Dual-Milling Machining Centre for Long Workpiece Throughput
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Solution Overview
Problem
Machining centers for elongated metallic workpieces, particularly for producing drive elements like drill strings, face inefficiencies and slow processing speeds, especially when dealing with workpieces exceeding 5 meters in length.
Innovation Solution
A machining center equipped with a storage device for rotatable workpiece storage, multiple milling units with translational and rotational degrees of freedom, and a control device for coordinated movement and processing area management, allowing simultaneous machining by multiple units to enhance efficiency and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single milling unit is used to machine elongated metallic workpieces, then the device complexity is low, but the productivity is insufficient for workpieces exceeding 5 meters in length
Solution Approach 1:
The workpiece is divided into multiple machining areas (first machining area and second machining area), and a corresponding number of milling units (first milling unit and second milling unit) are assigned to each area. This segmentation allows simultaneous machining of different sections of the elongated workpiece, thereby increasing productivity while managing device complexity through functional division.
Solution Approach 2:
The invention transitions from sequential machining along the workpiece length to parallel machining by introducing multiple milling units operating simultaneously in different spatial zones. This dimensional expansion from single-point to multi-point processing resolves the contradiction between productivity and device complexity.
2Productivity
If multiple milling units are used to machine different areas simultaneously, then the productivity is improved, but the control complexity increases
Solution Approach 1:
The control device is designed as a universal multi-functional system that can simultaneously manage multiple milling units, coordinate their movements, and control machining parameters across different areas. This centralized control approach handles the complexity by providing integrated functionality rather than separate control systems for each milling unit.
Solution Approach 2:
The control device incorporates feedback mechanisms to monitor and coordinate the operations of multiple milling units in real-time, ensuring synchronized machining and preventing interference between units. This feedback system manages control complexity by maintaining coordinated operation across all milling units.
3Loss of time
If the storage device supports only one workpiece at a time, then the device complexity is low, but the loss of time occurs due to sequential processing
Solution Approach 1:
The storage device is segmented into multiple independent storage units (first storage unit and second storage unit), each capable of holding a workpiece. This segmentation allows one workpiece to be processed while another is prepared or loaded, eliminating idle time and reducing the loss of time without requiring a completely complex new storage system.
Solution Approach 2:
The multi-unit storage device enables preliminary actions such as pre-loading or pre-positioning of workpieces while the main machining operation is ongoing. This reduces downtime by preparing the next workpiece in advance, thereby addressing the time loss issue without proportionally increasing device complexity.
Data Source
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AI summary
Machining center (1) for machining an elongated metallic workpiece (2), in particular for manufacturing a drive element, especially for a drill string, comprising: a bearing device (3) for holding an elongated metallic workpiece (2) to be machined, a first milling unit (5) movable in at least one degree of freedom relative to a workpiece (2) held by means of the bearing device (3), a second milling unit (6) movable in at least one degree of freedom relative to a workpiece (2) held by means of the bearing device (2), a control device (8),which is configured to control movements of the first milling unit (5) in the at least one degree of freedom of movement in or within a first machining area (B1) of the workpiece (2) assigned to the first milling unit (5) and to control movements of the second milling unit (6) in the at least one degree of freedom of movement in or within a second machining area (B2) of the workpiece (2) assigned to the second milling unit (6).