The present invention provides an on-machine real-time measurement method and system for a full-closed loop five-axis computer numerical control machine tool. In the system, a high-precision coaxial fixture in a displacement measurement component is used for connecting the component with the machine tool spindle; a multifunctional evaluation electronics box reads the signals of the grating scale of each machine axis in real time, and synchronously triggers the displacement sensor to collect the measured workpiece surface information; a synchronous communication module caches the grating scale signals of each machine axis and the measurement signals of the sensor to the FIFO rotation buffering module of the host computer in parallel to reduce the burden of high-speed transmission; and the host computer performs data processing and coordinate transformation of the grating scale data and the measurement information in the FIFO module, and finally obtains the three-dimensional geometric information of the measured workpiece surface.

The present invention provides an on-machine real-time measurement method and system for a full-closed loop five-axis computer numerical control machine tool. In the system, a high-precision coaxial fixture in a displacement measurement component is used for connecting the component with the machine tool spindle; a multifunctional evaluation electronics box reads the signals of the grating scale of each machine axis in real time, and synchronously triggers the displacement sensor to collect the measured workpiece surface information; a synchronous communication module caches the grating scale signals of each machine axis and the measurement signals of the sensor to the FIFO rotation buffering module of the host computer in parallel to reduce the burden of high-speed transmission; and the host computer performs data processing and coordinate transformation of the grating scale data and the measurement information in the FIFO module, and finally obtains the three-dimensional geometric information of the measured workpiece surface.

A servo controller includes a speed command creation unit, a torque command creation unit, a speed detection unit, a speed control loop, a speed control gain, a filter, a parameter storage unit, a sinusoidal disturbance input unit, a frequency characteristics calculation unit, and a parameter adjustment unit. The parameter storage unit stores a history of past frequency characteristics obtained by the frequency characteristics calculation unit in correlation with past parameter history.

A servo controller includes a speed command creation unit, a torque command creation unit, a speed detection unit, a speed control loop, a speed control gain, a filter, a parameter storage unit, a sinusoidal disturbance input unit, a frequency characteristics calculation unit, and a parameter adjustment unit. The parameter storage unit stores a history of past frequency characteristics obtained by the frequency characteristics calculation unit in correlation with past parameter history.

A servo controller includes a speed command creation unit, a torque command creation unit, a speed detection unit, a speed control loop, a speed control gain, a sinusoidal disturbance input unit, an actual frequency characteristics calculation unit, a reference characteristics changing unit, a reference frequency characteristics calculation unit, and a control gain adjustment unit. The sinusoidal disturbance input unit changes a frequency sequentially, a reference frequency characteristics calculation unit calculates reference frequency characteristics for characteristics designated by the reference characteristics changing unit sequentially for respective frequencies, the actual frequency characteristics calculation unit calculates actual frequency characteristics of a control system sequentially for respective frequencies, and the reference frequency characteristics calculation unit stores a characteristic formula of the reference characteristics changing unit when the reference frequency characteristics and the actual frequency characteristics match most closely.

A servo controller includes a speed command creation unit, a torque command creation unit, a speed detection unit, a speed control loop, a speed control gain, a sinusoidal disturbance input unit, an actual frequency characteristics calculation unit, a reference characteristics changing unit, a reference frequency characteristics calculation unit, and a control gain adjustment unit. The sinusoidal disturbance input unit changes a frequency sequentially, a reference frequency characteristics calculation unit calculates reference frequency characteristics for characteristics designated by the reference characteristics changing unit sequentially for respective frequencies, the actual frequency characteristics calculation unit calculates actual frequency characteristics of a control system sequentially for respective frequencies, and the reference frequency characteristics calculation unit stores a characteristic formula of the reference characteristics changing unit when the reference frequency characteristics and the actual frequency characteristics match most closely.

A circuit includes a processor that analyzes a pulse width modulated (PWM) signal feedback from a brushless DC motor to determine a transition between a mutual inductance zero crossing condition and a Back Electro Motive Force (BEMF) zero crossing condition of the brushless DC motor. A mutual inductance controller is executed by the processor to commutate the brushless DC motor at startup of the motor when the mutual inductance zero crossing condition is detected by the processor. A BEMF controller is executed by the processor to commutate the brushless DC motor after startup of the motor when the BEMF zero crossing condition is detected by the processor.

An automated method for discovering features in a repeatable process includes measuring raw time series data during the process using sensors. The time series data describes multiple parameters of the process. The method includes receiving, via a first controller, the time series data from the sensors, and stochastically generating candidate features from the raw time series data using a logic block or blocks of the first controller. The candidate features are predictive of a quality of a work piece manufactured via the repeatable process. The method also includes determining, via a genetic or evolutionary programming module, which generated candidate features are most predictive of the quality of the work piece, and executing a control action with respect to the repeatable process via a second controller using the most predictive candidate features. A system includes the controllers, the programming module, and the sensors.

An automated method for discovering features in a repeatable process includes measuring raw time series data during the process using sensors. The time series data describes multiple parameters of the process. The method includes receiving, via a first controller, the time series data from the sensors, and stochastically generating candidate features from the raw time series data using a logic block or blocks of the first controller. The candidate features are predictive of a quality of a work piece manufactured via the repeatable process. The method also includes determining, via a genetic or evolutionary programming module, which generated candidate features are most predictive of the quality of the work piece, and executing a control action with respect to the repeatable process via a second controller using the most predictive candidate features. A system includes the controllers, the programming module, and the sensors.

The present invention provides an on-machine real-time measurement method and system for a full-closed loop five-axis computer numerical control machine tool. In the system, a high-precision coaxial fixture in a displacement measurement component is used for connecting the component with the machine tool spindle; a multifunctional evaluation electronics box reads the signals of the grating scale of each machine axis in real time, and synchronously triggers the displacement sensor to collect the measured workpiece surface information; a synchronous communication module caches the grating scale signals of each machine axis and the measurement signals of the sensor to the FIFO rotation buffering module of the host computer in parallel to reduce the burden of high-speed transmission; and the host computer performs data processing and coordinate transformation of the grating scale data and the measurement information in the FIFO module, and finally obtains the three-dimensional geometric information of the measured workpiece surface.