Copying Guide Attachment for Accurate Robotic Trim Machining
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Solution Overview
Problem
Conventional machining robots have low positioning accuracy and rigidity compared to machine tools, limiting their ability to perform high-accuracy cutting operations, especially those requiring large reaction forces, such as outline trim processing, which often necessitates manual operation by skilled personnel.
Innovation Solution
An attachment for a machining apparatus featuring a copying guide with an air supply passage that contacts a copying mold on the workpiece side, allowing for precise positioning and force control of a tool attached to a spindle, enabling high-accuracy cutting operations with large reaction forces using a robot.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a robot is used for cutting machining, then automation and productivity are improved, but positioning accuracy and manufacturing precision deteriorate due to low rigidity of robot arm
Solution Approach 1:
A copying guide is introduced as an intermediary component that contacts the copying mold and guides the tool. The copying guide transfers the contour information from the copying mold to the tool path, enabling the robot to achieve high positioning accuracy without requiring high inherent rigidity. The copying guide acts as a mediator between the low-precision robot and the high-precision copying mold.
Solution Approach 2:
The system uses a copying mold that replicates the desired workpiece contour. The robot follows this physical copy by maintaining contact between the copying guide and the copying mold surface, thereby reproducing the molded shape with high accuracy despite the robot's inherent positioning limitations.
2Manufacturing precision
If manual copying is performed by skilled operator, then positioning accuracy is improved, but labor intensity and operation complexity increase
Solution Approach 1:
The copying guide is designed to automatically follow the contour of the copying mold through mechanical contact, without requiring manual guidance or adjustment by an operator. The system performs the copying action autonomously, eliminating the need for skilled manual operation while maintaining high copying accuracy.
Solution Approach 2:
The manual mechanical skill of the operator is replaced by an automated robot system equipped with a copying guide. The robot's automated control system substitutes for the operator's expertise, performing the copying operation consistently without requiring years of training or experience.
3Manufacturing precision
If large scale machine tool is used for high accuracy cutting, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The high-precision positioning function is extracted from the robot arm and transferred to the copying guide and copying mold system. This allows the use of a simple, low-cost robot for the moving and positioning tasks, while the precision requirement is satisfied by the dedicated copying interface, avoiding the need for a complex, large-scale machine tool.
Solution Approach 2:
Instead of investing in expensive, large-scale machine tools with high inherent rigidity and precision, the system uses a simpler, more economical robot combined with a reusable copying mold. The copying mold serves as a precision reference that can be used repeatedly with different robots, reducing overall system cost and complexity.
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
Enables high-accuracy cutting machining operations like outline trim processing, outline rough processing, and drilling with large reaction forces, improving processing efficiency and quality while reducing the need for large-scale machine tools.
Implementation Method 1
an air supply passage adapted to supply air ejected toward the workpiece side through a clearance between the tool and the through hole
Data Source
AI summary
According to one implementation, an attachment for a machining apparatus includes: a copying guide in a machining apparatus side and an air supply passage. The copying guide has a through hole for passing a tool through. The copying guide is contacted to a copying mold placed in a workpiece side. The copying guide is attached to a spindle holding and rotating the tool. The air supply passage is adapted to supply air ejected toward the workpiece side through a clearance between the tool and the through hole.