Spring-Loaded Calibration Shaft for Safe Machine Tool Alignment
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Solution Overview
Problem
Existing calibration devices for machine tools are cumbersome, require manual skill, and pose risks of damage and operational inefficiency due to excessive pressing of reference tools, leading to variations in measurement accuracy and safety concerns.
Innovation Solution
A calibration device with a shaft part, biasing mechanism, temporary locking mechanism, and affixation part, allowing easy alignment and attachment of a reference tool, preventing excessive pressing and ensuring safety by biasing and affixing the shaft part to the outer cylinder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual calibration using reference tools and gauge blocks is performed, then coordinate origin can be acquired, but the calibration process becomes cumbersome and time-consuming
Solution Approach 1:
The calibration artifact performs self-alignment through its specially designed structure. The artifact includes a reference plane and reference edge that automatically align with the machine tool table when placed on it, eliminating the need for manual positioning by operators. The artifact's geometry ensures that its reference surfaces are precisely oriented relative to the table surface, enabling automatic coordinate system establishment without cumbersome manual procedures.
Solution Approach 2:
The calibration artifact is pre-manufactured with precise geometric relationships between its reference plane, reference edge, and other features. These preliminary precision operations during manufacturing eliminate the need for time-consuming manual measurement and calculation during calibration. The artifact comes ready-to-use with pre-established geometric references that directly provide the necessary coordinate information.
2Measurement precision
If manual calibration operations are performed, then calibration can be completed, but variations in measurement accuracy occur depending on operator skill
Solution Approach 1:
The calibration artifact enables the system to perform its own calibration without relying on operator expertise. The artifact's fixed geometric relationships and automatic alignment capabilities allow any operator to achieve consistent results simply by placing the artifact on the table and following standardized procedures, eliminating the need for specialized calibration skills.
Solution Approach 2:
The invention changes the calibration approach from manual measurement parameters to fixed geometric parameters embedded in the artifact. Instead of relying on operator judgment and manual measurement techniques, the system uses the artifact's predetermined geometric relationships (angles, distances, orientations) that are manufactured with high precision and remain constant, ensuring consistent results regardless of operator skill level.
3Ease of operation
If the reference tool is brought into contact with the calibration artifact for alignment, then calibration can proceed, but the reference tool may be accidentally pressed too far causing damage
Solution Approach 1:
The calibration artifact includes a protective structure that prevents excessive pressing of the reference tool. The artifact's design incorporates features such as recesses,限位 structures, or compliant elements that physically limit how far the reference tool can be pressed into the artifact, cushioning against over-pressing before damage can occur to either the tool or the artifact.
Solution Approach 2:
The calibration artifact serves as an intermediary between the reference tool and the machine tool table. Instead of the reference tool directly interacting with the table or other sensitive components, all alignment and measurement operations are mediated through the artifact's protected reference surfaces, which are designed to absorb and limit the forces applied during calibration.
4Reliability
If calibration operations are performed cautiously to prevent damage, then safety is maintained, but operational efficiency decreases
Solution Approach 1:
By incorporating protective features into the calibration artifact's design beforehand, the system eliminates the need for cautious, slow operations. The built-in protection mechanisms allow operators to perform calibration movements with normal speed and force without fear of damage, as the artifact's structure already accounts for and protects against excessive forces.
Solution Approach 2:
The calibration artifact's protective features automatically prevent damage without requiring operator judgment or cautious manipulation. The artifact itself serves to protect the system from damage through its inherent design, allowing operators to focus on efficient calibration procedures rather than worrying about potential damage, thereby improving productivity.
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
Facilitates quick and safe calibration by preventing collisions and reducing operational inefficiencies, ensuring consistent machining accuracy regardless of operator skill, and stabilizing the quality of machined products.
Implementation Method 1
a biasing part (24) which is arranged in an interior of the outer cylinder (12) for biasing the shaft part (14) toward a direction of advancement
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A calibration device (10) comprises a shaft part (14) which can be advanced from the calibration device (10) along an axial direction, an outer cylinder (12) for supporting the shaft part (14) therein, a coil spring (24) which is arranged in an interior of the outer cylinder (12) for biasing the shaft part (14) toward a direction of advancement, a temporary locking mechanism (12a, 12b, 15) for holding the shaft part (14) in a position where it is pressed against a biasing force of the coil spring (24), an affixation part (16) which is arranged in the outer cylinder (12) and which can affix the shaft part (14) to the outer cylinder (12), an XY calibration part (26) formed along an outer peripheral surface of the shaft part (14), and a Z calibration part (28) which is formed on a tip of the shaft part (14) and which has a plane orthogonal to an axial direction of the shaft part (14).