Computer controlled machine tool contouring system

Claim 2

In a contouring system including a machine tool, said machine tool having a cutting element with a lateral surface which is substantially symmetrical about a first or Z axis, and a workpiece support table having a top surface substantially disposed in a plane perpendicular to said Z axis, wherein said cutting element both rotates about and translates along said Z axis, and wherein said workpiece support table both rotates about a second or C axis, said C axis being parallel to said Z axis, and translates along a third or X axis, said X axis being perpendicular to said Z axis and having a point of intersection with said C and Z axes, the improvement comprising: a means for controlling said rotating and translating motions of said cutting element and said workpiece support table including: A. a cutting element drive means for rotating said cutting element at a predetermined angular velocity about said Z axis, and B. a positioning control means for controlling the relative position of said cutting element with respect to a sequence of predetermined spatial points, each of said spatial points bearing a predetermined spatial relationship to said top surface and each of said points having an associated reference tangent line segment passing therethrough, with said tangent line segment disposed parallel to said top surface of said support table at a predetermined angle defined with respect to a reference line segment on said top surface so that said support table is synchronously translated along said X axis and rotated about said C axis and said cutting element is translated along said Z axis, said cutting element having a contact point on the periphery thereof successively located at each of said spatial points and said cutting element further having its lateral surface at said contact point successively tangent to each of said reference tangent line segments at its associated spatial point.

Claim 3

In a contouring system including a machine tool, said machine tool having a cutting element with a lateral surface which is substantially symmetrical about a first or Z axis, and a workpiece support table having a top surface substantially disposed in a plane perpendicular to said Z axis, wherein said cutting element both rotates about and translates along said Z axis, and wherein said workpiece support table both rotates about a second or C axis, said C axis being parallel to said Z axis, and translates along a third or X axis, said X axis being perpendicular to said Z axis and having points of intersection with said C and Z axes, and further including a cutting element dressing means, wherein said dressing means translates along a fourth or P axis, said P axis being perpendicular to said Z axis and having a point of intersection with said Z axis, the improvement comprising: a means for controlling said rotating and translating motions of said cutting element and said workpiece support table including: A. a cutting element drive means for rotating said cutting element at a predetermined angular velocity about said Z axis, and B. a positioning control means for selectively controlling: i. the relative position of said cutting element with respect to a sequence of predetermined spatial points, each of said spatial points bearing a predetermined spatial relationship to said top surface and each of said points having an associated reference tangent line segment passing therethrough with said tangent line segment disposed parallel to said top surface of said support table at a predetermined angle defined with respect to a reference line segment on said top surface so that said support table is synchronously translated along said X axis and rotated about said C axis and said cutting element is translated along said Z axis, said cutting element having a contact point on the periphery thereof successively located at each of said spatial points and further having the lateral surface of said cutting element at said contact point tangent to each of said reference tangent line segments at its associated spatial point, and ii. the position of said cutting element along said Z axis and the relative position of said dressing means with respect to said cutting element lateral surface, whereby said dressing means is selectively translated along said P axis to dress said lateral surface of said cutting element.

Claim 4

In a contouring system including a machine tool, said machine tool having a cutting element with a lateral surface which is substantially symmetrical about a first or Z axis, and a workpiece support table having a top surface substantially disposed in a plane perpendicular to said Z axis, wherein said cutting element both rotates about and translates along said Z axis, and wherein said workpiece support table both rotates about a second or C axis, said C axis being parallel to said Z axis, and translates along a third or X axis, said X axis being perpendicular to said Z axis and having points of intersection with said C and Z axes, and further including a cutting element dressing means, wherein said dressing means translates along a fourth or P axis, said P axis being perpendicular to said Z axis and having a point of intersection with said Z axis, the improvement comprising: a means for controlling said rotating and translating motions of said cutting element and said workpiece support table including: A. a cutting element drive means for rotating said cutting element at a predetermined angular velocity about said Z axis, and B. a positioning control means for selectively controlling: i. the relative position of said cutting element with respect to a sequence of predetermined spatial points, each of said spatial points bearing a predetermined spatial relationship to said top surface and each of said points having an associated reference tangent line segment passing therethrough with said tangent line segment disposed parallel to said top surface of said support table at a predetermined angle defined with respect to a reference line segment on said top surface so that said support table is synchronously translated along said X axis and rotated about said C axis and said cutting element is translated along said Z axis, said cutting element having a contact point on the periphery thereof successively located at each of said spatial points and further having the lateral surface of said cutting element at said contact point tangent to each of said reference tangent line segments at its associated spatial point, and ii. the position of said cutting element along said Z axis and the relative position of said dressing means with respect to said cutting element lateral surface, whereby said dressing means is selectively translated along said P axis to dress said lateral surface of said cutting element.

Claim 5

A contouring system according to claim 2 wherein said positioning control means further comprises means to store input data including: A. contour data representative of the coordinates of each of said sequence of predetermined spatial points, said coordinates being measured with respect to a reference coordinate system on the top surface of said support table, B. pressure angle data for each of said spatial points relating said predetermined angle associated with each of said tangent line segments to said coordinates of the associated spatial point, and C. wheel radius data representative of the radial dimension of said cutting element.

Claim 6

A contouring system according to claim 3 wherein said positioning control means further comprises means to generate sensor data including: actual position data representative of the relative position of said cutting element with respect to said reference coordinate system of said top surface.

Claim 7

A contouring system according to claim 4 wherein A. said contour data is in polar coordinate form providing R and θ coordinate values for each of said sequence at spatial points, each R value being a measure of a radial line segment extending from said C axis to its associated spatial point and each θ value being a measure of the angular displacement of said radial line segment from a C axis angular zero reference line segment, and B. said pressure angle data providing a pressure angle or α value for each of said sequence of spatial points, said pressure angle value being a measure of the angle formed by a line segment perpendicular to said reference tangent line segment and passing through its associated spatial point, and said radial line segment extending from said C axis to its associated spatial point.

Claim 8

A contouring system according to claim 4 wherein: A. said coordinate data is in differential polar coordinate form providing R and θ coordinate values for a first of said sequence of spatial points, said R value being a measure of a radial line segment extending from said C axis to its associated spatial point and said θ value being a measure of the angular displacement of said radial line segment from a C axis angular zero reference line segment, and providing ΔR and Δθ coordinate values for each of the remaining spatial points, each ΔR value being a measure of the change in the radial distance from said C axis of the associated spatial point relative to the radial distance from said C axis to the preceding spatial point in said sequence and each Δθ value being a measure of the change in angular displacement of the radial line segment connecting the associated spatial point and said C axis relative to the corresponding angular displacement associated with the preceding spatial point in said sequence, and B. said pressure angle data is in differential form providing an α value for the first of said sequence of spatial points and a Δα value for each of the others of said sequence of spatial points, each Δα value being a measure of the change in pressure angle associated with each spatial point and the corresponding value for the previous spatial point in said sequence of points, said pressure angle value being a measure of the angle formed by a line segment perpendicular to said reference tangent line segment and passing through its associated spatial point, and said radial line segment extending from said C axis to its associated spatial point.

Claim 9

A contouring system according to claim 4 wherein said positioning control means further comprises: A. a data transformation means for transforming said input data and said sensor data to machine tool drive data, said drive data including: i. X-axis position error, velocity and acceleration drive data representative of the required position change, velocity and acceleration of said workpiece support table along said X axis for said cutting element contact point to approach said spatial point, ii. C-axis integrated velocity error drive data representative of the required change in angular velocity of said workpiece support table about said C axis for said cutting element contact point to approach said spatial point, and iii. Z-axis position drive data representative of the required position change for said cutting element contact point to approach said spatial point along said Z axis, B. a drive signal generating means for generating X axis position error, X axis velocity, X axis acceleration, C axis integrated velocity error, Z axis position error signals, and P axis position signals, from said machine tool drive data.

Claim 10

A contouring system according to claim 7 wherein said positioning control means further comprises: A. an actuating means including: i. an X axis servo positioning system for translating said support table along said X axis in response to said X axis position error, X axis velocity and X axis acceleration signals, ii. a C axis servo positioning system for rotating said support table about said C axis in response to said C axis integrated velocity error signals, iii. a Z axis servo positioning system for translating said cutting element along said Z axis in response to said Z axis position error signals, and iv. a P axis servo positioning system for translating said dressing element along said P axis in response to said P axis position signals.

Claim 11

A contouring system according to claim 8 wherein said data transformation means comprises: A. a first transformation means for transforming said stored input data to axis control data for each of said spatial points in said sequence, and storing said axis control data, said axis control data including: i. C axis position data or γ data representative of the relative angular displacement of a line segment connecting said Z axis with said C axis measured with respect to a C axis angular zero reference line segment on said support table, with said cutting element having said contact point located at said spatial point and the lateral surface of said cutting element at said contact point being tangent to the tangent line associated with said spatial point, and ii. X-axis position change data or C data representative of the ratio ΔX/Δγ of the required change in position of said support table, ΔX, along said X axis to position said cutting element with a contact point located at said spatial point and with the lateral surface of said cutting element at said contact point being tangent to the tangent line associated with said spatial point, from the corresponding position of said support table associated with the immediately preceding spatial point in said sequence of spatial points, to the change in γ data, Δγ, associated with said successive points in said sequence, and B. a second transformation means for transforming said axis control data and said sensor data machine tool drive data.

Claim 12

A contouring system according to claim 9 wherein said first transformation means includes means for: A. selectively generating and storing γ and C data for additional spatial points between selected pairs of said sequence of spatial points when the difference between the C data associated with a pair of said sequence of spatial points exceeds a predetermined threshold, and B. selectively inhibiting said storage of said axis control data for one of said sequence of spatial points when the difference between the γ data associated with that spatial point and the γ data associated with the immediately preceding spatial point in said succession is less than a predetermined threshold.

Claim 13

A contouring system according to claim 9 wherein said second transformation means comprises a computation means, said computation means including: A. receiving means for periodically receiving said sensor data, said sensor data being representative of the displacement, X PW , along the X axis and rotational displacement γ W about the C axis of the cutting element relative to said support table, the period of said receiving operation being performed during interrogation intervals having duration Δt, B. an identification means operative during each interrogation interval to identify the γ data associated with one of said spatial points as current γ data, γ N , C. a subtraction means operative during each interrogation interval and following each identification operation performed by said identification to generate a Δγ signal representative of the difference between γ W and the corresponding angular displacement γ H from the immediately preceding interval, according to the formula: Δγ = Δ W - Δ H , D. a best estimate of C signal generating means operative during each interrogation interval and following each subtraction operation performed by said subtraction means to generate an intermediate signal, γ 1 , according to the formula: ##EQU16## E. a comparison and identification means operative during each interrogation interval to compare the signals γ 1 and γ N , and when γ 1 is greater than γ N , to direct said identification means to identify the γ data associated with the next spatial point in said sequence as current data, γ N , and to identify as current C data, the C data stored with the γ data associated with γ N , F. an estimated γ signal generation means operative during each interrogation interval to generate an estimated γ signal, γ E , according to the formula: γ.sub.E = γ.sub.W + Δγ, G. a correction signal and X velocity data generation means operative during each interrogation interval to generate an X position correction data, ΔX d , representative of the product of the current C data and the difference between γ E and the corresponding value from the immediately preceding interval, according to the formula: ΔX.sub.d = (γ.sub.E - γ.sub.EH).C, said ΔX d data being representative of said X axis velocity drive data, H. a desired position signal generation means operative during each interrogation interval to generate an X desired position signal X d representative of the sum of the corresponding X desired position signal from the immediately preceding interval, X dH , and ΔX d , according to the formula: X.sub.d = X.sub.dH + ΔX.sub.d, I. an X acceleration data generation means operative during each interrogation interval to generate X acceleration data representative of the difference between ΔX d and the corresponding signal from the immediately preceding interval ΔX dH , said acceleration data being representative of said X axis acceleration drive data, J. an X position error data generation means operative during each interrogation interval to generate X position error data representative of the difference between X PW and X d , said X position error data being representative of said X axis position error drive data.

Claim 14

A contouring system according to claim 8 wherein said positioning control means further comprises: A. a P axis signal generating means for directing a cutting element dressing operation at predetermined times by generating said P axis position signals and applying said P axis position signals to said P axis servo positioning system, whereby said dressing means is translated along said P axis to dress said cutting element to a predetermined radial dimension, B. a first means associated with said P axis signal generating means for modifying said stored cutting element radius data during each of said cutting element dressing operations, whereby said stored cutting element radius data is representative of the current cutting element radius, C. a second means associated with said P axis signal generating means operative following each of said cutting element dressing operations to direct said drive signal generating means to generate said X axis position error, X axis velocity, X axis acceleration, C axis integrated velocity error and Z axis position error signals from said stored contour data, said stored pressure angle data, said stored modified cutting element radius data.

Claim 15

A contouring system according to claim 12 wherein said data transformation means comprises: A. a first transformation means for transforming said stored input data to axis control data for each of said spatial points in said sequence, and storing said axis control data, said axis control data including: i. C axis position data or data representative of the relative angular displacement of a line segment connecting said Z axis with said C axis measured with respect to a C axis angular zero reference line segment on said support table with said cutting element having said contact point located at said spatial point and the lateral surface of said cutting element at said contact point being tangent to the tangent line associated with said spatial point, and ii. X-axis position change data or C data representative of the ratio ΔX/Δγof the required change in position of said support table, ΔX, along said X axis to position said cutting element with a contact point located at said spatial point and with the lateral surface of said cutting element at said contact point being tangent to the tangent line associated with said spatial point, from the corresponding position of said support table associated with the immediately preceding spatial point in said sequence of spatial points, to the change in γ data, Δγ, associated with said successive points in said sequence, and B. a second transformation means for transforming said axis control data and said sensor data to said machine tool drive data.

Claim 16

A contouring system according to claim 13 wherein said first transformation means is a programmed digital computer.

Claim 17

A contouring system according to claim 13 wherein said first transformation means includes means for: A. selectively generating and storing γ and C data for additional spatial points between selected pairs of said sequence of spatial points when the difference between the C data associated with a pair of said sequence of spatial points exceeds a predetermined threshold, and B. selectively inhibiting said storage of said axis control data for one of said sequence of spatial points when the difference between the γ data associated with that spatial point and the γ data associated with the immediately preceding spatial point in said succession is less than a predetermined threshold.

Claim 18

A contouring system according to claim 13 wherein said first transformation means is operative to transform said stored input data to said axis control data during a first time period, said first time period being associated with each of said cutting element dressing operations and wherein said second transformation means is operative to transform said axis control data and said sensor data to said machine tool drive data during a second time period, said second time period following said first time period and ending prior to the commencement of the next of said cutting element dressing operations.

Claim 19

A contouring system according to claim 16 wherein said second transformation means comprises a computation means, said computation means including: A. receiving means for periodically receiving said sensor data, said sensor data being representative of the displacement, X PW , along the X axis and rotational displacement γ W about the C axis of the cutting element relative to said support table, the period of said receiving operation being performed during interrogation intervals having duration Δt, B. an identification means operative during each interrogation interval to identify the γ data associated with one of said spatial points as current γ data, γ N , C. a subtraction means operative during each interrogation interval and following each identification operation performed by said identification to generate a Δγ signal representative of the difference between γ W and the corresponding angular displacement γ H from the immediately preceding interval, according to the formula: Δγ = γ.sub.W - γ.sub.H D. a best estimate of C signal generating means operative during each interrogation interval and following each subtraction operation performed by said subtraction means to generate an intermediate signal, γ 1 , according to the formula: ##EQU17## E. a comparison and identification means operative during each interrogation interval to compare the signals γ 1 and γ N , and when γ 1 is greater than γ N , to direct said identification means to identify the γ data associated with the next spatial point in said sequence as current data, γ N , and to identify as current C data, the C data stored with the γ data associated with γ N , F. an estimated γ signal generation means operative during each interrogation interval to generate an estimated γ signal, γ E , according to the formula: γ.sub.E = γ.sub.W + Δγ, G. a correction signal and X velocity data generation means operative during each interrogation interval to generate an X position correction data, ΔX d , representative of the product of the current C data and the difference between γ E and the corresponding value from the immediately preceding interval, according to the formula: ΔX.sub.d = (γ.sub.E - γ.sub.EH).C, said ΔX d data being representative of said X axis velocity drive data, H. a desired position signal generation means operative during each interrogation interval to generate an X desired position signal X d representative of the sum of the corresponding X desired position signal from the immediately preceding interval, X dH , and ΔX d , according to the formula: X.sub.d = X.sub.dH + ΔX.sub.d, I. an X acceleration data generation means operative during each interrogation interval to generate X acceleration data representative of the difference between ΔX d and the corresponding signal from the immediately preceding interval ΔX dH , said acceleration data being representative of said X axis acceleration drive data, J. an X position error data generation means operative during each interrogation interval to generate X position error data representative of the difference between X PW and X d , said X position error data being representative of said X axis position error drive data.

Claim 20

A contouring system according to claim 2 wherein said positioning control means further controls the relative position of said cutting element whereby the period of time between positioning said contact point at successive ones of said spatial points is directly proportional to the distance between said successive spatial points, with a predetermined constant of proportionality.

Claim 21

A contouring system according to claim 18 wherein said positioning control means further comprises means to store input data including: A. contour data representative of the coordinates of each of said sequence of predetermined spatial points, said coordinates being measured with respect to a reference coordinate system on the top surface of said positioning table, B. pressure angle data for each of said spatial points relating said predetermined angle associated with each of said tangent line segments to said coordinates of the associated spatial points, C. wheel radius data representative of the radial dimension of said cutting element, and D. surface velocity or V s data representative of said predetermined constant of proportionality relating said periods of time associated with the positioning of said contact point between successive ones of said spatial points to the distance between said successive spatial points.

Claim 22

A contouring system according to claim 19 wherein said positioning control means further comprises means to generate sensor data including: actual position data representative of the relative position of said cutting element with respect to said reference coordinate system of said top surface.

Claim 23

A contouring system according to claim 20 wherein: A. said contour data is in polar coordinate form providing R and θ coordinate values for each of said sequence at spatial points, each R value being a measure of a radial line segment extending from said C axis to its associated spatial point and each θ value being a measure of the angular displacement of said radial line segment from a C axis angular zero reference line segment, and B. said pressure angle data providing a pressure angle or α value for each of said sequence of spatial points, said pressure angle value being a measure of the angle formed by a line segment perpendicular to said reference tangent line segment and passing through its associated spatial point, and said radial line segment extending from said C axis to its associated spatial point.

Claim 24

A contouring system according to claim 20 wherein: A. said coordinate data is in differential polar coordinate form providing R and θ coordinate values for a first of said sequence of spatial points, said R value being a measure of a radial line segment extending from said C axis to its associated spatial point and said θ value being a measure of the angular displacement of said radial line segment from a C axis angular zero reference line segment, and providing ΔR and Δθ coordinate values for each of the remaining spatial points, each ΔR value being a measure of the change in the radial distance from said C axis of the associated spatial point relative to the radial distance from said C axis to the preceding spatial point in said sequence and each Δθ value being a measure of the change in angular displacement of the radial line segment connecting the associated spatial point and said C axis relative to the corresponding angular displacement associated with the preceding spatial point in said sequence, and B. said pressure angle data is in differential form providing an α value for the first of said sequence of spatial points and a Δα value for each of the others of said sequence of spatial points, each Δα value being a measure of the change in pressure angle associated with each spatial point and the corresponding value for the previous spatial point in said sequence of points, said pressure angle value being a measure of the angle formed by a line segment perpendicular to said reference tangent line segment and passing through its associated spatial point, and said radial line segment extending from said C axis to its associated spatial point.

Claim 25

A contouring system according to claim 20 wherein said positioning control means further comprises: A. a data transformation means for transforming said input data and said sensor data to machine tool drive data, said drive data including: i. X-axis position error, velocity and acceleration drive data representative of the required position change, velocity and acceleration of said workpiece support table along said X axis for said cutting element contact point to approach said spatial point, ii. C-axis integrated velocity error drive data representative of the required change in angular velocity of said workpiece support table about said C axis for said cutting element contact point to approach said spatial point, and iii. Z-axis position drive data representative of the required position change for said cutting element contact point to approach said spatial point along said axis, B. a drive signal generating means for generating X axis position error, X axis velocity, X axis acceleration, C integrated velocity error, Z axis position error signals and P axis position signals from said machine tool drive data.

Claim 26

A contouring system according to claim 23 wherein said positioning control means further comprises: A. an actuating means including: i. an X axis servo positioning system for translating said support table along said X axis in response to said applied X axis position error, X axis velocity and X axis acceleration signals, ii. a C axis servo positioning system for rotating said positioning table about said C axis in response to said C axis integrated velocity error signals, iii. a Z axis servo positioning system for translating said cutting element along said Z axis in response to said Z axis error position signals, and iv. a P axis servo positioning system for translating said dressing element along said P axis in response to said P axis position signals.

Claim 27

A contouring system according to claim 24 wherein said data transformation means comprises: A. a first transformation means for transforming said stored input data to axis control data for each of said spatial points in said sequence, and storing said axis control data, said axis control data including: i. C axis position data, or γ data representative of the relative angular displacement of a line segment connecting said Z axis with said C axis measured with respect to a C axis angular zero reference line segment on said support table with said cutting element having said contact point located at said spatial point and the lateral surface of said cutting element at said contact point being tangent to the tangent line associated with said spatial point, ii. X-axis position change data or C data representative of the ratio of the required change in position of said support table, ΔX, along said X axis to position said cutting element with a contact point located at said spatial point and with the lateral surface of said cutting element at said contact point being tangent to the tangent line associated with said spatial point, from the corresponding position of said support table associated with the immediately preceding spatial points, to the change in γ data, Δγ, associated with said successive points in said sequence, iii. C axis angular velocity, V, representative of the required angular velocity of said positioning table about said C axis to approach said spatial point with the contact point having said predetermined surface velocity, and B. a second transformation means for transforming said axis control data and said sensor data to said machine tool drive data.

Claim 28

A contouring system according to claim 25 wherein said first transformation means includes means for: A. selectively generating and storing γ, C and V data for additional spatial points between selected pairs of said sequence of spatial points when the difference between the C data associated with a pair of said sequence of spatial points exceeds a predetermined threshold, and B. selectively inhibiting said storage of said axis control data for one of said sequence of spatial points when the difference between the γ data associated with that spatial point and the γ data associated with the immediately preceding spatial point in said succession is less than a predetermined threshold.

Claim 29

A contouring system according to claim 25 wherein said second transformation means comprises a computation means, said computation means including: A. receiving means for periodically receiving said sensor data, said sensor data being representative of the displacement, X PW , along the X axis and rotational displacement γ W about the C axis of the cutting element relative to said support table, the period of said receiving operation being performed during interrogation intervals having duration Δt, B. an identification means operative during each interrogation interval to identify the γ data associated with one of said spatial points as current γ data, γ N , C. a subtraction means operative during each interrogation interval and following each identification operation performed by said identification to generate a Δγ signal representative of the difference between γ W and the corresponding angular displacement γ H from the immediately preceding interval, according to the formula: Δγ = γ.sub.W - γ.sub.H D. a best estimate of C signal generating means operative during each interrogation interval and following each subtraction operation performed by said subtraction means to generate an intermediate signal, γ, according to the formula: ##EQU18## E. a comparison and identification means operative during each interrogation interval to compare the signals γ 1 and γ N , and when γ 1 is greater than γ N , to direct said identification means to identify the γ data associated with the next spatial point in said sequence as current data, γ N , and to identify as current C and current V data the C and V data stored with the γ data associated with γ N , F. an estimated γ signal generation means operative during each interrogation interval to generate an estimated γ signal, γ E , according to the formula: γ.sub.E = γ.sub.W + Δγ, G. a correction signal and X velocity data generation means operative during each interrogation interval to generate an X position correction data, ΔX d , representative of the product of the current C data and the difference between γ E and the corresponding value from the immediately preceding interval, according to the formula: ΔX.sub.d = (γ.sub.E - γ.sub.EH).C, said ΔX d data being representative of said X axis velocity drive data, H. a desired position signal generation means operative during each interrogation interval to generate an X desired position signal X d representative of the sum of the corresponding X desired position signal from the immediately preceding interval, X dH , and ΔX d , according to the formula: X.sub.d = X.sub.dH + ΔX.sub.d, I. an X acceleration data generation means operative during each interrogation interval to generate X acceleration data representative of the difference between ΔX d and the corresponding signal from the immediately preceding interval ΔX dH said acceleration data being representative of said X axis acceleration drive data, J. an X position error data generation means operative during each interrogation interval to generate X position error data representative of the difference between X PW and X d , said X position error data being representative of said X axis position error drive data, and K. a C axis integrated velocity error generation means operative during each interrogation interval for generating V C data representative of the difference between said current V data and the sum of Δγ and the corresponding V C value from the immediately preceding interval, said V C data being representative of said C axis integrated velocity error data.

Claim 30

A contouring system according to claim 24 wherein said positioning control means further comprises: A. a P axis signal generating means for directing a cutting element dressing operation at predetermined times by generating said P axis position signals and applying said P axis position signals to said P axis servo positioning system, whereby said dressing means is translated along said P axis to dress said cutting element to a predetermined radial dimension, B. a first means associated with said P axis signal generating means for modifying said stored cutting element radius data during each of said cutting element dressing operations, whereby said stored cutting element radius data is representative of the current cutting element radius, C. a second means associated with said P axis signal generating means operative following each of said cutting element dressing operations to direct said drive signal generating means to generate said X axis position error, X axis velocity, X axis acceleration, C axis integrated velocity error and Z axis position error signals from said stored contour data, said stored pressure angle data, and said stored modified cutting element radius data and said surface velocity data.

Claim 31

A contouring system according to claim 28 wherein said data transformation means comprises: A. a first transformation means for transforming said stored input data to axis control data for each of said spatial points in said sequence, and storing said axis control data, said axis control data including: i. C axis position data or γ data representative of the relative angular displacement of a line segment connecting said Z axis with said C axis measured with respect to a C axis angular zero reference line segment on said support table with said cutting element having said contact point located at said spatial point and the lateral surface of said cutting element at said contact point being tangent to the tangent line associated with said spatial point, ii. X-axis position change data or C data representative of the ratio ΔX/Δγ of the required change in position of said support table, ΔX, along said X axis to position said cutting element with a contact point located at said spatial point and with the lateral surface of said cutting element at said contact point being tangent to the tangent line associated with said spatial point, from the corresponding position of said support table associated with the immediately preceding spatial point in said sequence of spatial points, to the change in γ data, Δγ, associated with said successive points in said sequence, iii. C axis angular velocity, V, representative of the required angular velocity of said positioning table about said C axis to approach said spatial point with the contact point having said predetermined surface velocity, and B. a second transformation means for transforming said axis control data and said sensor data to said machine tool drive data.

Claim 32

A contouring system according to claim 29 wherein said first transformation means is a programmed digital computer.

Claim 33

A contouring system according to claim 29 wherein said first transformation means includes means for: A. selectively generating and storing γ, C and V data for additional spatial points between selected pairs of said sequence of spatial points when the difference between the C data associated with a pair of said sequence of spatial points exceeds a predetermined threshold, and B. selectively inhibiting said storage of said axis control data for one of said sequence of spatial points when the difference between the γ data associated with that spatial point and the γ data associated with the immediately preceding spatial point in said succession is less than a predetermined threshold.

Claim 34

A contouring system according to claim 29 wherein said first transformation means is operative to transform said stored input data to said axis control data during a first time period, said first time period being associated with each of said cutting element dressing operations, and wherein said second transformation means is operative to transform said axis control data and said sensor data to said machine tool drive data during a second time period, said second time period following said first time period and ending prior to the commencement of the next of said cutting element dressing operations.

Claim 35

A contouring system according to claim 32 wherein said second transformation means comprises a computation means, said computation means including: A. receiving means for periodically receiving said sensor data, said sensor data being representative of the displacement, X PW , along the X axis and rotational displacement γ W about the C axis of the cutting element relative to said support table, the period of said receiving operation being performed during interrogation intervals having duration Δt, B. an identification means operative during each interrogation interval to identify the γ data associated with one of said spatial points as current γ data, γ N , C. a subtraction means operative during each interrogation interval and following each identification operation performed by said identification to generate a Δγ signal representative of the difference between γ W and the corresponding angular displacement γ H from the immediately preceding interval, according to the formula: Δγ = γ.sub.W - γ.sub.H D. a best estimate of C signal generating means operative during each interrogation interval and following each subtraction operation performed by said subtraction means to generate an intermediate signal, γ 1 , according to the formula: ##EQU19## E. a comparison and identification means operative during each interrogation interval to compare the signals γ 1 and γ N , and when γ 1 is greater than γ N , to direct said identification means to identify the γ data associated with the next spatial point in said sequence as current data, γ N , and to identify as current C and current V data the C and V data stored with the γ data associated with γ N , F. an estimated γ signal generation means operative during each interrogation interval to generate an estimated γ signal, γ E , according to the formula: γ.sub.E = γ.sub.W + Δγ, G. a correction signal and X velocity data generation means operative during each interrogation interval to generate an X position correction data, ΔX d , representative of the product of the current C data and the difference between γ E and the corresponding value from the immediately preceding interval, according to the formula: ΔX.sub.d = (γ.sub.E - γ.sub.EH).C, said ΔX d data being representative of said X axis velocity drive data, H. a desired position signal generation means operative during each interrogation interval to generate an X desired position signal X d representative of the sum of the corresponding X desired position signal from the immediately preceding interval, X dH , and ΔX d , according to the formula: X.sub.d = X.sub.dH + ΔX.sub.d, I. an X acceleration data generation means operative during each interrogation interval to generate X acceleration data representative of the difference between ΔX d and the corresponding signal from the immediately preceding interval ΔX dH , said acceleration data being representative of said X axis acceleration drive data, J. an X position error data generation means operative during each interrogation interval to generate X position error data representative of the difference between X PW and X d , said X position error data being representative of said X axis position error drive data, and K. a C axis velocity error generation means operative during each interrogation interval for generating V C data representative of the difference between said current V data and the sum of Δγ and the corresponding V C value from the immediately preceding interval, said V C data being representative of said C axis integrated velocity error data.

Claim 36

In a contouring system including a machine tool, said machine tool having a cutting element with a lateral surface which is substantially symmetrical about a first or Z axis, and a workpiece support table having a top surface substantially disposed in a plane perpendicular to said Z axis, wherein said cutting element both rotates about and translates along said Z axis, and wherein said workpiece support table both rotates about a second or C axis, said C axis being parallel to said Z axis, and translates along a third or X axis, said X axis being perpendicular to said Z axis and having points of intersection with said C and Z axes, and further including a cutting element dressing means, wherein said dressing means translates along a fourth or P axis, said P axis being perpendicular to said Z axis and having a point of intersection with said Z axis, the improvement comprising: a means for controlling said rotating and translating motions of said cutting element and said workpiece support table including: A. a cutting element drive means for rotating said cutting element at a predetermined angular velocity about said Z axis, and B. a positioning control means for selectively controlling: i. the relative position of said cutting element with respect to a sequence of predetermined spatial points, each of said spatial points bearing a predetermined spatial relationship to said top surface and each of said points having an associated reference tangent line segment passing therethrough with said tangent line segment disposed parallel to said top surface of said support table at a predetermined angle defined with respect to a reference line segment on said top surface so that said support table is synchronously translated along said X axis and rotated about said C axis and said cutting element is translated along said Z axis, said cutting element having a contact point on the periphery thereof successively located at one of a set of intermediate points wherein ach intermediate point is offset by a predetermined distance along said X axis from an associated one of said succession of spatial points, said predetermined offset distance being a decreasing function of time, and said cutting element further having its lateral surface at said contact point successively tangent to one of a set of offset line segments, each of said offset line segments being parallel to an associated reference tangent line segment and passing through one of said intermediate points, and ii. the position of said cutting element along the Z axis and the relative position of said dressing means with respect to said cutting element lateral surface, whereby said dressing means is selectively translated along the P axis to dress said lateral surface of said cutting element.

Claim 37

In a contouring system including a machine tool, said machine tool having a cutting element with a lateral surface which is substantially symmetrical about a first or Z axis, and a workpiece support table having a top surface substantially disposed in a plane perpendicular to said Z axis, wherein said cutting element both rotates about and translates along said Z axis, and wherein said workpiece support table both rotates about a second or C axis, said C axis being parallel to said Z axis, and translates along a third or X axis, said X axis being perpendicular to said Z axis and having points of intersection with said C and Z axes, and further including a cutting element dressing means, wherein said dressing means translates along a fourth or P axis, said P axis being perpendicular to said Z axis and having a point of intersection with said Z axis, the improvement comprising: a means for controlling said rotating and translating motions of said cutting element and said workpiece support table including: A. a cutting element drive means for rotating said cutting element at a predetermined angular velocity about said Z axis, and B. a positioning control means for selectively controlling: i. the relative position of said cutting element with respect to a sequence of predetermined spatial points, each of said spatial points bearing a predetermined spatial relationship to said top surface and each of said points having an associated reference tangent line segment passing therethrough with said tangent line segment disposed parallel to said top surface of said support table at a predetermined angle defined with respect to a reference line segment on said top surface so that said support table is synchronously translated along said X axis and rotated about said C axis and said cutting element is translated along said Z axis, said cutting element having a contact point on the periphery thereof successively located at one of a set of intermediate points wherein ach intermediate point is offset by a predetermined distance along said X axis from an associated one of said succession of spatial points, said predetermined offset distance being a decreasing function of time, and said cutting element further having its lateral surface at said contact point successively tangent to one of a set of offset line segments, each of said offset line segments being parallel to an associated reference tangent line segment and passing through one of said intermediate points, and ii. the position of said cutting element along the Z axis and the relative position of said dressing means with respect to said cutting element lateral surface, whereby said dressing means is selectively translated along the P axis to dress said lateral surface of said cutting element.

Claim 38

Method of generating a contour utilizing a computer controlled machine tool, said machine tool having a cutting element with a lateral surface which is substantially symmetrical about a first or Z axis, and a workpiece support table having a top surface substantially disposed in a plane perpendicular to said Z axis, wherein said cutting element both rotates about the translates along said Z axis, and wherein said workpiece support table both rotates about a second or C axis, said C axis being parallel to said Z axis, and translates along a third or X axis, said X axis being perpendicular to said Z axis and having points of intersection with said C and Z axes, said method comprising the steps of: A. storing R-θ-Z-V s -W r -α input data representative of: i. the coordinates of a predetermined sequence of spatial points on said contour, said coordinates being measured with respect to a reference coordinate system on said top surface, ii. a predetermined pressure angle associated with each of said spatial points, said pressure angle bearing a predetermined relation to said coordinate system, iii. the surface velocity at which a contact point on the periphery of said cutting element is to pass through each of said spatial points, iv. an initial radial dimension of said cutting element, B. periodically dressing said cutting element at predetermined dressing times whereby the radial dimension of said cutting element is reduced to a value differing by a predetermined increment from the corresponding value associated with the immediately preceding dressing time, C. periodically modifying said stored cutting element radial dimension data at said predetermined dressing times so that the modified radial dimension data is representative of the previously stored cutting element radial dimension data as reduced by said predetermined increment, D. transforming said stored data to γ-C-V axis control data for each of said spatial points during a first time period associated with each of said predetermined dressing times, E. periodically detecting and generating sensor data representative of the actual cutting element position relative to said support table during a second time period associated with each of said predetermined dressing times, each of said second time periods following the associated one of said first time periods and ending prior to the commencement of the next of said dressing steps, F. transforming said γ-C-V axis control data and said sensor data to X E -X V -X A -V C machine tool drive data during each of said second time periods, and G. controlling said support table according to said machine tool drive data to synchronously translate along said X axis and rotate about said C axis, and controlling said cutting element to translate along said Z axis, said cutting element having a contact point on the periphery thereof successively located at each of said spatial points and said cutting element being disposed at each of said spatial points at the pressure angle associated with said point, and such that the period of time between positioning said contact point at successive ones of said spatial points is directly proportional to the distance between said successive spatial points, with a predetermined constant of proportionality.

Claim 39

Method of generating a contour utilizing a computer controlled machine tool, said machine tool having a cutting element with a lateral surface which is substantially symmetrical about a first or Z axis, and a workpiece support table having a top surface substantially disposed in a plane perpendicular to said Z axis, wherein said cutting element both rotates about the translates along said Z axis, and wherein said workpiece support table both rotates about a second or C axis, said C axis being parallel to said Z axis, and translates along a third or X axis, said X axis being perpendicular to said Z axis and having points of intersection with said C and Z axes, said method comprising the steps of: A. storing R-θ-Z-V s -W r -α input data representative of: i. the coordinates of a predetermined sequence of spatial points on said contour, said coordinates being measured with respect to a reference coordinate system on said top surface, ii. a predetermined pressure angle associated with each of said spatial points, said pressure angle bearing a predetermined relation to said coordinate system, iii. the surface velocity at which a contact point on the periphery of said cutting element is to pass through each of said spatial points, iv. an initial radial dimension of said cutting element, B. periodically dressing said cutting element at predetermined dressing times whereby the radial dimension of said cutting element is reduced to a value differing by a predetermined increment from the corresponding value associated with the immediately preceding dressing time, C. periodically modifying said stored cutting element radial dimension data at said predetermined dressing times so that the modified radial dimension data is representative of the previously stored cutting element radial dimension data as reduced by said predetermined increment, D. transforming said stored data to γ-C-V axis control data for each of said spatial points during a first time period associated with each of said predetermined dressing times, E. periodically detecting and generating sensor data representative of the actual cutting element position relative to said support table during a second time period associated with each of said predetermined dressing times, each of said second time periods following the associated one of said first time periods and ending prior to the commencement of the next of said dressing steps, F. transforming said γ-C-V axis control data and said sensor data to X E -X V -X A -V C machine tool drive data during each of said second time periods, and G. controlling said support table according to said machine tool drive data to synchronously translate along said X axis and rotate about said C axis, and controlling said cutting element to translate along said Z axis, said cutting element having a contact point on the periphery thereof successively located at each of said spatial points and said cutting element being disposed at each of said spatial points at the pressure angle associated with said point, and such that the period of time between positioning said contact point at successive ones of said spatial points is directly proportional to the distance between said successive spatial points, with a predetermined constant of proportionality.

Claim 40

A contouring system according to claim 1 wherein said positioning control means further comprises means to store input data including: A. contour data representative of the coordinates of each of said sequence of predetermined spatial points, said coordinates being measured with respect to a reference coordinate system on the top surface of said support table, B. pressure angle data for each of said spatial points relating said predetermined angle associated with each of said tangent line segments to said coordinates of the associated spatial point, and C. wheel radius data representative of the radial dimension of said cutting element.

Claim 41

A contouring system according to claim 36 wherein said positioning control means further comprises means to generate sensor data including: actual position data representative of the relative position of said cutting element with respect to said reference coordinate system of said top surface.

Claim 42

A contouring system according to claim 37 wherein A. said contour data is in polar coordinate form providing R and θ coordinate for each of said sequence at spatial points, each R value being a measure of a radial line segment extending from said C axis to its associated spatial point and each θ value being a measure of the angular displacement of said radial line segment from a C axis angular zero reference line segment, and B. said pressure angle data providing a pressure angle or α value for each of said sequence of spatial points, said pressure angle value being a measure of the angle formed by a line segment perpendicular to said reference tangent line segment and passing through its associated spatial point, and said radial line segment extending from said C axis to its associated spatial point.

Claim 43

A contouring system according to claim 37 wherein: A. said coordinate data is in differential polar coordinate form providing R and θ coordinate values for a first of said sequence of spatial points, said R value being a measure of a radial line segment extending from said C axis to its associated spatial point and said θ value being a measure of the angular displacement of said radial line segment from a C axis angular zero reference line segment, and providing ΔR and Δθ coordinate values for each of the remaining spatial points, each ΔR value being a measure of the change in the radial distance from said C axis of the associated spatial point relative to the radial distance from said C axis to the preceding spatial point in said sequence and each Δθ value being a measure of the change in angular displacement of the radial line segment connecting the associated dspatial point and said C axis relative to the corresponding angular displacement associated with the preceding spatial point in said sequence, and B. said pressure angle data is in differential form providing an α value for the first of said sequence of spatial points and a Δα value for each of the others of said sequence of spatial points, each Δα value being a measure of the change in pressure angle associated with each spatial point and the corresponding value for the previous spatial point in said sequence of points, said pressure angle value being a measure of the angle formed by a line segment perpendicular to said reference tangent line segment and passing through its associated spatial point, and said radial line segment extending from said C axis to its associated spatial point.

Claim 44

A contouring system according to claim 37 wherein said positioning control means further comprises: A. a data transformation means for transforming said input data and said sensor data machine tool drive data, said drive data including: i. X-axis position error, velocity and acceleration drive data representative of the required position change, velocity and acceleration of said workpiece support table along said X axis for said cutting element contact point to approach said spatial point, ii. C-axis integrated velocity error drive data representative of the required change in angular velocity of said workpiece support table about said C axis for said cutting element contact point to approach said spatial point, and iii. Z-axis position drive data representative of the required position change for said cutting element contact point to approach said spatial point along said Z axis, B. a drive signal generating means for generating X axis position error, X axis velocity, X axis acceleration, C axis integrated velocity error, and Z axis position error signals from said machine tool drive data.

Claim 45

A contouring system according to claim 40 wherein said positioning control means further comprises: A. an actuating means including: i. an X axis servo positioning system for translating said support table along said X axis in response to said X axis position error, X axis velocity and X axis acceleration signals, ii. a C axis servo positioning system for rotating said support table about said C axis in response to said C axis integrated velocity error signals, iii. a Z axis servo positioning system for translating said cutting element along said Z axis in response to said Z axis position error signals.

Claim 46

A contouring system according to claim 41 wherein said data transformation means comprises: A. a first transformation means for transforming said stored input data to axis control data for each of said spatial points in said sequence, and storing said axis control data, said axis control data including: i. C axis position data or γ data representative of the relative angular displacement of a line segment connecting said Z axis with said C axis measured with respect to a C axis angular zero reference line segment on said support table, with said cutting element having said contact point located at said spatial point and the lateral surface of said cutting element at said contact point being tangent to the tangent line associated with said spatial point, and ii. X-axis position change data or C data representative of the ratio ΔX/Δγ of the required change in position of said support table, ΔX, along said X axis to position said cutting element with a contact point located at said spatial point and with the lateral surface of said cutting element at said contact point being tangent to the tangent line associated with said spatial point, from the corresponding position of said support table associated with the immediately preceding spatial point in said sequence of spatial points, to the change in γ data, Δγ, associated with said successive points in said sequence, and B. a second transformation means for transforming said axis control data and said sensor data machine tool drive data.

Claim 47

A contouring system according to claim 42 wherein said first transformation includes means for: A. selectively generating and storing γ and C data for additional spatial points between selected pairs of said sequence of spatial points when the difference between the C data associated with a pair of said sequence of spatial points exceeds a predetermined threshold, and B. selectively inhibiting said storage of said axis control data for one of said sequence of spatial points when the difference between the γ data associated with that spatial point and the γ data associated with the immediately preceding spatial point in said succession is less than a predetermined threshold.

Claim 48

A contouring system according to claim 42 wherein said second transformation means comprises a computation means, said computation means including: A. receiving means for periodically receiving said sensor data, said sensor data being representative of the displacement, X PW , along the X axis and rotational displacement γ W about the C axis of the cutting element relative to said support table, the period of said receiving operation being performed during interrogation intervals having duration Δt, B. an identification means operative during each interrogation interval to identify the γ data associated with one of said spatial points as current γ data, γ N , C. a subtraction means operative during each interrogation interval and following each identification operation performed by said identification to generate a Δγ signal representative of the difference between γ W and the corresponding angular displacement γ H from the immediately preceding interval, according to the formula: Δγ = γ W - γ H , D. a best estimate of C signal generating means operative during each interrogation interval and following each subtraction operation performed by said subtraction means to generate an intermediate signal, γ 1 , according to the formula: ##EQU20## E. a comparison and identification means operative during each interrogation interval to compare the signals γ 1 and γ N , when γ 1 is greater than γ N , to direct said identification means to identify the γ data associated with the next spatial point in said sequence as current data, γ N , and to identify as current C data, the C data stored with the γ data associated with γ N , F. an estimated γ signal generation means operative during each interrogation interval to generate an estimated γ signal, γ E , according to the formula: γ.sub.E = γ.sub.W + Δγ, G. a correction signal and X velocity data generation means operative during each interrogation interval to generate an X position correction data, ΔX d , representative of the product of the current C data and the difference between γ E and the corresponding value from the immediately preceding interval, according to the formula: ΔX.sub.d = (γ.sub.E - γ.sub.EH) . C, said ΔX d data being representative of said X axis velocity drive data, H. a desired position signal generation means operative during each interrogation interval to generate an X desired position signal X d representative of the sum of the corresponding X desired position signal from the immediately preceding interval, X dH , and ΔX d , according to the formula: X.sub.d = X.sub.dH + ΔX.sub.d, I. an X acceleration data generation means operative during each interrogation interval to generate X acceleration data representative of the difference between ΔX d and the corresponding signal from the immediately preceding interval ΔX dH , said acceleration data being representative of said X axis acceleration drive data, J. an X position error data generation means operative during each interrogation interval to generate X position error data representative of the difference between X PW and X d , said X position error data being representative of said X axis position error drive data.

Claim 49

A contouring system according to claim 1 wherein said positioning control means further controls the relative position of said cutting element whereby the period of time between positioning said contact point at successive ones of said spatial points is directly proportional to the distance between said successive spatial points, with a predetermined constant of proportionality.

Claim 50

A contouring system according to claim 45 wherein said positioning control means further comprises means to store input data including: A. contour data representative of the coordinates of each of said sequence of predetermined spatial points, said coordinates being measured with respect to a reference coordinate system on the top surface of said positioning table, B. pressure angle data for each of said spatial points relating said predetermined angle associated with each of said tangent line segments to said coordinates of the associated spatial point, C. wheel radius data representative of the radial dimension of said cutting element, and D. surface velocity or V s data representative of said predetermined constant of proportionality relating said periods of time associated with the positioning of said contact point between successive ones of said spatial points to the distance between said successive spatial points.

Claim 51

A contouring system according to claim 46 wherein said positioning control means further comprises means to generate sensor data including: actual position data representative of the relative position of said cutting element with respect to said reference coordinate system of said top surface.

Claim 52

A contouring system according to claim 47 wherein: A. said contour data is in polar coordinate form providing R and θ coordinate values for each of said sequence at spatial points, each R value being a measure of a spatial line segment extending from said C axis to its associated spatial point and each θ value being a measure of the angular displacement of said radial line segment from a C axis angular zero reference line segment, and B. said pressure angle data providing a pressure angle or α value for each of said sequence of spatial points, said pressure angle value being a measure of the angle formed by a line segment perpendicular to said reference tangent line segment and passing through its associated spatial point, and said radial line segment extending from said C axis to its associated spatial point.

Claim 53

A contouring system according to claim 47 wherein: A. said coordinate data is in differential polar coordinate form providing R and θ coordinate values for a first of said sequence of spatial points, said R value being a measure of a radial line segment extending from said C axis to its associated spatial point and said θ value being a measure of the angular displacement of said radial line segment from a C axis angular zero reference line segment, and providing ΔR and Δθ coordinate values for each of the remaining spatial points, each ΔR value being a measure of the change in the radial distance from said C axis of the associated spatial point relative to the radial distance from said C axis to the preceding spatial point in said sequence and each Δθ value being a measure of the change in angular displacement of the radial line segment connecting the associated spatial point and said C axis relative to the corresponding angular displacement associated with the preceding spatial point in said sequence, and B. said pressure angle data is in differential form providing an α value for the first of said sequence of spatial points and a Δα value for each of the others of said sequence of spatial points, each Δα value being a measure of the change in pressure angle associated with each spatial point and the corresponding value for the previous spatial point in said sequence of points, said pressure angle value being a measure of the angle formed by a line segment perpendicular to said reference tangent line segment and passing through its associated spatial point, and said radial line segment extending from said C axis to its associated spatial point.

Claim 54

A contouring system according to claim 47 wherein said positioning control means further comprises: A. a data transformation means for transforming said input data and said sensor data to machine tool drive data, said drive data including: i. X-axis position error, velocity and acceleration drive data representative of the required position change, velocity and acceleration of said workpiece support table along said X axis for said cutting element contact point to approach said spatial point, ii. C-axis integrated velocity error drive data representative of the required change in angular velocity of said workpiece support table about said C axis for said cutting element contact point to approach said spatial point, and iii. Z-axis position drive data representative of the required position change for said cutting element contact point to approach said spatial point along said axis, B. a drive signal generating means for generating X axis position error, X axis velocity, X axis acceleration, C integrated velocity error, and Z axis position error signals from said machine tool drive data.

Claim 55

A contouring system according to claim 50 wherein said positioning control means further comprises: A. an actuating means including: i. an X axis servo positioning system for translating said support table along said X axis in response to said applied X axis position error, X axis velocity and X axis acceleration signals, ii. a C axis servo positioning system for rotating said positioning table about said C axis in response to said C axis integrated velocity error signals, iii. a Z axis servo positioning system for translating said cutting element along said Z axis in response to said Z axis error position signals.

Claim 56

A contouring system according to claim 51 wherein said data transformation means comprises: A. a first transformation means for transforming said stored input data to axis control data for each of said spatial points in said sequence, and storing said axis control data, said axis control data including: i. C axis position data, or γ data representative of the relative angular displacement of a line segment connecting said Z axis with said C axis measured with respect to a C axis angular zero reference line segment on said support table with said cutting element having said contact point located at said spatial point and the lateral surface of said cutting element at said contact point being tangent to the tangent line associated with said spatial point, ii. X-axis position change data or C data representative of the ratio of the required change in position of said support table, ΔX, along said X axis to position said cutting element with a contact point located at said spatial point and with the lateral surface of said cutting element at said contact point being tangent to the tangent line associated with said spatial point, from the corresponding position of said support table associated with the immediately preceding spatial points, to the change in γ data, Δγ, associated with said successive points in said sequence, iii. C axis angular velocity, V, representative of the required angular velocity of said positioning table about said C axis to approach said spatial point with the contact point having said predetermined surface velocity, and B. a second transformation means for transforming said axis control data and said sensor data to said machine tool drive data.

Claim 57

A contouring system according to claim 52 wherein said first transformation includes means for: A. selectively generating and storing γ, C and V data for additional spatial points between selected pairs of said sequence of spatial points when the difference between the C data associated with a pair of said sequence of spatial points exceeds a predetermined threshold, and B. selectively inhibiting said storage of said axis control data for one of said sequence of spatial points when the difference between the γ data associated with that spatial point and the γ data associated with the immediately preceding spatial point in said succession is less than a predetermined threshold.

Claim 58

A contouring system according to claim 52 wherein said second transformation means comprises a computation means, said computation means including: A. receiving means for periodically receiving said sensor data, said sensor data being representative of the displacement, X PW , along the X axis and rotational displacement γ W about the C axis of the cutting element relative to said support table, the period of said receiving operation being performed during interrogation intervals having duration Δt, B. an identification means operative during each interrogation interval to identify the γ data associated with one of said spatial points as current γ data, γ N , C. a subtraction means operative during each interrogation interval and following each identification operation performed by said identification to generate a Δγ signal representative of the difference between γ W and the corresponding angular displacement γ H from the immediately preceding interval, according to the formula: Δγ = γ.sub.W - γ.sub.H D. a best estimate of C signal generating means operative during each interrogation interval and following each subtraction operation performed by said subtraction means to generate an intermediate signal, γ according to the formula: ##EQU21## E. a comparison and identification means operative during each interrogation interval to compare the signals γ 1 and γ N , and when γ 1 is greater than γ N , to direct said identification means to identify the γ data associated with the next spatial point in said sequence as current data, γ N , and to identify as current C and current V data the C and V data stored with the γ data associated with γ N , F. an estimated γ signal generation means operative during each interrogation interval to generate an estimated γ signal, γ E , according to the formula: γ.sub.E = γ.sub.W + Δγ, G. a correction signal and X velocity data generation means operative during each interrogation interval to generate an X position correction data, ΔX d , representative of the product of the current C data and the difference between γ E and the corresponding value from the immediately preceding interval, according to the formula: ΔX.sub.d = (γ.sub.E - γ.sub.EH). C, said ΔX d data being representative of said X axis velocity drive data, H. a desired position signal generation means operative during each interrogation interval to generate an X desired position signal X d representative of the sum of the corresponding X desired position signal from the immediately preceding interval, X dH , and ΔX d , according to the formula: X.sub.d = X.sub.dH + ΔX.sub.d, I. an X acceleratiion data generation means operative during each interrogation interval to generate X acceleration data representative of the difference between ΔX d and the corresponding signal from the immediately preceding interval ΔX dH , said acceleration data being representative of said X axis acceleration drive data, J. an X position error data generation means operative during each interrogation interval to generate X position error data representative of the difference between X PW and X d , said X position error data being representative of said X axis position error drive data, and K. a C axis integrated velocity error generation means operative during each interrogation interval for generating V C data representative of the difference between said current V data and the sum of Δγ and the corresponding V C value from the immediately preceding interval, said V C data being representative of said C axis integrated velocity error data.