Adaptive control for machine tools

• US 4,547,847 A
• Filed: 05/26/1983
• Issued: 10/15/1985
• Est. Priority Date: 06/09/1982
• Status: Expired due to Fees

• Current Assignee: Giddings & Lewis, Inc. (Maxcor, Inc.)
• Original Assignee: AMCA International Corporation
• Inventors: Olig, Eugene A., Ladwig, Lee R.
• Primary Examiner(s): Ruggiero, Joseph
• Application Number:
  US06/498,466
• Time in Patent Office: 873 Days
• Field of Search: 364/148, 364/167-171, 364/474, 364/475, 364/483, 364/511, 364/157, 364/183, 364/164, 364/165, 318/571, 318/561, 318/565, 318/650, 324/142, 408/8-13
• US Class Current: 700/52
• CPC Class Codes: G05B 19/4163 Adaptive control of feed or cutting velocity without NC B23Q15/12
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y10T 82/2502 with program control

Abstract

An adaptive control for a turning machine which adjusts the machining rate to maintain the actual horsepower dissipated at the cutter tip at a constant set point despite changing workpiece and cutter parameters. The machining rate is adjusted by control of the machine drive and tool feed to achieve required SFM and IPR values, respectively, within maximum and minimum SFM and IPR limits. "Speed" and "Axis" override controls are also provided. The rate of adjustment of SFM and IPR to a deviation of the cutter tip horsepower from the set point is inversely proportional to the measured system gain so that the response factor of the control loop is maximized. The commanded machining rate of (SFM) (IPR) product is periodically determined by estimating the actual machining rate and multiplying the estimate by the ratio of the set point to the cutter tip horsepower. The cutter tip horsepower is determined by subtracting the electrical loss, mechanical friction loss, and the net power required for net acceleration of the drive, from the measured electrical power supplied to the drive motor. The cutting efficiency is monitored to perform tool wear, tool breakage, and tool protection functions. The adaptive control also has soft engagement and soft disengagement functions for initiating and terminating the adaptive machining process.

Claims

1. The method of adaptively controlling a plant process to maintain the value of a process parameter [M] substantially in agreement with the value of a desired set point [m], the plant having an automatic adjustment device [33b] responsive to a command signal [Q_c ] to change at least one physical variable [Q], changes in said variable [Q] in turn causing the parameter [M] to change, the response of the parameter [M] to the variable [Q] being time variant in a fashion that is not predeterminable, said method comprising:

(a) supplying a command signal [Q_c ] to said adjustment device [33b] so that the latter produces the physical variable [Q],

(b) sensing the actual value of the physical parameter [M], and

said method being characterized by and including

(c) obtaining an estimate [Q_p ] of the present value of the physical variable [Q], and thereafter

(d) correctively changing said command signal [Q_c ] to take on a new value [Q_cn ] equal to the estimate [Q_p ] of the present value of the physical variable [Q] multiplied by the ratio of the set point value [m] to the actual value of the physical parameter [M].

2. The method set out in claim 1 further characterized in that said estimating step (c) obtains the estimate [Q_p ] of the present value of the physical variable [Q] by sensing the actual value of the physical varible [Q].

3. The method set out in claim 1 further characterized in that said estimating step (c) and said correctively changing step (d) are iteratively repeated at spaced instants of time, each correctively changing step (d) being performed after a corresponding estimating step (c).

4. The method as set out in claim 3 further characterized in that each estimating step (c) estimates the present value [Q_p ] of the physical variable [Q] as substantially equal to the new value [Q_cn ] determined by the preceding correctively changing step (d).

5. An adaptive feedback control system for regulation of a plant having an automatic adjustment device [33b] establishing the value of at least one physical variable [Q] affecting a process [33d] in the plant, the control system accepting a set point value [m] corresponding to a particular physical parameter of the process [33d] that is responsive to the value of the physical variable [Q], the control system having a process sensor [33e] monitoring the value [M] of the physical parameter, wherein the improvement comprises:

means [33c, 59] for obtaining an estimate [Q_p ] of the present value of the physical variable [Q], and

ratio calculator means [33a] for commanding the adjustment device to urge the physical variable [Q] to take on a value substantially equal to the product of the estimate [Q_p ] of the present value of the physical variable and the ratio of the set point value [m] to the value [M] of the physical parameter indicated by the process sensor.

6. The control system as claimed in claim 5, wherein the means [33c] for obtaining an estimate of the current value of the physical variable include an adjustment sensor measuring the value of the physical variable.

7. The control system as claimed in claim 5, wherein the ratio calculator means [33a] is part of a digital computer [50] programmed to iteratively calculate the product of the estimate of the current value of the physical variable and the ratio of the set point value to the value of the physical parameter indicated by the process sensor, and having means [56] for sending said product to the adjustment device [33b] so that the physical variable is urged to take on a value equal to said product.

8. The control system as claimed in claim 7, wherein the means [33c] for obtaining an estimate of the current value of the physical variable include memory means [59] for temporarily storing the product sent to the adjustment device [33b], and means [31] for establishing a time delay between iterations so that, at each iteration time, the temporarily stored product is a sufficiently valid estimate of the present value of the physical variable so that the control system is stable.

9. The method of adaptively controlling a plant process to maintain a process parameter [M] substantially in agreement with the value of a desired set point signal [m], the plant having an adjustment device [33b] responsive to a command signal [Q_c ] to change at least one physical variable [Q_m ], changes in said variable [Q_m ] in turn causing the plant to change said parameter [M] with a time-variant gain transfer function [G_p(s) =M/Q_m ] which is not predeterminable, said method comprising

(a) supplying a command signal [Q_c ] to said adjustment device so that the latter produces the physical variable [Q_m ],

(b) producing a first signal [M_o ] representing the actual value of the parameter [M] created by the plant, and

said method being characterized by and including

(c) producing a second signal representing the actual value of the variable [Q_m ], and

(d) correctively changing said command signal [Q_c ] to take on a new value [Q_cn ] equal to said second signal multiplied by the ratio of said set point value to the value of said first signal, such that Q_cn =Q_m ·

(m/M_o).

10. The method set out in claim 9 further characterized in that said corrective changing step (d) is iteratively repeated at spaced instants in time.

11. The method set out in claim 9 or claim 10 further characterized by the steps of

(e) at random points in time, adjusting the value of said command signal [Q_c ] by changing an override scale factor [K] applied thereto, and

(f) coincidentally with any performance of said step (e), adjusting the value of said desired set point [m] by identically changing the same scale factor [K] applied thereto.

12. The method of adaptively controlling a plant process to maintain a process parameter M substantially in agreement with the value of a desired set point signal m, the plant acting to change the parameter M according to changes in at least one input signal I_p with a time-variant gain (G_p(s) =M/I_p) which is not predeterminable, said method comprising

(a) supplying to the plant an input signal I_p,

(b) producing a signal M_o representing the actual value of the parameter M created by the plant, and

said method being characterized by and including

(c) correctively changing said input signal I_p to take on a new value I_pn equal to its original value I_pold multiplied by the ratio of the set point signal to the actual value signal M_o, such that I_pn =I_pold ·

(m/M_o).

13. The method set out in claim 12 further characterized in that

in the supplying step (a), the signal I_p supplied to the plant is updated at spaced time instants i, i+1, i+2 . . . to take on successive values I_pi, I_p(i+1), I_p(i+2) . . . ,

and in the correctively updating step (c), the signal I_p is correctively updated at said spaced time instants by forming each new value I_p(i+1) as the previous value I_pi multiplied by the ratio m/M_o.

14. The method set out in claim 13 further characterized in that in the producing step (b), the signal M_o is produced at spaced time instants j, j+1, j+2 such that the signal takes on values M_oj, M_o(j+1), M_o(j+2) . . . , and in the correctively changing step (c), said input signal I_p is correctively updated at the spaced time instants i, i+1, i+2 . . . to create each successive value as the previous value multiplied by the ratio of the set point signal m to the actual value signal M such that I_p(i+1) =I_p(i) ·

(m/M_or) where M_or is the most recent value of the signal M_o produced according to step (b).

15. The method set out in claim 12 further characterized in that said plant is a machine tool wherein the process is machining of a workpiece by a cutter, said parameter M is consumed horsepower, and said input signal I_p is a command for the relative machining rate Q_c.

16. The method set out in claim 15 further characterized in that said consumed horsepower is essentially the power expended at the cutter tip as the workpiece is being machined.

17. The method set out in claim 15 further characterized in that the command for the relative machining rate Q_c is formed by the product of two commanded variables for speed and feed, such variables being commanded by two respective command signals.

18. The method set out in claim 17 further characterized in that said two respective command signals are applied to the machine tool as desired values for surface speed SFM_c and feed IPR_c of the machining process, and from each successive change of the input signal I_p, and thus of the commanded relative machining rate Q, a value of one of said two respective command signals is picked and the other is computed according to the relationship Q_c =SFM_c ·

IPR_c.

19. In an adaptive control for a physical system, such system acting in response to an input signal I_p to change a controlled parameter HP which is affected by variables in addition to said input signal, the combination comprising:

(a) means for producing a set point signal HP_d representing a desired value for the parameter HP,

(b) repetitive means for producing a signal HP_m representing the actual value of the parameter HP while the system is operating with a known value I_po of the input signal I_p,

(c) repetitive means for determining a new value I_pn for the input signal I_p based upon the ratio HP_d /HP_m of the set point to the actual value multiplied by the known I_po, such that I_pn =(HP_d /HP_m)·

I_po and

(d) repetitive means for changing the input signal I_p to agree with the determined value I_pn, so that the actual value HP_m of the controlled parameter HP converges toward the value of the set point signal HP_d despite variations in the variables other than the input signal I_p which affect the controlled parameter HP.

20. The method of adaptively controlling a plant process to maintain a process parameter M substantially in agreement with the value of a desired set point signal m, the plant having an adjustment device responsive to at least one command signal I_pc to vary a physical variable I_p which affects the parameter M with a gain G_p(s) =M/I_p which is time variant and non-predeterminable, said method comprising

(a) creating at least one command signal I_pc,

(b) multiplying said command signal by an operator-adjustable override factor K to produce a final command signal I_pco such that I_pco =K·

I_pc,

(c) creating a set point signal m representing a desired value of the parameter M,

(d) multiplying said set point m by the same operator-adjustable factor K to produce a final set point signal M_o,

(e) sensing, and representing by a signal M_o, the actual value of said parameter M,

(f) sensing, and representing by a signal I_pm, the actual value of said physical variable I_p, and

(g) correctively changing said command signal I_pc to take on a new value I_pcn equal to the value of the actual variable I_p multiplied by the ratio of the final set point signal m_o to the actual value signal M_o, such that I_pcn =I_pm ·

(m_o /M_o) whereby said parameter M converges in value toward agreement with the value of said set point signal m when the factor K is 1.0, but upon operator-performed adjustment of said override factor K to values other than 1.0 to modify the range of variation of said variable I_p, the negating of the override action is avoided by a corresponding change in the effective set point m_o at which said parameter is maintained.

21. The method defined by claim 20 further characterized in that

(a1) said step (a) includes creating a plurality of n command signals I_pc1, I_pc2 . . . I_pcn jointly affecting the process parameter M,

(b1) said step (b) includes multiplying each of said individual command signals by a respective one of individual operator-adjustable override factors K₁, K₂ . . . K_n such that individual final command signals are created, viz.

22. An iterative control system for regulating a physical plant [70'"'"'], the plant receiving a control signal [I_p ] and emitting an output value [M], the control system receiving a set point value [m], and the control system having a calculator [73"] for repetitively generating the control signal [I_p ] as a predetermined control function [f(M, m)] of the output value [M] and the set point value [m], the function being predetermined so that the output value [M] tends to track the set point value [m], wherein the improvement comprises:

the control system having a user adjustable override control [64, 65] supplying an override factor [K], means for scaling the control function [f] of the calculator [73"] by the scale factor [K] to generate the control signal [I_p ] so that the value of the control signal [I_p ] is substantially equal to the product [Kf] of the control function [f] and the scale factor [K], and wherein the set point value [m] is scaled by the scale factor [K] before being applied to the control function [f], so that the tendency of the control function [f] to negate the override action is avoided by a correspondingly scaled set point value [Km] being applied to the control function [f].

23. The control system as claimed in claim 22, wherein the physical plant [70'"'"'] receives a second control signal [I_p2 ] and wherein the improvement further comprises the calculator [73"] having means for generating a second corresponding control function [f₂ (M, Km)] of the output value [M] and the scaled set point value [Km], the second control function [f₂ ] being predetermined so that the output value [M] tends to track the set point value [m] when the second control function [f₂ ] generates the second control signal [I_p2 ], the system having a second user adjustable override control [64, 65] supplying a second override factor [K₂ ], means for scaling the second control function [f₂ ] by the second scale factor [K₂ ] to generate the second control signal [I_p2 ] substantially equal to the product [K₂ f₂ ] of the second scale factor [K₂ ] and the second control function [f₂ ], and wherein the set point value [m] is additionally scaled by the second scale factor [K₂ ] before being applied to both the first control function [f] and the second control function [f₂ ], so that the tendencies of the control functions [f, f₂ ] to negate the override action is avoided, and the relative weights of the control values [I_p, I_p2 ] are adjusted by the override controls [64, 65].

24. In a control system for a machine tool having means to rotate and feed a workpiece relative to a cutter, and wherein the relative surface speed, designatable SFM, of such rotation with respect to the cutter edge is kept in agreement with a first set point signal SFM_o, and the relative feed, designatable IPR of the cutter edge into the workpiece, is kept in agreement with a second set point signal IPR_o, the system further having means for producing actual value signals SFM_m and IPR_m which change in response to changes in SFM_o and IPR_o, respectively,

(a) means for producing command signals SFM_c and IPR_c representing commanded values of relative speed and feed,

(b) operator adjustable means for overriding said commanded values to produce said set point signals SFM_o and IPR_o from the command signals SFM_c and IPR_c such that

25. In a control system for a machine tool having means to rotate and feed a workpiece relative to a cutter, and wherein the relative surface speed, designatable SFM, of such rotation with respect to the cutter edge is kept in agreement with a first set point signal SFM_o ;

and the relative feed, designatable IPR of the cutter edge into the workpiece, is kept in agreement with a second set point signal IPR_o,

(a) means for producing command signals SFM_c and IPR_c representing commanded values of relative speed and feed,

(b) operator adjustable means for overriding said commanded values to produce said set point signals SFM_o and IPR_o from the command signals SFM_c and IPR_c such that

space="preserve" listing-type="equation">SFM.sub.o =KS.sub.o ·

SFM.sub.c

space="preserve" listing-type="equation">IPR.sub.o =KI.sub.o ·

IPR.sub.c

where KS_o and KI_o are multipliers adjustable in value by the machine operator from a normal value of 1.0,

(c) means for producing a set point signal HP_d representing the machining power desired to be applied in creating said relative rotation,

(d) means for periodically updating at least one of said two command signals SFM_c, IPR_c during operation of the machine according to the relationship

space="preserve" listing-type="equation">CS.sub.i =HP.sub.d /HP.sub.a ·

KS.sub.o ·

KI.sub.o ·

CS.sub.(i-1)

where CS is the said one command signal and HP_a is the actual power applied in maintaining said relative rotation, thereby effectively to change the power set point HP_d to HP_d ·

KS_o ·

KI_o by the same percentage as the changes in percentage of both the speed and feed when the operator makes adjustments of said means (b).

26. An automatic control system for a machine tool accepting a desired power signal comprising, in combination,

means for measuring the power consumed by the machine drive in moving the cutting tool relatively at a controllable surface speed transversely across a workpiece surface, generating a measured power signal indicating actual machining power,

automatic means for generating a relative machining rate command signal which changes according to the ratio of the desired power signal to the measured power signal,

drive control means responsive to said command signal for adjusting said relative surface speed to thereby bring and hold the actual machining power in substantial agreement with said desired power signal.

27. The combination as claimed in claim 26, further comprising high limit means for preventing said relative surface speed from exceeding a predetermined maximum value at which machining may continuously occur without excessive heating of the cutting tool.

28. The combination as claimed in claim 27, further comprising low limit means for preventing said relative surface speed from falling below a predetermined minimum value below which shavings from the workpiece do not break into chips and thus tend to clog the machine tool.

29. The combination as claimed in claim 26, further comprising low limit means for preventing said relative surface speed from falling below a predetermined minimum value below which shavings from the workpiece do not break into chips and thus tend to clog the machine tool.

30. The combination as claimed in claim 26, further comprising a second control means for regulating cutting power generally independent of said drive control means, the second control means being responsive to said command signal in a predetermined apportioning such that the joint effect of said drive control means and the second control means brings actual machining power into substantial agreement with said desired power signal.

31. The combination as claimed in claim 30, wherein the second control means adjust the rate of feed of the cutting tool into the workpiece.

32. The combination as claimed in claim 31, further comprising means for detecting when said drive control means and said second control means attempt to create relative speed and feed values both of which are less than respective predetermined minimum limit values, and means responsive to such detection for thereupon terminating the machining process.

33. The combination as claimed in claim 30, further comprising user apportioning means for accepting time varying apportionment factors from the user during the machining process and proportionally allocating the machining rate control signal between the drive control means and the second control means.

34. The combination as claimed in claim 31, wherein the second control means is responsive to said command signal to change actual machining power, and said drive control means holds said relative speed essentially constant at a predetermined maximum value (SFM_max), under conditions such that the desired power would exceed the actual power if the feed and speeds were respectively IPR_min and SFM_max.

35. The combination as claimed in claim 34, wherein the drive control means is responsive to said command signal to change actual machining power, and said second control means holds feed rate essentially constant at said predetermined minimum value (IPR_min), under conditions such that the actual power would exceed desired power if the feed and speeds were respectively IPR_min and SFM_max.

36. The combination as claimed in claim 30, further comprising a user-controlled drive scaling means for scaling the response of the drive control means by time-varying scale factors received from the user during the machining process and proportionally adjusting the response of the drive control means to said command signal.

37. The combination as claimed in claim 36, further comprising a second user-controlled scaling means for scaling the response of the second control means by a second time variant scale factor received from the user during the machining process and proportionately adjusting the response of the second control means to said command signal.

38. The combination as claimed in claim 36, wherein the drive scaling means further includes scaling means for proportionately scaling the desired power signal.

39. A control system for a machine tool, such machine tool having

(i) drive means to relatively rotate a workpiece and a cutter at a surface speed designatable as SFM,

(ii) feed means to relatively feed the workpiece and cutter at a feed rate designatable as IPR,

(iii) means responsive to input signals SFM_o and IPR_o for controlling said means (i) and (ii) to keep the actual speed and feed SFM_a and IPR_a in agreement with such signals,

and said machine tool having physical characteristics such that a cutting efficiency factor CEF, proportional to horsepower per cubic inch per minute of workpiece material removal, varies according to the relation

View Dependent Claims (41, 42)

41. The combination as claimed in claim 39 or claim 40, wherein the means (e) for substituting the new value signal further comprises means for comparing the new value signal SFM_n to a predetermined limit SFM_max and substituting SFM_max for the previous SFM_o signal value if the new value signal SFM_n is greater than the predetermined limit SFM_max.

42. The combination as claimed in claim 39 or claim 40, wherein the means (e) for substituting the new value signal further comprises means for comparing the new value signal SFM_n to a predetermined limit SFM_min and substituting SFM_min for the previous SFM_o signal value if the new value signal SFM_n is less than the predetermined limit SFM_min.

40. A control system for a machine tool, such machine tool having

(i) drive means to relatively rotate a workpiece and a cutter at a surface speed designatable as SFM,

(ii) feed means to relatively feed the workpiece and cutter at a feed rate designatable as IPR,

(iii) means responsive to input signals SFM_o and IPR_o for controlling said means (i) and (ii) to keep the actual speed and feed SFM_a and IPR_a in agreement with such signals, and said machine tool having physical characteristics such that a cutting efficiency factor CEF, proportional to horsepower per cubic inch per minute of workpiece material removal, varies according to the relation

43. A control system for a machine tool, such machine tool having

(i) drive means to relatively rotate a workpiece and a cutter at a surface speed designatable as SFM,

(ii) feed means to relatively feed the workpiece and cutter at a feed rate designatable as IPR,

(iii) means responsive to input signals SFM_o and IPR_o for controlling said means (i) and (ii) to keep the actual speed and feed SFM_a and IPR_a in agreement with such signals,

and said machine tool having physical characteristics such that a cutting efficiency factor CEF, proportional to horsepower per cubic inch per minute of workpiece material removal, varies according to the relation

View Dependent Claims (44, 47)

44. The combination as claimed in claim 43, wherein the means (e) for substituting the new value signal further comprises means for comparing the new value signal IPR_n to a predetermined limit IPR_max and substituting IPR_max for the previous IPR_o signal value if the new signal value IPR_n is greater than the predetermined limit IPR_max.

47. The combination as claimed in claim 44 or claim 46, wherein the means (e) for substituting the new value signal further comprises means for comparing the new value signal IPR_n to a predetermined limit IPR_min and substituting IPR_min for the previous IPR_o signal value if the new signal value IPR_n is less than the predetermined limit IPR_min.

45. A control system for a machine tool, such machine tool having

(i) drive means to relatively rotate a workpiece and a cutter at a surface speed designatable as SFM,

(ii) feed means to relatively feed the workpiece and cutter at a feed rate designatable as IPR,

(iii) means responsive to input signals SFM_o and IPR_o for controlling said means (i) and (ii) to keep the actual speed and feed SFM_a and IPR_a in agreement with such signals,

and said machine tool having physical characteristics such that a cutting efficiency factor CEF, proportional to horsepower per cubic inch per minute of workpiece material removal, varies according to the relation

View Dependent Claims (46)

46. The combination as claimed in claim 45, wherein the means (e) for substituting the new value signal further comprises means for comparing the new value signal IPR_n to a predetermined limit IPR_max and substituting IPR_max for the previous IPR_o signal value if the new signal value IPR_n is greater than the predetermined limit IPR_max.

48. A control system for a machine tool, such machine tool having

(i) drive means to relatively rotate a workpiece and a cutter at a surface speed designatable as SFM,

(ii) feed means to relatively feed the workpiece and cutter at a feed rate designatable as IPR,

(iii) means responsive to input signals SFM_o and IPR_o for controlling said means (i) and (ii) to keep the actual speed and feed SFM_a and IPR_a in agreement with such signals,

and said machine tool having physical characteristics such that a cutting efficiency factor CEF, proportional to horsepower per cubic inch per minute of workpiece material removal, varies according to the relation

View Dependent Claims (49, 50, 51)

49. The combination as claimed in claim 48, wherein means (f) for determining new value signals SFM_n and IPR_n comprises means for comparing the new relative machining rate Q_n to an intermediate threshold Q₂ defined as the product of a maximum SFM limit SFM_max and a minimum IPR limit IPR_min, and

setting SFM_n to SFM_max and setting IPR_n according to

50. The combination as claimed in claim 48, wherein means (f) for determining new value signals SFM_n and IPR_n further comprises means for comparing the new relative machining rate Q_n to a maximum threshold Q₃ defined as the product of a maximum IPR limit IPR_max and a maximum SFM limit SFM_max, and means for setting SFM_n to SFM_max and setting IPR_n to IPR_max if Q_n exceeds Q₃.

51. The combination as claimed in claim 48, further comprising means for comparing the new relative machining rate Q_n to a minimum threshold Q₁ defined as the product of a minimum IPR limit IPR_min and a minimum SFM limit SFM_min, and means for taking corrective action if Q_n is less than Q₁.

52. In a numerically-controlled machine tool system having a holder for a workpiece, a cutting tool, a cutting tool holder, a feed motor means accepting a feed velocity control signal for feeding the cutting tool into the workpiece, a drive motor means accepting a drive velocity control signal for establishing a relative transverse velocity of the cutting tool across the surface of the workpiece, a drive power measuring means for generating a measured drive power signal indicating power required to maintain the drive velocity, a drive velocity measuring means for generating a measured drive velocity signal indicating the drive velocity, numerical converter means for converting measured signals to numerical values and numerical control values to control signals, and a digital computing means for entering machining parameters and performing numerical and logical functions and interfaced to said numerical converter means, the improved control method which comprises the steps of:

(a) inputting a set point signal representing desired machining power into the digital computing means, and

(b) inputting the numerical values of the measured drive power signal and the measured drive velocity signal into the digital computing means, and

(c) computing a drive velocity numerical control value approximately proportional to the product of the numerical value of the measured drive velocity signal and the set point signal, divided by the numerical value of the measured drive power signal,

(d) outputting the drive velocity numerical control value to the numerical converter means for conversion to the drive velocity control signal, and

(e) repeating steps (b) through (d) generally continuously while feeding the cutting tool into the workpiece throughout a substantial part of the machining process, so that the machine tool system is adaptively controlled to maintain machining at a generally constant power level corresponding to the desired machining power despite changing functional relations between machining parameters.

53. The control method as claimed in claim 52, wherein step (a) further comprises inputting a maximum drive velocity limit into the digital computing means, and step (c) further comprises setting the computed drive velocity to the maximum drive velocity limit if the computed drive velocity exceeds the maximum drive velocity limit.

54. In a numerically-controlled machine tool system having a holder for a workpiece, a cutting tool, a cutting tool holder, a feed motor means accepting a feed velocity control signal for feeding the cutting tool into the workpiece, a drive motor means accepting a drive velocity control signal for establishing a relative transverse velocity of the cutting tool across the surface of the workpiece, a drive power measuring means for generating a measured drive power signal indicating power required to maintain the drive velocity, a drive velocity measuring means for generating a measured drive velocity signal indicating the drive velocity, a feed velocity measuring means for generating a measured feed velocity signal indicating feed velocity, numerical converter means for converting measured signals to numerical values and numerical control values to control signals, and a digital computing means for entering machining parameters and performing numerical and logical functions and interfaced to said numerical converter means, the improved control method which comprises the steps of:

(a) inputting a desired machining power set point into the digital computing means,

(b) inputting the numerical values of the measured drive power signal and the measured feed velocity signal into the digital computing means,

(c) computing a feed velocity numerical control value proportional to the product of the numerical value of the measured feed velocity signal and the power set point, divided by the numerical value of the measured drive power signal, and

(d) outputting the feed velocity numerical control value to the numerical converter means for conversion to the feed velocity control signal.

55. The control method as claimed in claim 54, wherein

step (b) further comprises inputting the numerical value of the measured drive velocity signal into the digital computing means,

step (c) further comprises computing a drive velocity numerical control value proportional to the product of the numerical value of the measured drive velocity signal and the power set point, divided by the numerical value of the measured drive power signal, and

step (d) further comprises outputting the drive velocity numerical control value to the numerical converter means for conversion to the drive velocity control signal.

56. The control method as claimed in claim 55, wherein the feed velocity control signal and the drive velocity control signal are scaled by manually controllable scale factors before driving the feed motor means and drive motor means, and the power set point is scaled jointly by the same scale factors before use in step (c), so that the machine tool rapidly responds to changes in the manually controlled scale factors and the control system accommodates the expected change in machining power level.

57. The control method as claimed in claim 55, wherein step (a) further comprises inputting a maximum feed velocity limit and a minimum feed velocity limit into the digital computing means, and step (c) further comprises setting the computed feed velocity to the maximum feed velocity limit if the computed feed velocity exceeds the maximum feed velocity limit, and setting the computed feed velocity to the minimum feed velocity limit if the computed feed velocity is less than the minimum feed velocity limit.

58. The control method as claimed in claim 57, wherein

step (a) further comprises inputting a maximum drive velocity limit and a minimum drive velocity limit into the digital computing means, and

step (b) further comprises inputting the numerical value of the measured drive velocity signal into the digital computing means, and

step (c) further comprises setting a drive velocity numerical control value equal to the maximum drive velocity limit, but if the computed feed velocity limit is less than the minimum feed velocity limit and is therefore set to the minimum feed velocity limit, then the drive velocity numerical control value is set proportional to the product of the numerical value of the measured drive velocity signal and the power set point, divided by the numerical value of the measured drive power signal, but if the drive velocity numerical control value is set to a value less than the minimum drive velocity limit, then the machining process is temporarily suspended, thereby permitting the machine operator to insert a sharp cutting tool to correct for the slow machining rate, and

step (d) further comprises outputting the drive velocity numerical control value to the numerical converter means for conversion to the drive velocity control signal.

59. The control method as claimed in claim 57, wherein before the adaptive control method of claim 57 is initiated, the workpiece is accelerated to a programmed drive velocity with the cutting tool disengaged and then the tool is advanced into the workpiece at the minimum feed velocity limit to a substantial distance so that a substantial initial drive power level is achieved and initial convergence toward the power set point is facilitated while minimizing the initial force on the cutting tool.

60. The control method in claim 57, wherein steps (b)-(d) are iteratively repeated and the computation of feed velocity numerical control values is suspended in step (c) in subsequent interations of step (c) after a computed feed velocity numerical control value is less than the minimum feed velocity limit and is therefore set to the minimum feed velocity limit.

61. The control method in claim 57, wherein

the numerically-controlled machine tool system controls a turning machine and the drive velocity measuring means is responsive to the angular velocity of the workpiece,

the numerically-controlled machine tool system has a cutting tool feed velocity measuring means for generating a radial feed displacement signal indicating the displacement of the cutting tool from the axis of the turning workpiece, and

step (c) further comprises a computation of the radial feed velocity, proportional to the change in the numerical value of the radial feed displacement divided by the numerical value of the angular drive velocity, and a scaling computation of the angular drive velocity involving the numerical value of the radial feed displacement signal as a scaling factor, so that the numerical value of the radial feed velocity indicates the radial depth of cut into the workpiece by the cutting tool, and the comparison between the drive velocity limits and the numerical value of the drive velocity are indicative of the transverse velocity of the workpiece surface at the cutting tool.

62. The control method in claim 54, wherein the drive motor means is an electric motor and the drive velocity measuring means includes a means for measuring the rotational velocity of the motor and the power measuring means is a wattmeter responsive to the electrical power consumed by the drive motor, and wherein step (c) further comprises a computation to calculate the true power consumed by the workpiece material removal process at the cutting tool for use as the numerical value of the measured drive power signal in the computations in step (c), said computation including a computation to correct for power variation due to net acceleration of the inertial mass of the rotating parts of the machine tool, by subtracting, from the numerical value of the measured power consumed by the drive motor, the net power required to accelerate the inertial mass.

63. The control method as claimed in claim 62, further comprising the step of computing the power delivered to the inertial mass as proportional to the product of a pre-determined moment of inertia, the numerical value of the measured angular drive velocity signal, and the rate of change of the numerical value of the measured angular drive velocity over repeated measurements of the angular drive velocity signal.

64. The control method in claim 62, wherein the computation in step (c) to calculate the true power consumed by the workpiece material removal process at the cutting tool further includes the subtraction of the frictional losses of the drive system of the machine tool, computed as generally proportional to the product of a pre-determined constant of friction and the numerical value of the measured drive angular velocity signal.

65. The method as claimed in claim 62, wherein the computation in step (c) to calculate the true power consumed by the workpiece material removal process at the cutting tool further includes the subtraction of electrical loss in the drive motor, computed as the product of the motor current squared and a predetermined constant of resistance characteristic of the motor, and said motor current is determined as a predetermined function of the numerical value of the measured drive angular velocity signal.

66. The method as claimed in claim 62, wherein the numerically controlled machine tool is a turning machine, and the pre-determined moment of inertia is computed before the adaptive control process of steps (a) through (c) are initiated by:

accelerating the machine drive with the cutting tool disengaged from the workpiece, and

calculating the moment of inertia by dividing the numerical value of the power measured during the acceleration by the numerical value of the measured drive angular velocity and by the time rate of change in the numerical value of the measured drive angular velocity, so that power measurements compensate for the moment of inertia of the particular workpiece.

67. The method as claimed in claim 54, further comprising the steps of:

repetitively computing a cutting efficiency factor generally proportional to the numerical value of the drive power and inversely proportional to the product of the numerical value of the drive velocity, the numerical value of the feed velocity, and a numerical depth of cut value,

repetitively comparing the cutting efficiency factor to a predetermined low efficiency factor limit preset to a fraction of the cutting effiency factor normally computed for a sharp tool, and

terminating the machining process when the cutting efficiency factor reaches the low efficiency factor limit, so that a broken cutting tool is detected and the machine tool is stopped for tool replacement.

68. The method as claimed in claim 54, further comprising the steps of

repetitively computing a cutting efficiency factor generally proportional to the numerical value of the drive power and inversely proportional to the product of the numerical value of the drive velocity, the numerical value of the feed velocity, and a numerical depth of cut value,

repetitively comparing the cutting efficiency factor to a predetermined high efficiency factor limit preset substantially above the cutting efficiency factor normally computed for a sharp tool, and

terminating the machining process when the cutting efficiency factor reaches the limit, so that a dull tool is detected and the machine tool is stopped for tool replacement.

69. The method as claimed in claim 67 or claim 68 wherein the depth of cut value is obtained as a predetermined constant from the part program stored in the memory of the numerical control unit.

70. The method as claimed in claim 54, further comprising the steps of:

initially computing an initial relative cutting efficiency factor generally proportional to the numerical value of the drive power and inversely proportional to the product of the numerical value of the drive velocity and the numerical value of the feed velocity as the cutting tool is initially cutting into the workpiece, and

thereafter repetitively computing a current relative cutting efficiency factor generally proportional to the numerical value of the drive power and inversely proportional to the product of the numerical value of the drive velocity and the numerical value of the feed velocity,

repetitively comparing the current relative cutting efficiency factor to a low efficiency factor limit set to a fraction of the initial relative cutting efficiency factor, and

terminating the machining process when the relative cutting efficiency parameter reaches the low efficiency factor limit, so that a broken tool is detected and the machine tool is stopped for tool replacement.

71. The method as claimed in claim 54, further comprising the steps of:

initially computing an initial relative cutting efficiency factor generally proportional to the numerical value of the drive power and inversely proportional to the product of the numerical value of the drive velocity and the numerical value of the feed velocity as the cutting tool is initially cutting into the workpiece, and

thereafter repetitively computing a current relative cutting efficiency factor generally proportional to the numerical value of the drive power and inversely proportional to the product of the numerical value of the drive velocity and the numerical value of the feed velocity,

repetitively comparing the current relative cutting efficiency factor to a high efficiency factor limit set to substantially greater than the initial relative cutting efficiency factor, and terminating the machining process when the relative cutting efficiency factor reaches the low efficiency factor limit, so that a dull tool is detected and the machine tool is stopped for tool replacement.

72. The method as claimed in claim 71 wherein the high efficiency factor limit is set to substantially greater than the initial relative cutting efficiency factor by setting the high efficiency factor limit to the product of a preset high limit factor and the initial relative cutting efficiency factor, said high limit factor being substantially greater than one.

73. The method as claimed in claim 67 or claim 68 or claim 58 or claim 59, wherein the drive power is compensated for the net power required for net acceleration of the drive, before using the drive power to calculate the cutting efficiency factor, by subtracting the net power required for net acceleration from the drive power, so that transient variations in drive power coincident with net acceleration do not trigger the false detection of an improper tool condition.