Automated Insert Replacement Device for Machining Tools
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Solution Overview
Problem
Tools with multiple machining inserts, such as honeycomb router bits, require lengthy and tedious manual replacement, leading to operator fatigue and musculo-skeletal disorders due to the small size and positioning challenges of the inserts.
Innovation Solution
A device comprising a positioner, screwdriver station, grip device, conveyor with multiple stations, and a control center that automates the replacement process, allowing for quick and reliable exchange of inserts with minimal operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual replacement of machining inserts is performed, then operator control and flexibility are maintained, but replacement time increases and operator fatigue leads to musculo-skeletal disorders
Solution Approach 1:
The system performs self-service through automated insert replacement. The robot gripper automatically grasps inserts from receptacles, positions them on the tool head, and secures them with screws without continuous human intervention. The conveyor system automatically feeds new inserts and collects used ones, enabling the system to service itself during operation.
Solution Approach 2:
Manual mechanical operations are replaced by an automated robotic system. The robot gripper substitutes human hands for grasping small inserts, the screwdriver station replaces manual screw tightening, and the automated conveyor system substitutes manual insert handling. This mechanical substitution eliminates operator fatigue while maintaining precision.
2Reliability
If all inserts are replaced manually, then complete tool maintenance is achieved, but the process becomes lengthy and tedious
Solution Approach 1:
The system maintains continuous useful action by automatically replacing all inserts on the tool head without interruption. The robot systematically moves from one insert position to the next, continuously performing grasping, positioning, and securing operations. The conveyor system continuously feeds new inserts and removes used ones, ensuring the replacement process flows without delays.
Solution Approach 2:
The insert replacement process is segmented into discrete automated operations: insert detection, gripper positioning, insert grasping, transport to receptacle, new insert retrieval, positioning on tool head, and screw securing. Each segment is performed automatically by specialized components, enabling complete replacement of multiple inserts efficiently and reliably.
3Area of stationary object
If inserts are held small and positioned densely on the head, then tool compactness is improved, but gripping difficulty increases
Solution Approach 1:
The robot gripper acts as an intermediary between the operator and the small inserts. Instead of human fingers directly grasping difficult-to-hold inserts, the specialized gripper with adjustable fingers provides a mechanical intermediary that can adapt to small insert dimensions and secure them reliably. This intermediary eliminates the gripping difficulty while maintaining dense insert arrangement.
Data Source
AI summary
The invention relates to a replacement device (1) for replacing machining inserts (900) on a tool (800) comprising a body (810) and a head (820) carrying at least one machining insert (900), each insert being held on the head (820) by a screw. The device (1) comprises:a positioner (50) including a holder element (59) suitable for holding the body (810) of the tool;a screwdriver station with a screw gun (60) suitable for tightening and loosening the screws, the positioner (50) being suitable for moving the tool relative to the screwdriver station;a grip device (70) suitable for picking up and putting down an insert (900);a conveyor (500) having a plurality of receptacles (510) for inserts, and having distributed along it a first station (100) with the grip device (70), a second station (200) with a turning mechanism (20) for turning the inserts around, a third station (300) with an unloading mechanism (30) for unloading the inserts, and a fourth station (400) with an insert feed mechanism (40);a transport mechanism (80) suitable for moving the grip device (70) between the positioner (50) and the first station (100) of the conveyor (500); anda control center (600) suitable for automatically controlling one or more of the mechanisms and devices and/or the conveyor of the replacement device (1).