Electromagnetic Tool Head Switching for Wear-Reduced Edge Milling
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Solution Overview
Problem
Existing tool units for machining edges are mechanically complex, leading to high structural and maintenance costs, wear issues, and the need for complete replacement upon damage, with no flexibility to use standardized drives.
Innovation Solution
A simplified tool unit with a switching drive featuring an electromagnet and a magnetically attractable actuating armature, positioned between the tool head and drive motor, allowing for reliable switching between active and passive positions without contact, using a standardized drive motor and minimizing wear by eliminating the need for complex transmission and independent mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex mechanical switching drive with coaxial guides and integrated construction is used, then switching reliability is improved, but device complexity and maintenance cost increase
Solution Approach 1:
The patent replaces the complex mechanical switching drive with an electromagnetic actuator that uses magnetic fields instead of mechanical guides and bearings. The electromagnetic actuator receives rotational commands from the control unit and converts them to rotational movement of the tool head, eliminating the need for complex coaxial mechanical guidance systems while maintaining reliable switching between milling profiles
Solution Approach 2:
The electromagnetic actuator serves multiple functions: it acts as both the switching mechanism and the rotational drive for the tool head. By integrating these functions into a single component, the patent reduces overall device complexity while maintaining the ability to reliably switch between different milling profiles through electronic control
2Ease of manufacture
If standardized drive motors are used, then cost is reduced, but adaptability to different tool configurations is limited
Solution Approach 1:
The patent implements a dynamically controllable system where the electromagnetic actuator can be programmed through a teaching unit to adapt to different tool configurations. The control unit stores and processes control data that enables the same standardized drive motor to accommodate various tool heads and milling profiles through software configuration rather than mechanical modification
Solution Approach 2:
The system allows configuration parameters to be changed through electronic programming rather than physical modification. The teaching unit enables operators to input and store control data that adjusts the operational parameters of the standardized drive motor, allowing it to adapt to different tool configurations while maintaining cost-effectiveness
3Manufacturing precision
If complex integrated construction is used, then switching precision is improved, but ease of repair deteriorates
Solution Approach 1:
The patent divides the system into separable functional modules: the electromagnetic actuator, the tool head, and the control unit with teaching capability. This modular design allows the electromagnetic actuator to be independently replaced or repaired without affecting other components, significantly improving maintenance ease while maintaining switching precision through electronic control
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
The solution reduces mechanical complexity, wear, and maintenance costs, enabling reliable switching between different milling profiles using a standardized drive motor, with the tool head mounted solely via the drive shaft, ensuring a robust and cost-effective solution.
Implementation Method 1
the switching drive includes at least one electromagnet and an actuating armature which is made from a magnetically attractable material and is arranged in a region of action of the at least one electromagnet
Data Source
AI summary
A tool unit includes a tool head, a motor and a switching drive for the head. The head has a first section with first blades and a second section with second blades. The second section is movable to and fro between a passive and an active position relative to the first section, the second blades being retracted in the passive position, and the second blades projecting axially beyond the first blades in the active position. The drive includes an electromagnet and an actuating armature made from magnetically attractable material and is arranged in the region of action of the electromagnet. The electromagnet is positioned between the head and the motor and is fastened to a housing part of the motor such that it cannot be rotated. The armature is connected fixedly to the second section. A gap remains between the electromagnet and the armature in the passive and active position.