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Collision Monitoring with Tool Geometry

CNC Sinumerik

Goal -- WPM

Ready
Exercise Algorithm Area
1PROGRAM CHECK_COLLISION(CURRENT_TOOL_POS, TARGET_TOOL_POS, TOOL_RADIUS, WORKPIECE_BOUNDS)

2

3// Simplified Collision Monitoring based on Tool Envelope and Workpiece Bounds

4// CURRENT_TOOL_POS: Current X, Y, Z coordinates of the tool center.

5// TARGET_TOOL_POS: Target X, Y, Z coordinates of the tool center.

6// TOOL_RADIUS: Radius of the cutting tool.

7// WORKPIECE_BOUNDS: A bounding box (min_x, max_x, min_y, max_y, min_z, max_z) of the workpiece.

8

9VAR collision_detected = FALSE

10VAR safe_distance_threshold = 0.1 // Small buffer to avoid false positives

11

12// --- Check for collision during linear move ---//

13// This is a simplified check. A more robust system would discretize the path

14// or use swept volume analysis.

15

16// Check if the bounding box of the tool's movement path intersects with the workpiece bounds.

17VAR min_move_x = MIN(CURRENT_TOOL_POS.X, TARGET_TOOL_POS.X) - TOOL_RADIUS

18VAR max_move_x = MAX(CURRENT_TOOL_POS.X, TARGET_TOOL_POS.X) + TOOL_RADIUS

19VAR min_move_y = MIN(CURRENT_TOOL_POS.Y, TARGET_TOOL_POS.Y) - TOOL_RADIUS

20VAR max_move_y = MAX(CURRENT_TOOL_POS.Y, TARGET_TOOL_POS.Y) + TOOL_RADIUS

21VAR min_move_z = MIN(CURRENT_TOOL_POS.Z, TARGET_TOOL_POS.Z) - TOOL_RADIUS

22VAR max_move_z = MAX(CURRENT_TOOL_POS.Z, TARGET_TOOL_POS.Z) + TOOL_RADIUS

23

24// Check for overlap between the tool's swept volume bounding box and workpiece bounding box

25IF max_move_x < WORKPIECE_BOUNDS.min_x OR min_move_x > WORKPIECE_BOUNDS.max_x THEN

26// No X-axis overlap

27ELSE IF max_move_y < WORKPIECE_BOUNDS.min_y OR min_move_y > WORKPIECE_BOUNDS.max_y THEN

28// No Y-axis overlap

29ELSE IF max_move_z < WORKPIECE_BOUNDS.min_z OR min_move_z > WORKPIECE_BOUNDS.max_z THEN

30// No Z-axis overlap

31ELSE

32// Potential overlap in all axes. This is a simplified collision detection.

33// A more accurate check would involve projecting the workpiece geometry

34// onto the tool's path or vice-versa.

35collision_detected = TRUE

36PRINT "Potential collision detected during linear move!"

37END IF

38

39// --- Additional checks could include: ---

40// 1. Checking against specific geometric features of the workpiece (e.g., chamfers, fillets).

41// 2. Considering tool length and shank collisions.

42// 3. Analyzing tool engagement angle and chip formation.

43

44IF collision_detected THEN

45// In a real system, this would trigger an alarm and halt the machine.

46PRINT "COLLISION ALARM: Halting program."

47G0 Z[SAFE_Z_FOR_EMERGENCY_STOP]

48SPINDLE_OFF

49M5

50GOTO END_PROGRAM

51END IF

52

53// If no collision, proceed with the move (this macro would typically be called before the motion command)

54PRINT "Move is safe."

55

56END_PROGRAM:

57END_PROGRAM
Algorithm description viewbox

Collision Monitoring with Tool Geometry

Algorithm description:

This program implements a simplified collision monitoring system for CNC machining. It checks if the path of a cutting tool, considering its radius, might intersect with the defined boundaries of the workpiece. This is a fundamental safety feature that helps prevent costly damage to the machine, tool, and workpiece by detecting potential collisions before they occur. It's a crucial component in automated manufacturing environments.

Algorithm explanation:

The `CHECK_COLLISION` program provides a basic collision detection mechanism. It takes the current and target tool positions, the tool's radius, and the workpiece's bounding box as input. The core logic checks if the bounding box of the tool's linear movement path (expanded by the tool's radius) overlaps with the workpiece's bounding box. If there's an overlap in all three axes (X, Y, and Z), it flags a potential collision. This is a highly simplified approach; a robust system would involve more sophisticated geometric checks, such as discretizing the tool path into smaller segments or using swept volume analysis to accurately determine intersection. The algorithm includes a `safe_distance_threshold` to mitigate false positives. If a collision is detected, it prints a warning, moves the tool to a safe emergency stop height, and halts the spindle and program. This macro would typically be called before executing any motion command to ensure safety.

Pseudocode:

DEFINE SUBPROGRAM CHECK_COLLISION(CURRENT_TOOL_POS, TARGET_TOOL_POS, TOOL_RADIUS, WORKPIECE_BOUNDS)

    SET collision_detected = FALSE
    SET safe_distance_threshold = 0.1

    CALCULATE min_move_x, max_move_x, min_move_y, max_move_y, min_move_z, max_move_z for tool path bounding box

    IF NO overlap in X OR NO overlap in Y OR NO overlap in Z THEN
        // No collision detected in this axis
    ELSE
        SET collision_detected = TRUE
        PRINT "Potential collision detected!"
    END IF

    IF collision_detected THEN
        PRINT "COLLISION ALARM!"
        MOVE RAPID to SAFE_Z_FOR_EMERGENCY_STOP
        STOP SPINDLE
        HALT PROGRAM
    ELSE
        PRINT "Move is safe."
    END IF

END SUBPROGRAM