Adjustable Roller Machining Assembly for Uneven Flanges
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Solution Overview
Problem
Existing machining assemblies for large tubular elements are dangerous, costly, difficult to install, and result in suboptimal machining due to vibration and uneven surfaces, particularly affecting the flanges of industrial vessels and wind turbine pylons.
Innovation Solution
A machining assembly with adjustable support rollers and a machining head that can adapt to uneven surfaces, using a hinge system to maintain a flat imaginary plane for precise machining, and a belt sander for efficient surface finishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional machining assembly with fixed support is used, then the machining structure is simple, but the machining precision deteriorates due to vibration and inability to adapt to uneven surfaces
Solution Approach 1:
The patent applies dynamics by making the support rollers movable along the arms rather than fixed. This allows the support rollers to dynamically adjust their positions to follow the contour of uneven flange surfaces, enabling the machining head to maintain consistent spacing and cutting depth throughout the machining process, thereby improving machining precision without requiring complex active control systems
Solution Approach 2:
The patent changes the positional parameters of the support rollers along the arms, allowing them to move to different locations based on the surface profile. This parameter adjustment enables the system to adapt to varying surface conditions and maintain optimal machining geometry, resolving the contradiction between simplicity and precision
2Object-affected harmful factors
If shielding is added to protect operators, then safety is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the machining operation from the traditional stationary setup and moves it to a portable, movable platform. By making the entire machining assembly mobile and self-contained, it can be positioned close to the workpiece and operated in a controlled manner, inherently improving safety without requiring extensive shielding structures
3Manufacturing precision
If accurate setting and alignment are performed, then machining precision is improved, but installation time and cost increase
Solution Approach 1:
The patent implements self-service through the automatic positioning capability of the support rollers. As the arms rotate and the support rollers move along them, they automatically find and maintain the correct positions relative to the flange surface profile. This self-positioning mechanism eliminates the need for manual alignment and setting operations, achieving both precision and time efficiency
Data Source
Figure 1~2
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AI summary
A circular workpiece surface is machined by a machining device comprising a positioning frame (2) and a machining device (10) connected to the positioning frame (2). The machining device (10) includes a machining head movable along the circular surface to machine the circular surface. The positioning frame (2) comprises a first subframe (3), provided with first support rollers (5) adapted to roll over the circular surface in a circular direction, and a second subframe (4) coupled to the first subframe (3). The position of the second subframe (4) is adjustable with respect to the first subframe (3). The machining head (11) of the machining device (10) is located between a pair of second support rollers (6) provided on the first subframe (3) or the second subframe. The machining head and the engagement surface of said pair of second support rollers (6) lie in one flat imaginary plane.