Automated Cross Slide System for Flange Resurfacing

Solution Overview

Problem

Conventional machining of industrial equipment, such as flange connections, is time-consuming, prone to operator error, and poses safety risks due to manual operation, especially in hazardous environments, leading to production downtime and inaccurate resurfacing.

Innovation Solution

An automated cross slide system with a cross slide mechanism, powered by servo motors and controlled by a communications hub and administrative processor, which uses pre-defined specification profiles to accurately machine surfaces without manual intervention, allowing for on-site operation and reduced downtime.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional manual machining is used, then the equipment can be remached at a machine shop, but production downtime increases due to removal and transportation

Engineering Contradiction:

Improveflange face surface specificationVSAvoidproduction downtime

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

A portable automated cross slide system with cutting tool is introduced as an intermediary solution that can be brought to the equipment location. This eliminates the need to remove and transport heavy equipment to a machine shop, thereby reducing production downtime while maintaining machining capability through automated precision cutting operations

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Manual mechanical machining operations are replaced with an automated cross slide system controlled by servo motors and computer numerically controlled (CNC) technology. This substitution eliminates manual intervention, improves machining precision, and enables the system to operate in hazardous environments where manual operation would be unsafe

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If manual operation by operator is used, then the machining can be performed, but operator safety is at risk in hazardous environments

Engineering Contradiction:

Improveremachining capabilityVSAvoidoperator safety risk

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The automated cross slide system performs machining operations autonomously without requiring operator presence in hazardous environments. The system uses automated tool positioning, cutting parameter control, and cycle execution to complete remachining tasks independently, thereby eliminating operator exposure to harmful factors such as volatile organic compounds and flammable atmospheres

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical machining operations are replaced with an automated cross slide system controlled by servo motors and computer numerically controlled (CNC) technology. This substitution eliminates manual intervention, improves machining precision, and enables the system to operate in hazardous environments where manual operation would be unsafe

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If manual operation is used, then the operator can control the machining, but operator error may result in defective surfaces

Engineering Contradiction:

Improvemanual control flexibilityVSAvoidremachined surface accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

Manual mechanical machining operations are replaced with an automated cross slide system controlled by servo motors and computer numerically controlled (CNC) technology. This substitution eliminates manual intervention, improves machining precision, and enables the system to operate in hazardous environments where manual operation would be unsafe

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The automated cross slide system incorporates feedback mechanisms through CNC control that continuously monitor and adjust cutting parameters, tool position, and machining depth. This closed-loop control ensures consistent machining accuracy and eliminates variability introduced by manual operation, guaranteeing that remachined surfaces meet specification requirements

Inventive Principle:

Principle #23Feedback

4Productivity

If automated cross slide system is used, then productivity increases and accuracy improves, but device complexity increases

Engineering Contradiction:

Improvemachining speed and accuracyVSAvoidautomated system structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The automated cross slide system is designed with universal applicability to machine various industrial equipment surfaces including flange connections, radial fits, piping, turbines, and pumps. By consolidating multiple machining capabilities into a single portable platform with interchangeable tools and programmable operations, the system achieves high productivity and accuracy without proportionally increasing complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Manual mechanical machining operations are replaced with an automated cross slide system controlled by servo motors and computer numerically controlled (CNC) technology. This substitution eliminates manual intervention, improves machining precision, and enables the system to operate in hazardous environments where manual operation would be unsafe

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 automated system significantly reduces production downtime, enhances machining accuracy, and improves safety by enabling precise resurfacing of industrial equipment surfaces according to specifications without the need for manual operation, even in hazardous environments.

Implementation Method 1

a first ball screw; a first gear box mounted to at least one of the pair of back plate end caps; a first servo motor connected between the first gear box and a first drive

Methodology Applied

Scientific EffectBall screw mechanism: Screw

Implementation Method 2

a pair of back plate linear guides mounted longitudinally to the back plate support member; a pair of front plate linear guides mounted longitudinally to the front plate support member

Methodology Applied

Scientific EffectLinear guide: Lubrication

Data Source

PatentUS9649695B1Automated cross slide system

Publication Date: 2017.05.16 MERIDIAN EQUIP

AI summary

An automated cross slide system having a cross slide with a back plate, a front plate and a saddle. The back plate can have a pair of end caps, a pair of linear guides, a first ball screw, a first gear box, a first servo motor, a first drive, and a first manual feed knob and the front plate can have a pair of end caps, a pair of linear guides, a second ball screw, a second gear box, a second servo motor, a second drive, and a second manual feed knob. The system can have a power supply, a communications hub with a processor and data storage connected to a network. The system can have a library of specification profiles and a human machine interface for accessing the library and controlling the first and second drives to cut a target piece in accordance with a selected specification profile.