Face Milling Large Workpieces Using Laser Reference Planes
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Solution Overview
Problem
Machining large workpiece surfaces outside of a production hall, such as on construction sites like wind turbines and diesel engines, is challenging due to the need for precise alignment and the high costs and weight of existing machinery, which often results in premature wear of components due to lack of flatness.
Innovation Solution
A method involving the creation of a reference surface with strategically placed indentations, using a laser leveling device to define a reference plane, and then machining the surface to match this plane, allowing for precise alignment and machining without the need for complex measuring technology, using a portable milling tool that fits into these indentations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a milling machine or lathe is firmly fastened to the tower for machining large workpiece surfaces, then machining precision can be achieved, but the device weight becomes extremely high and processing costs increase
Solution Approach 1:
The reference surface is segmented into multiple support points formed by indentations distributed across the workpiece surface. Instead of using a single massive reference structure, the reference surface is divided into discrete localization points that collectively define the reference plane, reducing the need for heavy supporting infrastructure.
Solution Approach 2:
The patent replaces the traditional mechanical reference system (massive machine beds, roller bearings, linear guide systems) with an optical measurement system (laser beam) to define the reference plane. The laser beam provides the reference without requiring heavy mechanical support structures, thereby reducing device weight while maintaining precision.
2Manufacturing precision
If a milling machine is firmly fastened to the tower for machining large workpiece surfaces, then machining precision can be achieved, but processing costs become high
Solution Approach 1:
The patent replaces expensive mechanical reference systems with a laser-based optical system. The laser beam provides precise reference plane definition without requiring costly mechanical components like roller bearings or linear guides, significantly reducing processing costs while maintaining the required surface flatness.
Solution Approach 2:
The patent creates a virtual copy of the reference plane using a laser beam, which can be projected and maintained without physical contact with the workpiece. This optical copy eliminates the need for expensive mechanical reference structures and allows for flexible repositioning and adjustment without additional cost.
3Productivity
If traditional machining methods are used for large surfaces, then machining can be performed, but comprehensive checking of processing success cannot be carried out with the processing system alone
Solution Approach 1:
The patent merges the reference plane definition and measurement functions into the machining system itself. The laser beam that defines the reference plane is integrated with the machining process, allowing the same system to both machine and verify the workpiece surface, enabling comprehensive self-checking without separate measurement equipment.
Solution Approach 2:
The patent implements feedback by using the laser beam to continuously monitor the position of the cutting tool relative to the reference plane during machining. This real-time feedback allows the system to detect and correct deviations, ensuring processing success can be comprehensively checked and verified by the processing system itself.
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
This method enables efficient and accurate machining of large surfaces with reduced equipment weight and processing costs, allowing for dynamic compensation of structural movements and achieving the required flatness without extensive measuring systems.
Implementation Method 1
A reference plane can be defined by a laser beam, in which case a laser beam that is expanded in area or that rotates in one plane is used.
Data Source
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AI summary
The method involves machining work piece surface (2) by a machining tool based on initially fixed reference surface (3). The reference surface is determined by insertion of a recess (4) into the work piece surface, where base (5) of the recess forms supporting points of the reference surface. A reference plane (6) is used for determining the reference surface, and distance measures (A1, A2) of the base of the recess for the reference plane are determined based on location of the supporting points on the work piece surface.