Hybrid CNC milling machine for machining metallic and non-metallic materials

Abstract

The present patent application relates to a hybrid CNC milling machine (1) comprising a structural chassis (2) and a Cartesian motion system (3) configured with three main axes (X, Y and Z), which use linear guides (25) and stepper motors or servomotors connected to a conventional control system. The machine incorporates a hybrid machining head (4), which includes a water-cooled 7 hp milling spindle (7), dedicated to machining aluminium tubes, and a 4 hp milling spindle (8) used for cutting and machining sheets of ACM, wood and other materials. The worktable (5) is provided with automatic positioning cylinders (9) and lateral fastening devices (17) with adjustable movable jaws (19, 21) connected to a vacuum pump (20). The machine further comprises an extension module (10) with an access-control mechanism for square tubes, including a pneumatic piston (12) and a tilting hatch (14). By combining sheet and tube cutting and machining functionalities, the invention promotes increased precision, efficiency and cost-effectiveness, eliminating the need for multiple pieces of equipment and being applicable to the field of manufacturing façades, doors and various metal structures.

Description

[0001] Hybrid CNC milling machine for machining metallic and non-metallic materials.

[0002] FIELD OF THE INVENTION

[0003]

[0001] This patent application relates to a hybrid CNC milling machine configured for a wide range of applications in machining and cutting metallic and non-metallic materials. The field of application is geared towards the manufacturing industry, more particularly for companies specializing in the production of ACM facades, doors, frames, and aluminum profile structures. The present invention aims to provide a multifunctional piece of equipment capable of machining aluminum frames and profiles, cutting and machining ACM (Aluminum Composite Material) sheets, and processing round or square metal tubes, promoting greater versatility, precision, and efficiency in material processing. Additionally, the present invention contributes to reducing operational costs and the need for multiple pieces of equipment, optimizing production processes and ensuring better use of industrial resources.

[0004] PROBLEM TO BE SOLVED

[0005]

[0002] Currently, there are CNC routers designed exclusively for cutting metal and non-metallic sheets. These machines do not have the capacity to perform both machining and cutting of aluminum profiles on a single machine. This creates the need to use different machines for distinct tasks. Thus, the operator needs to cut sheets on a specific machine and, if it is necessary to cut tubular parts, will be required to use another machine designed for this type of cutting. Furthermore, if the company or the operator does not have this second machine, it will be necessary to send the parts to another location for tubular cutting. This situation entails additional costs for the manufacturer, including the investment in two separate pieces of equipment, which reflects the current reality of machining.

[0006] CURRENT STATE OF THE ART

[0003] The current state of the art document US11565360B2 is known, which teaches about a control system for a wood numerical machining center, which includes a CNC (Computer Numerical Control) controller connected to a bus to manage multiple bidirectional and parallel control units, covering control of the headstock, worktable, human-machine interface and communication. The headstock control comprises drive units for milling spindles and vertical, horizontal and rotational movement, with each unit interconnected to data and control buses. The control system also incorporates input and output (I / O) modules, position and speed detection devices, motors and associated drive devices, allowing precise movements in the X, Y and Z directions. The servo feeder units move the table and milling devices, ensuring synchronized control.The architecture emphasizes modularity, bidirectional communication, and precision for efficient operation across multiple axes and functions.

[0007]

[0004] Document US2820187 teaches about an automated control system for a bridge-type planing mill, enabling high-precision machining operations on multiple axes. The system uses electric motors to move components such as the longitudinal table, the cutting head, and a universal fixture composed of angularly adjustable plates. The position and movement of the axes are controlled by feed spindles, commutator systems, and counters, which receive commands from punched cards or tapes containing coded information. These commands are processed by a central control unit, comparing the expected values ​​with the feedback data generated by commutators in real time. The system allows for incremental and absolute adjustment of speeds, directions, and positions, ensuring precision in operations such as linear cuts, perforations, or the generation of complex surfaces, including three-dimensional surfaces.Furthermore, safety mechanisms verify the correct functioning of the reading and control devices to prevent errors, providing reliability and efficiency in the machining process.

[0008]

[0005] Document RO138252 describes a modular and reconfigurable structure for a gantry-type CNC milling machine, characterized by the use of extruded aluminum profiles to ensure a rigid and customizable structure. The configuration includes two fixed uprights connected by a table on which the workpiece is fixed, with a work unit mounted on the gantry that moves along the (X, Y, Z) axes. The uprights have upper profiles with channels for linear guides and supports for bearings and ball screws. The uprights are composed of lower and upper profiles of rectangular section, connected by vertical and horizontal profiles for greater structural rigidity. The table is formed by additional profiles, and the structure is reinforced with strategically positioned profiles to avoid interfering with the machine's operation. The coaxiality of the ball screw bearings is ensured by supports with protrusions that fit into the profile channels.The profiles used vary in cross-section, being 40x120 mm for main components and 40x40 mm for secondary reinforcements and supports, providing strength and modular flexibility.

[0009]

[0006] Document US6390900 describes a finishing tool for workpiece edges, configured to operate on a machining machine without the need to lift the workpiece from the table support surface, as shown in Figures 1 to 4. The tool has a one-piece carbide steel construction, including a removable shank section, mounted on the shaft of a 9 hp motor capable of operating at up to 18,000 rpm. The head section has a top surface, a parallel bottom surface, and an annular side surface with a profile corresponding to the previously milled edge of the workpiece. The annular surface is coated with synthetic abrasive particles, preferably synthetic diamond grit, facilitating high-precision finishing.Unlike conventional tools, the robust configuration of this tool allows for edge finishing directly on the table, without interfering with the support surface, operating at higher speeds and feed rates, such as 8,000 rpm and 300 inches per minute. The robust construction also results in greater durability, better finish, and enables use on small radius corners due to the reduced head diameter. Productivity is increased by avoiding interruptions in the operating cycle for workpiece repositioning, reducing manufacturing costs and improving overall process efficiency. Modifications or adaptations to the tool are possible provided they maintain the spirit and scope of the invention, as described in the appended claims.

[0010]

[0007] Document BR 102023010496-7 teaches about a set of structural elements designed to integrate additive and subtractive manufacturing operations in a CNC milling machine, ensuring efficiency, precision, and equipment protection. The rubber cushion acts as an interface between the original milling machine table and the modified table for combined operations, reducing vibrations and protecting workpiece quality. The protective plate isolates the work area, preventing damage to the machine from high-temperature metal splashes during arc welding. The tool turret support connects the additive operation to the CNC milling machine, allowing precise vertical adjustment of the welding torch to align with the milling tool, while the torch holder securely fixes the torch in a triangular profile, enabling further adjustments.Finally, the worktable is designed to withstand high temperatures and facilitate the clamping of parts with widely spaced holes, being mounted on rubber cushions to minimize interference. These elements work in an integrated manner, optimizing the milling machine's adaptation for hybrid processes.

[0011]

[0008] The present invention differs technically from the prior art documents cited by incorporating innovative functionalities in a single hybrid device, intended for machining metallic and non-metallic materials, while addressing specific limitations identified in the analyzed documents. Unlike document US11565360B2, which emphasizes modular and bidirectional control in machining centers, the present invention innovates by featuring automatic positioning cylinders for precise sheet alignment and an extension module equipped with automatic lateral clamping devices, elements absent in the prior art.Furthermore, unlike document US2820187, which focuses on automated control systems based on external commands, the present invention integrates advanced clamping and access control functionality for metal pipes, using mechanisms such as the pneumatic piston and the tilting gate, which allow for precise and safe handling of parts in a single piece of equipment.

[0009] On the other hand, document RO138252 deals with a rigid modular structure for CNC gantry milling machines, but does not teach about the functional integration of automated clamping devices and dynamic positioning mechanism present in the machine described herein.

[0012]

[0010] Document US6390900 is limited to edge finishing tools, whereas the present invention combines milling and cutting functionalities in different materials, focusing on versatility and economy of operational resources.

[0013]

[0011] Finally, unlike document BR 102023010496-7, which is intended for the integration of additive and subtractive operations, the present invention focuses on the hybrid machining of metal sheets and tubes, offering integrated solutions that optimize productivity and precision.

[0014] OBJECTIVES OF THE INVENTION

[0015]

[0012] The objective of the present invention is to provide a hybrid device capable of combining, in a single machine, the machining of sheets of metallic and non-metallic materials, as well as the functionality of processing aluminum tubes, eliminating the need for multiple devices.

[0016]

[0013] The objective of the present invention is to increase efficiency and precision in the manufacturing process of aluminum parts, enabling the execution of cuts, grooves and openings in metal tubes with greater uniformity and control.

[0017]

[0014] The objective of the present invention is to reduce dependence on skilled labor and the need for outsourced services, optimizing production flow and reducing operating costs.

[0018]

[0015] The objective of the present invention is to promote savings in the initial investment of consumers, by integrating distinct functionalities into a single piece of equipment, eliminating the need to purchase separate machines.

[0019]

[0016] The objective of the present invention is to minimize material losses and displacement of parts between equipment or external installations, increasing the productivity and reliability of industrial processes.

[0017] The objective of the present invention is to serve a wide range of industrial applications, including the manufacture of ACM facades, doors, frames, and aluminum profile structures, expanding the versatility and reach of the machine.

[0020] OF THE INVENTION

[0021]

[0018] The present invention comprises a hybrid CNC milling machine, designed to integrate, in a single piece of equipment, the machining functionalities of metal and non-metal sheets, as well as the processing of aluminum tubes, eliminating the need for multiple machines. The invention includes a Cartesian motion system with three main axes X, Y and Z, a hybrid machining head with two distinct milling axes, and a worktable equipped with automatic positioning cylinders and lateral clamping devices, ensuring precision, stability and versatility in the processing of different materials. The system is equipped with an extension module with an access control mechanism for metal tubes, which includes a pneumatic piston and a tilting gate, allowing precise and safe positioning of materials. This results in greater operational efficiency, reduced material losses and increased productivity.Additionally, the present invention features collection drawers to facilitate waste disposal and automatic mechanisms for adjusting the height of the movable grippers, contributing to greater flexibility in processing pipes of different dimensions, as well as reduced operating costs and less dependence on specialized labor.

[0022] ADVANTAGES OF THE INVENTION

[0023]

[0019] The present invention offers the following advantages:

[0024] A combination of functionalities in a single piece of equipment, allowing for the machining of metal and non-metallic sheets, as well as the processing of aluminum tubes;

[0025] Significant reduction in the need for labor, promoting greater automation and efficiency in the production process;

[0026] Elimination of the need to purchase and operate two separate pieces of equipment to perform sheet and tube cutting and machining tasks; Increased precision and efficiency in the manufacture of aluminum parts, with uniform, high-quality cuts and finishes;

[0027] Reduced initial investment, since a single hybrid device is capable of performing multiple functions, lowering costs for the consumer;

[0028] Increased productivity, by allowing all processes to be carried out on a single machine, without the need to move materials to outsourced services;

[0029] Minimizing material losses by eliminating the transport of parts between different equipment or locations, thus preserving their quality and integrity;

[0030] Greater versatility in application, making it suitable for industries that manufacture ACM facades, doors, frames, and aluminum profile structures.

[0031] Optimization of physical space in the installation, due to the integration of functionalities in a single compact device;

[0032] Increased reliability of industrial processes, with an efficient and integrated system that reduces dependence on external equipment and services.

[0033] DESCRIPTION OF THE FIGURES

[0034]

[0020] The following figures are presented to better explain the patent application in an illustrative and non-limiting manner:

[0035]

[0021] Fig. 1: shows a perspective view of the hybrid CNC milling machine for machining metallic and non-metallic materials;

[0036]

[0022] Fig. 2: shows a perspective view of the hybrid CNC milling machine for machining metallic and non-metallic materials, showing the sheet positioning cylinders;

[0037]

[0023] Fig. 3: shows a perspective view of the plurality of lateral fastening devices, arranged sequentially in the extension module;

[0038]

[0024] Fig. 4: shows a perspective view of the side clamping devices with two movable jaws: wherein the first movable jaw is actuated by a vacuum pump;

[0039]

[0025] Fig. 5: shows a perspective view of the movable grippers configured with height adjustment mechanisms;

[0040]

[0026] Fig. 6: shows a perspective view of the pneumatic piston moving the tilting door to a horizontal position, 180°, allowing the introduction of the metal tube;

[0027] Fig. 7: shows a perspective view of the drawers to prevent machined material residue from falling to the floor, facilitating cleaning and disposal.

[0041] DETAILED DESCRIPTION OF THE INVENTION

[0042]

[0028] The HYBRID CNC MILLING MACHINE FOR MACHINING METALLIC AND NON-METALLIC MATERIALS consists of a CNC milling machine (1) composed of a chassis (2) and a Cartesian motion system (3), which includes three main axes, namely, the X, Y and Z axes. Each axis is composed of linear guides (25) and stepper motors or servomotors, connected to a conventional control system (not shown). It also includes a machining head (4) and a work table (5), configured by a flat base (6).

[0043]

[0029] In more detail, the machining head (4) of the CNC milling machine (1) is configured with a 7 hp water-cooled milling spindle (7) dedicated to machining aluminum tubes, and a 4 hp milling spindle (8) used for machining and cutting ACM sheets, wood, acrylics, galvanized sheets, aluminum sheets and their derivatives, making the CNC milling machine (1) a hybrid machine.

[0044]

[0030] The work table (5) is equipped with positioning cylinders (9) to facilitate the square positioning of the sheets. The positioning cylinders (9) are controlled automatically, i.e., when activated by the control system, they are ejected to provide square positioning of the sheets or retracted to allow the insertion of the sheets.

[0045]

[0031] Furthermore, the CNC milling machine (1) is equipped with an extension module (10) integrated into the worktable (5). This extension module (10) is configured with an access control mechanism (11) for metal tubes, which is equipped with a pneumatic piston (12), fixed to the base of the extension module (10). The pneumatic piston (12) is connected to an articulated arm (13), coupled to the end of the pneumatic piston rod (12). The articulated arm (13) is connected to a tilting gate (14), fixed in bearings (15) by means of a shaft (16), which connects to the end of the articulated arm (13). The tilting gate (14) is configured to act as a physical barrier that prevents or allows access to metal tubes. In its initial configuration, the tilting door (14) is positioned at an angle of approximately 90° in relation to the work table (5), blocking the passage of the metal tubes.

[0046]

[0032] When the pneumatic piston (12) is at rest, it keeps the articulated arm (13) and, consequently, the tilting gate (14) in a vertical position, at 90°, preventing the introduction of metal tubes. Upon receiving an opening command, the pneumatic piston (12) is activated by compressed air, moving the articulated arm (13). This rotational movement tilts the tilting gate (14) to a horizontal position, at 180°, allowing the tube to be introduced into the processing area.

[0047]

[0033] The CNC milling machine (1) is equipped with a plurality of side clamping devices (17), arranged sequentially along guide rails (18). Each of the side clamping devices (17) is mounted equidistantly to ensure uniform clamping of large materials, such as metal tubes or ACM sheets. Each of the side clamping devices (17) includes two movable jaws: a first movable jaw (19), actuated by a vacuum pump (20), and a second movable jaw (21), which remains fixed. Both movable jaws are made of non-slip material, such as rubber or technical polymer, to prevent damage to the tubes and ensure firmness during handling. The vacuum pump (20) is connected to the first movable jaw (19) by means of flexible hoses (22).The vacuum pump (20) generates sufficient negative pressure to drive the linear movement of the first movable gripper (19), enabling it to be opened and closed as needed for fastening.

[0048]

[0034] Both movable clamps (19 and 21) are fitted with height adjustment mechanisms (23), which allow the clamping of tubes of different dimensions to be adapted.

[0049]

[0035] When the pneumatic piston (12) moves the tilting gate (14) to a horizontal position, 180°, it allows the metal tube to be inserted and fitted into the side clamping devices (17). The metal tube is positioned between the first movable clamp (19) and the second movable clamp (21), and the first movable clamp (19) is actuated by the vacuum pump (20), moving towards the second movable clamp (21) until the metal tube is firmly clamped. If the metal tube has varying dimensions, the operator can use the height adjustment mechanisms (23) to align the movable clamps (19 and 21) as needed, ensuring uniform contact across the entire surface of the metal tube. When clamping is no longer required, the vacuum pump (20) stops operating, allowing the first movable clamp (19) to return to its initial position.

[0050]

[0036] Nevertheless, the CNC milling machine (1) includes four drawers (24) to prevent machined material residue from falling on the floor, facilitating cleaning and disposal.

[0051]

[0037] In summary, the hybrid CNC milling machine (1), as described, has as its main advantage its ability to combine, in a single piece of equipment, functionalities for machining metal and non-metal sheets, as well as aluminum tubes, eliminating the need for two separate machines to perform these operations. The side clamping devices (17) allow the precise clamping of metal tubes for making grooves and openings, contributing to the reduction of labor, increased precision and efficiency in the manufacturing process of aluminum parts. Additionally, the present invention promotes significant savings in the initial investment, since it eliminates the need to purchase separate machines, as well as increasing productivity by reducing dependence on outsourced services and the movement of materials, thus avoiding losses and optimizing the production process.This set of advantages makes the hybrid CNC milling machine (1) an innovative, efficient and highly cost-effective solution for the industry.

Claims

CLAIMS 1) HYBRID CNC MILLING MACHINE FOR MACHINING METALLIC AND NON-METALLIC MATERIALS, comprising a chassis (2); a Cartesian motion system (3) configured with three main axes X, Y and Z, each axis being composed of linear guides (25) and stepper motors or servomotors connected to a conventional control system; a machining head (4) composed of: a 7 hp water-cooled milling spindle (7), dedicated to machining aluminum tubes; and a 4 hp milling spindle (8), used for machining and cutting ACM sheets, wood, acrylics, galvanized sheets, aluminum sheets and their derivatives; a work table (5) configured by a flat base (6), characterized by the work table (5) being equipped with automatic positioning cylinders (9) for aligning the sheets;an extension module (10), integrated into the work table (5), in which a sequential plurality of side clamping devices (17) are configured, arranged along guide rails (18), each side clamping device (17) being composed of: a first movable clamp (19), connected to a vacuum pump (20); and a second fixed movable clamp (21), both configured with height adjustment mechanisms (23); the extension module (10) comprises a pneumatic piston (12), connected to an articulated arm (13), which, in turn, actuates a tilting door (14), arranged in bearings (15), for access control of metal tubes; 2) A HYBRID CNC MILLING MACHINE FOR MACHINING METALLIC AND NON-METALLIC MATERIALS, according to claim 1, is characterized by having movable grippers (19, 21) made of non-slip material, such as rubber or technical polymer. 3) A HYBRID CNC MILLING MACHINE FOR MACHINING METALLIC AND NON-METALLIC MATERIALS, according to claim 1, is characterized by the positioning cylinders (9) being automatically controlled by the conventional control system, allowing the precise positioning of the sheets on the work table (5). 4) A HYBRID CNC MILLING MACHINE FOR MACHINING METALLIC AND NON-METALLIC MATERIALS, according to claim 1, is characterized by the tilting door (14) of the extension module (10) being moved to the horizontal position at 180° by the pneumatic piston (12), to allow the introduction of the metal tubes into the lateral clamping devices (17). 5) A HYBRID CNC MILLING MACHINE FOR MACHINING METALLIC AND NON-METALLIC MATERIALS, according to claim 1, is characterized by the vacuum pump (20) connected to the first movable gripper (19) generating negative pressure to allow the linear movement of the first movable gripper (19), adjusting its position to grip pipes or sheets. 6) A HYBRID CNC MILLING MACHINE FOR MACHINING METALLIC AND NON-METALLIC MATERIALS, according to claim 1, is characterized by having collection drawers (24) to collect machined material waste.

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