for the machining tool using the comparison;   generating a first feed rate dither adjustment value;   combining the first feed rate dither adjustment value with the first feed rate value such that noise is added to the first feed rate value based on the first feed rate dither adjustment value; and   controlling the feed rate of the machining tool relative to the workpiece to maintain the present value of the spindle load approximately equal to the present value of the target spindle load using one or more of the first feed rate value, the first feed rate dither adjustment value, and the second feed rate dither adjustment value.   
     
     
         16 . A method according to  claim 15 , further comprising receiving the present value of the target spindle load from one or more of a user and a control system communicatively coupled to the adaptive controller. 
     
     
         17 . A method according to  claim 15 , further comprising adjusting the present value of the target spindle load using a spindle load scaling parameter that, one or more of, increases and decreases the present value of the target spindle load. 
     
     
         18 . A method according to  claim 17 , further comprising receiving the spindle load scaling parameter value from one or more of a user and a control system communicatively coupled to the adaptive controller. 
     
     
         19 . A method according to  claim 15 , further comprising randomly generating the first feed rate dither adjustment value from within a predetermined range of values having a minimum value and a maximum value, wherein the minimum value and the maximum value are received from one or more of a user and a control system communicatively coupled to the adaptive controller. 
     
     
         20 . A method according to  claim 19 , further comprising generating the first feed rate dither adjustment value only after a predetermined time period has elapsed after a previous second feed rate dither adjustment value has been generated. 
     
     
         21 . A method according to  claim 19 , further comprising receiving the time period value from one or more of a user and a control system communicatively coupled to the adaptive controller.