UItiMotion

Paul J. Gray, Ph.D.

Manager • Path Planning

• Front-End Design

• R&D

What is UltiMotion? • An entirely new software-based

motion control system

• Wholly owned by Hurco

• Awarded 4 patents

• Superior to Hurco Standard

Motion

Machining a part is a lot

like running a race

The Part Program is the

tool path map of the track

Interpret the Race Track

Race team generates the

strategy and pace notes

that describe the obstacles

and markers in the course

Program Interpreter 1. Load the part program instructions

(map)

2. Program Interpreter uses

• Part & tool setup

• Machine Kinematics

to generate machine-specific motion

data (pace notes)

3. The data is sent to the motion

system for real-time processing

Start the race by activating the

motion system

Start Cycle!

The Motion System Primary Components

Software and hardware that handle the physics of a CNC machine:

The Motion System 1. Motion Planning Co-Driver & Driver

2. Motion Control Driver

3. Servo Drives & Motors Race Car

Software and hardware that handle the physics of a CNC machine:

UltiMotion Components

A. Motion Planning

• Smoothing

• Look-Ahead & dynamic model

B. Control Loop

• Feed Forward

• Feedback

1. Motion Planning Co-Driver & Driver

2. Motion Control Driver

Motion Planning Smoothing & Look Ahead

Motion Planning Co-driver interprets pace notes

Calls out upcoming obstacles to the driver

Driver plans smoothest, fastest trajectory

within bounds of the track and vehicle limits

Motion Planning CNC Motion Planning includes:

1. Smoothing the path within machine

tolerances

2. Optimizing velocity and acceleration based

on the axes physical limits

Nominal Path – Centre of track

Nominal Path – Centre of track

Path Tolerance – Width of track

Nominal Path – Centre of track

Path Tolerance – Width of track

Optimal Path

Ultimotion Smoothing

• Patented curvature controlled

smoothing system

• Increases performance and

surface finish without sacrificing

part accuracy

Co-driver calls out the pace notes ahead of

obstacles

Driver anticipates the speed to navigate

obstacles based on vehicle performance

CNC Motion Controller

Anticipates acceleration and deceleration to

navigate an optimized trajectory

Based on measured characteristics of the

machine (dynamics of the axes)

What is Look Ahead?

Example

G01 X60 F2000

Y50

Y50

X

Y

X60

• Cannot accelerate & decelerate

instantaneously Y50

X

Y

X60

X-Axis

Time

Velo

city Y-Axis

• S-Curve velocity profile gives

smooth motion

• X stops before Y starts giving a

sharp corner

Y50

X

Y

X60

X-Axis

Time

Velo

city Y-Axis

Time

Velo

city X-Axis Y-Axis

Sharp

• Add small overlap

• Gives micro radius

• Cannot detect on part

• Significantly improves cycle times

Y50

X

Y

X60

X-Axis

Time

Velo

city Y-Axis Y-Axis

Time

Velo

city X-Axis

Time

Velo

city X-Axis Y-Axis

Sharp Micro

radius

Too much overlap will round corners Y50

X

Y

X60

X-Axis

Time

Velo

city Y-Axis Y-Axis

Time

Velo

city X-Axis Y-Axis

Time

Velo

city X-Axis

Time V

elo

city X-Axis Y-Axis

Sharp Micro

radius

Rounded

corner

To improve cycle times and surface finish we need

1. Smooth tool paths

2. Good control of velocity, acceleration, and Jerk

3. Robust control loop to handle real-time disturbances and

changing loads

Y-Axis

Time

Velo

city X-Axis

Micro

radius

Mo

tio

n P

lan

nin

g

To improve cycle times and surface finish we need

1. Smooth tool paths

2. Good control of velocity, acceleration, and Jerk

3. Robust control loop to handle real-time disturbances and

changing loads

Y-Axis

Time

Velo

city X-Axis

Micro

radius

The UltiMotion Motion Planning system generates optimal

trajectories to squeeze the most out of your machine

Driver’s View

How far to look?

Start

End

Co-driver calls out a few obstacles ahead of current position

Look Ahead plans the smoothest, fastest trajectory

Obstacles at the end are not relevant at the start

Rally Race Stage

More Speed Look Farther

How far to look?

Myth: High block look ahead is necessary for

high-speed machining

Truth: Larger look ahead doesn’t hurt, but

may not be needed

UltiMotion Dynamic Look-Ahead

Proprietary, patented system

Dynamic variable length

Looks as far as it needs to

Up to 10,000 blocks

Never runs out of data

The Control Loop Feed Forward and Feedback

The Control Loop Look-Ahead

Driver plans the trajectory, accelerations & decelerations

Motion Planning output is the input to the Control Loop

Feed Forward Driver executes the predicted steering, gas and braking

levels to navigate the race track obstacles

For CNC it is the predicted output gains to the axes

servo drives to follow the tool path

This is the primary output of the control system

In a perfect world, the

machine would follow

the output exactly

Feed Forward

Feedback Control Driver monitors and adjusts controls based on the actual

response of the car

CNC Machine has axes encoders to measure actual

position and velocity

Feedback control makes small adjustments to servo

gains to compensate for real-world conditions

The Control Loop Control Loop = Feed Forward + Feedback

Feed Forward provides major portion of controller output

Feedback only has to correct for small disturbances by

monitoring following error

The UltiMotion Control Loop

Dynamic velocity, acceleration,

and Jerk modeling and control

Advanced digital filters for

vibration control and smooth

motion

Summary Putting it all together

Putting it all together Start with the part program (map)

Putting it all together Generate machine-specific motion data using part & tool setup

and machine Kinematics (pace notes)

Start Cycle begins the race

Putting it all together

Motion Planning 1. Smooth the path within

tolerance

2. Look-Ahead:

Advanced dynamic velocity,

acceleration, and jerk modeling

and control

Output feeds the Control Loop

Putting it all together Control Loop 1. Feed Forward: Predict control gains /

gas, steering, brake input

2. Feedback:

Monitor vehicle trajectory, adjust

controls if off track

Control monitors encoders and adjusts

axes control gains

41

UltiMotion Features What can UltiMotion do for you?

Superior Tapping Tapping requires tight coordination spindle and linear axes

Only available with UltiMotion

1. True Master-Slave control

Linear axes are slave to the Spindle (master)

The Spindle feedback is the linear axes control loop input

More accurate tapping

1. True Master-Slave control

Example—Badly tuned spindle

1. True Master-Slave control

Example—Badly tuned spindle

Superior Tapping 2. High-Speed Tap Retract

Up to 1000% faster retract out of tapped hole for faster

throughput

Master-Slave control

ensures accuracy

3. Override and motion hold

during tapping

4. Power loss Tap Recovery

E-Stop Tap Recovery

E-Stop Tap Recovery

E-Stop & Power Loss Control

During power loss or E-stop event, Ultimotion can:

retract smoothly

or hold the controlled position until brake engages

even during Tapping

On subsequent power-up, UltiMotion can extract the tap from the

hole without damaging the thread

Customer Testimonials

3D Solutions

Standard Motion

2 hours 20 min

40% gain in throughput 1.4 parts for every 1 they were making before

UltiMotion

1 hours 40 min

American Precision Machining

Ultimotion Standard Motion

50 minutes 1 hour 15 minutes

50% gain in throughput 1.5 parts for every 1 they were making before

Wepco Example from customer states:

S7 tool steel

100 hour part down to 30 hours

Over 230% gain in throughput

3.3 parts for every 1 part they were making before

“With UltiMotion … We are achieving extremely high feed

rates up to 800 IMP. … And I don't have to polish the mold!

the finish is that good.”

Dave Parmlee

High-Speed Machining

UltiMotion Standard Motion

High-Speed Machining • Identical

programs

• 29% cycle time

reduction

• Better surface

finish

Who can benefit from UltiMotion? Virtually all industries and parts

Both Conversational and NC users

Particularly:

3- through 5-Axis contouring

Pocketing

High-Speed Machining

Because of:

1. Higher feed rates

2. Smoother motion

3. Better surface finish

4. Higher accuracy

Repetitive drilling due to smoother rapid motion

Repetitive tapping from High Speed Tap Retract

Thank You