Air Slide Apparatus Vibration Control in Precision Roll Turning

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Solution Overview

Problem

Conventional roll turning lathes experience significant time and precision issues when machining large roll molds for optical products, as they require machining vast numbers of fine grooves, leading to vibration due to air slide apparatus deformation and inertia forces, which lowers machining efficiency and precision.

Innovation Solution

A precision roll turning lathe equipped with an air slide apparatus featuring a linear motor-driven air slider on a floating guide rail, a piezo element for precise cutting edge adjustment, and an inertia force correction mechanism to prevent vibration, along with a cutting chip suction apparatus to maintain air and power supply without bending cables, allowing for high-speed and precise machining.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If an air slide apparatus with cable chain is used to supply air and electric power to the air slider, then the air slider can move, but the cable chain deforms causing vibration that lowers machining precision

Engineering Contradiction:

Improveair slider movementVSAvoidmachining precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent replaces the mechanical cable chain system with a magnetic field-based power transmission system. A linear motor mounted on the guide rail generates a magnetic field that directly drives the air slider, eliminating the need for physical cable chains. This substitution removes the source of deformation and vibration, allowing the air slider to move smoothly without compromising machining precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Speed

If the air slider starts to move or changes direction, then the air slider can adjust position, but inertia force causes vibration that lowers machining precision

Engineering Contradiction:

Improveair slider response speedVSAvoidmachining precision

Core Design Contradiction:

SpeedVSManufacturing precision

Solution Approach 1:

The patent implements a feedback control system where sensors detect the position and motion state of the air slider in real-time. When the air slider starts to move or changes direction, the control system receives feedback signals and adjusts the magnetic field strength and direction accordingly. This feedback mechanism compensates for inertia forces, preventing vibration and maintaining machining precision during dynamic operations.

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If conventional roll turning lathe methods are used to machine vast numbers of fine grooves, then the roll mold can be machined, but it takes extremely long time (500 hours or 3 weeks)

Engineering Contradiction:

Improvefine groove machining capabilityVSAvoidmachining speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces the conventional mechanical carriage feed system with an air slide apparatus driven by a linear motor. This substitution enables high-speed movement of the cutting tool along the roll mold while maintaining precise positioning. The magnetic field-driven system can accelerate and decelerate rapidly without mechanical inertia constraints, allowing the machining of tens of thousands of fine grooves to be completed in a fraction of the original time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The solution enables dramatically faster machining of fine grooves, significantly reducing the time required for completing one groove and enhancing precision and efficiency, allowing for the machining of tens of thousands of grooves in a large-sized roll within two weeks compared to conventional methods which take three weeks or more.

Implementation Method 1

a linear motor for driving the air slider

Methodology Applied

Scientific EffectLinear motor: Linear Motor

Implementation Method 2

for causing slight displacement of the position of the cutting edge of the diamond tool in a cutting direction by utilizing expansion and contraction of a piezo element upon application of a voltage to the element

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 3

an air slider having a diamond tool, capable of traveling in a floating state on the guide rail

Methodology Applied

Scientific EffectAir bearing: Air Lubrication

Data Source

PatentUS8272302B2Precision roll turning lathe

Publication Date: 2012.09.25 TOSHIBA MASCH CO LTD

AI summary

There is provided a precision roll turning lathe which can perform machining of fine grooves at a dramatically higher speed as compared to conventional roll turning lathes, thus significantly shortening time taken for machining one groove. The precision roll turning lathe includes: a bed; a headstock, mounted on the bed, having a main spindle for rotating a roll as a workpiece while holding one end of the roll by means of a chuck; a tail stock, mounted on the bed and disposed opposite the headstock, for rotatably supporting the other end of the roll; a carriage including a saddle mounted on the bed movably in the longitudinal direction of the roll, and a table mounted on the saddle movably in a direction perpendicular to the longitudinal direction of the roll; and an air slide apparatus, mounted on the table, including a guide rail extending parallel to the roll in the longitudinal direction, an air slider having a diamond tool, capable of traveling in a floating state on the guide rail, and a linear motor for driving the air slider.