Acoustic Element Recess Machining via Planing Head Dynamics
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Solution Overview
Problem
Existing methods for producing acoustic elements with intersecting indentations are limited by slow production, high costs, and difficulty in changing parameters, particularly when using wooden blanks, due to complex machining processes.
Innovation Solution
A method using a planing head with relative movement to the material blank's feed direction allows for quick and precise cutting of second indentations without interrupting the feed movement, enabling easy shape parameter changes and stable production, using a cutting machine with simple design and superimposed adjustment and feed directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If disc milling tools with shaft movement are used to mill semicircular second recesses, then the acoustic element can be produced with intersecting grooves and recesses, but the production speed decreases due to stopping the feed motion or moving the shaft
Solution Approach 1:
The invention makes the cutting tool (planing head) movable relative to the workpiece in the feed direction, transforming the static shaft positioning system into a dynamic one where the planing head can move back and forth along the feed direction while the workpiece continues to feed, eliminating the need to stop feed motion and enabling continuous high-speed production of second recesses with precise semicircular cross-sections
2Productivity
If the shaft with disc milling tools is moved along with feed motion to mill second recesses, then continuous production is possible, but the machine complexity increases due to the movement mechanism
Solution Approach 1:
Instead of moving the workpiece relative to a stationary cutting tool (conventional approach), the invention inverts the relationship by making the cutting tool (planing head) move relative to the workpiece in the feed direction. This inversion simplifies the overall machine structure while enabling continuous production, as the planing head's movement along the feed direction can be achieved with a simple linear guide and motor system
3Adaptability or versatility
If disc milling tools are repositioned or replaced to change second recess parameters, then different acoustic element designs can be produced, but the time consumption increases
Solution Approach 1:
The invention enables parameter changes of the second recesses (depth, width, spacing) by adjusting the position and movement parameters of the planing head relative to the workpiece, rather than physically repositioning or replacing tools. This allows rapid reconfiguration of acoustic element designs by simply programming different feed rates, positioning offsets, and planing head movement parameters, dramatically reducing setup time and increasing versatility
4Extent of automation
If press forming process is used to form acoustic elements, then production can be automated, but the material selection is limited to pressable materials excluding wood
Solution Approach 1:
The invention replaces the press forming mechanical system with a machining system using a planing head that removes material to create second recesses. This substitution allows the use of wooden blanks and other materials that cannot be press-formed, while maintaining automation through programmed feed motion and planing head movement, thus expanding material versatility without sacrificing automation capability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method significantly enhances the speed and precision of producing acoustic elements with variable second indentations, reducing production time and costs while maintaining sound absorption quality, and allows for easy assembly into larger acoustic panels.
Implementation Method 1
At least one planing head (21, 22) is used to machine the second recesses (2) into the second side (12) of the material blank (10)
Data Source
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AI summary
A method for manufacturing an acoustic element comprising the steps of: forming the acoustic element from a material blank, wherein the acoustic element formed from the material blank has first recesses on a first side of the acoustic element and second recesses on a second side of the acoustic element opposite the first side, wherein the first recesses extend with their longitudinal axis along a first direction, wherein the second recesses extend with their longitudinal axis along the first direction, wherein the first recesses and the second recesses intersect, so that openings are formed between the first recesses of the first side and the second recesses of the second side, wherein the second recesses are machined from the material blank using at least one cutting tool (21, 22) of a machining tool.wherein the material blank (10) passes through the machining machine (20) with a feed movement in a feed direction (24) that is parallel to the first direction of the acoustic element, wherein the at least one machining tool rotates about an axis of rotation arranged parallel to an axis direction (26), wherein the at least one machining tool is moved in a positioning direction (25) during the machining of the second recesses (2) in order to machine the second recesses (2) along the first direction; wherein the at least one machining tool is at least one planing head (21, 22), wherein the material blank performs a relative movement parallel to the first direction and/or to the feed direction (24) with respect to the axis of rotation of the at least one planing head (21, 22).