Portable Boring Bar Feed and Alignment for Precise Line Boring
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Solution Overview
Problem
Portable line boring machines face challenges in efficiently aligning and moving boring bars within workpieces due to limited precision and flexibility in existing feed and alignment mechanisms, which affects the accuracy and efficiency of material removal and addition processes.
Innovation Solution
The proposed solution includes a feed assembly with a gear mechanism for directional movement of the boring bar, an alignment device with a conical surface for precise alignment, and a clamp assembly for secure engagement of the lead screw, along with a drive unit and sensor system for controlled operation and feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional feed mechanism is used, then the boring bar can move along the bar axis, but the precision and flexibility of movement is limited
Solution Approach 1:
The patent replaces conventional mechanical feed mechanisms with an electric motor-driven lead screw system. The electric motor (26) rotates the lead screw (42), which translates rotational motion into precise linear movement of the boring bar through the nut (142). This substitution provides more precise control and flexibility while reducing mechanical complexity through electrification and electronic control.
Solution Approach 2:
The patent incorporates sensors (31) that detect operational characteristics and feed this information to the controller (31). The controller uses this feedback to adjust and optimize the feed rate and movement precision of the boring bar. This closed-loop feedback system enables precise control of the feed mechanism while maintaining adaptability to different operating conditions.
2Manufacturing precision
If a conventional alignment device is used, then the boring bar can be positioned, but the alignment accuracy is insufficient
Solution Approach 1:
The patent employs alignment cones (46) that are used to pre-align the boring bar (14) with the bore of the workpiece before the actual boring operation begins. These cones are inserted into the bore and provide a precise geometric reference that guides the boring bar into correct alignment. This preliminary alignment action ensures high manufacturing precision is achieved from the start of the operation.
Solution Approach 2:
The patent replaces manual mechanical alignment methods with an electric motor-driven system that can precisely position and orient the boring bar. The electric motor provides controlled rotation and positioning, while the lead screw mechanism enables precise linear adjustment. This electrified system offers both high alignment accuracy and ease of operation through electronic control.
3Adaptability or versatility
If the lead screw is permanently fixed, then the connection is stable, but the portability and adaptability of the machine is reduced
Solution Approach 1:
The patent employs a dynamic clamp assembly (44) that can transition between clamped and unclamped states. The clamp members (114, 118) are biased by springs (not explicitly numbered but implied by the clamping mechanism) and can be actuated to engage or disengage from the lead screw (42). This dynamic design allows the lead screw connection to be stable during operation (when clamped) while enabling easy assembly, disassembly, and adjustment (when unclamped), thus providing both reliability and portability.
Solution Approach 2:
The clamp assembly is divided into separate clamp members (114, 118) that can independently engage the lead screw. This segmentation allows the clamping function to be applied locally at specific points on the lead screw, providing secure connection where needed while maintaining overall machine portability and adaptability. The segmented design also facilitates easier maintenance and adjustment.
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
This configuration enhances the precision and efficiency of boring bar movement, enabling accurate alignment and controlled material removal or addition, improving the overall performance and portability of the portable boring machine.
Implementation Method 1
an alignment member connectable to the clamp and having a conical surface engageable with a bore of a workpiece
Implementation Method 2
a drive mechanism supported by the drive unit housing and operable to rotate the bar about the bar axis
Implementation Method 3
a lead screw engageable with the feed assembly and defining a lead screw axis
Data Source
AI summary
A boring bar assembly, a feed assembly, an alignment device for a boring bar assembly. The boring bar assembly may include a boring bar extending along a bar axis; a drive unit including a drive unit housing, and a drive mechanism supported by the drive unit housing and operable to rotate the bar about the bar axis; a feed assembly configured to move the bar along the bar axis; and a lead screw engageable with the feed assembly and defining a lead screw axis