Flat Deburring Machine with Automatic Brush Height Adjustment
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Solution Overview
Problem
Current deburring processes for large-sized flat parts, such as flame-cut parts, face challenges with manual methods being dangerous and tedious, abrasive belt grinding being expensive and ineffective, and shot blasting being unsuitable for heavy burrs, while existing automated systems struggle with precise measurement of brush wear due to irregular surfaces and clogging issues.
Innovation Solution
A machine with automatic measuring means using on-board encoder wheels and a height measuring sensor to detect brush contact with a reference plane, allowing for precise adjustment of brush height based on wear and part thickness, ensuring effective deburring without excessive brush wear or damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If photoelectric or laser beam measuring means are used to detect brush wear, then measurement capability is provided, but the measuring means become unreliable due to irregular brush surfaces and rapid clogging
Solution Approach 1:
A flat reference key is introduced as an intermediary element with a precisely defined top surface that serves as a stable reference plane. The brush wear measurement is indirectly obtained by measuring the distance between the brush surface and this reference plane, avoiding direct measurement of the irregular brush surface itself. This mediator eliminates the clogging and reliability issues associated with direct photoelectric or laser measurement of brush surfaces.
Solution Approach 2:
Instead of directly measuring the complex, irregular brush surface, the system creates a simplified copy or representation of the measurement problem by using the flat reference key's top surface as a proxy. The measurement is taken on this clean, regular surface rather than on the brush itself, effectively copying the reference level without the drawbacks of measuring the brush directly.
2Measurement precision
If manual measurements of brush diameter are carried out, then brush wear can be assessed, but the process becomes tedious and time-consuming
Solution Approach 1:
The system enables automatic self-measurement by incorporating sensors that continuously monitor the distance between the brush surface and the reference key. The measurement process is automated and integrated into the normal operation of the brushing machine, eliminating the need for manual intervention. The system serves itself by automatically detecting brush wear and triggering appropriate responses without requiring operator time for manual measurements.
Solution Approach 2:
The measurement function is made continuous rather than intermittent. The sensors continuously monitor brush wear during machine operation, providing ongoing measurement data without stopping production. This continuous measurement approach eliminates the periodic manual measurement interruptions and ensures constant awareness of brush condition.
3Manufacturing precision
If precise adjustment of brush height is implemented, then deburring quality is improved, but the complexity of the system increases due to multiple measurement and adjustment components
Solution Approach 1:
The flat reference key serves as a simple intermediary that provides a stable reference plane without adding significant complexity. Instead of complex direct measurement systems, the reference key creates a simple geometric reference that can be easily measured against, simplifying the overall measurement and adjustment architecture while maintaining high precision.
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 efficient and precise deburring by automatically adjusting brush height according to wear and part thickness, enhancing the deburring process by preventing excessive brush wear and ensuring consistent treatment of complex parts.
Implementation Method 1
the means for detecting the contact of the brushes (3) on the reference plane (P) are constituted by on-board encoder wheels (9), integral with the shafts (2a) of the motors (2) of the brushes (3)
Implementation Method 2
a height measuring sensor (10) arranged above the support plate (4), outside the rotating assembly, to detect the position of the support plate (4)
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The present invention relates to a machine (1) for flat deburring parts, including at least one self-propeller (2) combined with at least one metal brush (3) and mounted on a supporting plate (4), also rotated by a motor (7) and arranged above a belt (5) for conveying the parts to be treated (6), such as to feed same in a linear movement (L) under the rotary supporting plate (4) and to place same in contact with the metal brushes (3), which are also rotary, in order to achieve a brushing action in a plurality of directions, characterised by comprising automatic measurement means for detecting the contact between the peripheral leading surface of the brushes (3) and a reference plane (P) consisting of the conveyor belt (5) or of the part to be treated (6), such as to reset the height of said brushes (3) relative to the reference plane (P), depending on the degree of wear thereof, prior to a deburring operation.