Automated Disc Tool Replacement System for Grinding Machines
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Solution Overview
Problem
Automated disc tools, such as grinding discs, rapidly lose their grinding surface in automated applications, necessitating efficient replacement solutions to improve efficiency.
Innovation Solution
A disc tool replacement machine that determines the tool holder's position, unfastens and removes the old disc tool, and fastens a new one using a controller, fastening tool, and gripper system, allowing for automated and efficient disc tool swapping without interrupting the robot's work process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated disc tools are used to improve productivity, then productivity increases, but the grinding surface is lost rapidly requiring frequent replacements
Solution Approach 1:
The system enables automated self-service replacement of disc tools. The robot automatically positions the tool holder, the fastening tool unscrews the fixing member, the gripper removes the worn disc tool and installs a new one, and then automatically fastens the fixing member again. This eliminates the need for manual operator intervention and allows continuous operation without interrupting the robot's work process.
2Ease of operation
If manual replacement of disc tools is performed, then operator control is maintained, but operator intervention increases workload and reduces efficiency
Solution Approach 1:
The patent replaces manual mechanical operations with an automated mechanical system. The robot's positioning system replaces manual tool holder placement, the fastening tool with motorized screwing mechanism replaces manual unscrewing and fastening, and the gripper system replaces manual disc tool removal and installation. This substitution eliminates operator physical workload while maintaining precise control through automated positioning and fastening forces.
3Reliability
If multiple tool holders are used to maintain continuous operation, then operational continuity is improved, but the number of components increases
Solution Approach 1:
The system performs preliminary action by maintaining a supply of pre-positioned new disc tools ready for immediate installation. When a disc tool needs replacement, the system automatically retrieves a new disc tool from the storage position and installs it without requiring operator intervention or waiting for manual preparation. This ensures operational continuity with minimal tool holder inventory.
4Productivity
If automated replacement system is implemented, then operational efficiency is improved, but device complexity increases
Solution Approach 1:
The system achieves multi-functionality by integrating multiple operations into a single automated replacement station. The robot performs both positioning of the tool holder and final installation, the fastening tool handles both unscrewing the fixing member and fastening it again, and the gripper system manages both removal of old disc tools and installation of new ones. This consolidation reduces the need for separate specialized devices for each operation.
Data Source
AI summary
A method and a machine for automatically changing a disc tool to a tool holder of an automated machine working with the disc tools is disclosed. The method includes in the disc tool replacement machine: determining that the tool holder is in a replacement area in the disc tool replacement machine; unfastening a fixing member of the tool holder by applying an unfastening force to the fixing member, wherein the fixing member fixes a disc tool to a backing plate of the tool holder through a through hole at a centre of the disc tool; removing the disc tool from the tool holder after said unfastening; inserting a new disc tool to the tool holder; and fastening the fixing member of the tool holder by applying a fastening force to the fixing member, thus fixing the disc tool to the backing plate of the tool holder through the through hole.