Feed Roller Synchronization for Stable Peeling of Variable-Diameter Rods
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Solution Overview
Problem
Conventional peeling machines face challenges in rapidly opening/closing and accurately positioning feed rollers for round rod-like works of varying diameters, leading to issues with grasping force and stability, particularly when processing soft materials like aluminum.
Innovation Solution
The peeling machine incorporates a feed mechanism with a roller opening/closing driving mechanism using a ball screw-type driving mechanism and a rack pinion-type synchronizing mechanism, along with a grasping-force applying cylinder, allowing for rapid and precise control of feed roller positioning and grasping force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the moving speed of the upper and lower holders is increased to improve working efficiency, then productivity is improved, but manufacturing precision deteriorates because it becomes difficult to accurately position the feed rollers and suitably grasp the work with appropriate grasping force according to the type of work
Solution Approach 1:
The feed roller control system is segmented into two independent subsystems: (1) a synchronizing mechanism with rack and pinion that controls the opening/closing motion and positioning of both holders simultaneously, and (2) a separate grasping-force applying mechanism using cylinders that independently controls the grasping force. This segmentation allows high-speed positioning through the synchronizing mechanism while maintaining precise grasping force control through the separate force application system, resolving the contradiction between productivity and positioning accuracy.
Solution Approach 2:
The system employs dynamic control where the synchronizing mechanism enables rapid opening/closing motion for high productivity, while the grasping-force applying cylinders dynamically adjust the grasping force according to work diameter and type. This dynamic separation allows the system to operate at high speeds while maintaining appropriate grasping force for different work conditions, preventing both slippage and transfer flaws.
2Productivity
If the moving speed of the upper and lower holders is increased to improve working efficiency, then productivity is improved, but reliability deteriorates because it becomes difficult to grasp the work with appropriate grasping force according to the diameter of the work
Solution Approach 1:
The control system is divided into motion control (synchronizing mechanism) and force control (grasping-force applying cylinders) subsystems. This allows high-speed operation for improved productivity while maintaining reliable grasping through dedicated force control that adapts to different work diameters and types, ensuring stable grasping without slippage even at high speeds.
Solution Approach 2:
The grasping-force applying cylinders change the grasping force parameter according to work diameter and type, enabling the system to maintain appropriate grasping pressure for different works while operating at high speeds. This parameter adaptation ensures reliable grasping stability across varying work conditions without compromising productivity.
3Reliability
If the grasping force with respect to the work is increased to prevent slippage, then reliability is improved, but object-generated harmful factors worsen because non-slip protrusions on the outer peripheral surfaces of the feed rollers may cause a transfer flaw on the surface of the work
Solution Approach 1:
The system dynamically adjusts the grasping force parameter based on work diameter and material type through the grasping-force applying cylinders. This allows the use of appropriate grasping force for each work condition, preventing slippage-induced defects while avoiding excessive force that would cause transfer flaws from non-slip protrusions, thus eliminating the harmful effect while maintaining reliability.
4Device complexity
If conventional cylinders are used to control opening/closing of feed rollers, then device complexity is reduced, but manufacturing precision deteriorates because it is difficult to rapidly open/close the feed rollers and accurately position the feed rollers with respect to the work
Solution Approach 1:
The synchronizing mechanism merges the opening/closing motion control and positioning functions into a single integrated rack and pinion system that simultaneously controls both upper and lower holders. This unified mechanism achieves rapid opening/closing and accurate positioning while maintaining relatively simple device structure, resolving the contradiction between simplicity and 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
This configuration enables rapid and reliable vertical opening/closing of feed rollers, stable grasping of works with appropriate pressure, preventing slippage and transfer flaws, while maintaining compactness and durability.
Implementation Method 1
a roller opening/closing driving mechanism using a ball screw-type driving mechanism
Implementation Method 2
a rack pinion-type synchronizing mechanism
Implementation Method 3
a grasping-force applying cylinder disposed in the roller opening/closing driving mechanism to apply a downward work grasping force to the second holder
Data Source
AI summary
A peeling machine according to the present invention includes a cutter head and a feed mechanism having upper and lower feed rollers, and the feed mechanism includes a first holder that supports the lower feed roller, a second holder that supports the upper feed roller, a roller opening/closing driving mechanism, a synchronizing mechanism that has a pinion disposed in the same vertical plane as axes of the both feed rollers and first and second racks, and a grasping-force applying cylinder that applies a downward work grasping force to the second holder.