Low-Profile Flexible Tooling Pods for Dense CNC Part Support
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Solution Overview
Problem
Existing flexible tooling systems for CNC machines are limited by high costs, minimum tooling system size, and insufficient support for parts, leading to deformation under machining forces, especially with larger spacing between actuators and thermal sensitivity, making them impractical for many CNC machines with varying z-axis heights.
Innovation Solution
A low-profile flexible tooling system with pods containing variable position assemblies that replicate the function of multiple actuators, allowing for closer spacing of tooling elements, reduced cable requirements, and localized air and vacuum control, enabling greater support density and flexibility in holding complex parts without major retrofits to the CNC machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional flexible tooling systems use individual actuators for each tooling element, then positioning accuracy is achieved, but system cost and complexity increase significantly
Solution Approach 1:
The system divides the tooling table into multiple modular pods, each containing multiple tooling elements (up to 7 per pod). This segmentation allows the complex positioning task to be distributed across simpler modular units, reducing overall system complexity while maintaining positioning accuracy through coordinated control of elements within each pod.
Solution Approach 2:
Multiple tooling elements are merged into single pods that share common actuators and control systems. Instead of one actuator per tooling element, each pod uses a shared actuator system that can position multiple elements, significantly reducing the total number of actuators and system complexity while maintaining the ability to achieve required positioning accuracy.
2Device complexity
If flexible tooling systems use large spacing between actuators, then system cost is reduced, but part deformation increases under machining forces
Solution Approach 1:
The tooling system is segmented into multiple pods distributed across the table surface. Each pod contains multiple tooling elements that can be independently positioned, allowing for closer effective spacing of support points without requiring proportionally more actuators. This segmentation enables better support density for preventing part deformation while controlling system cost.
Solution Approach 2:
The system adds vertical positioning capability to tooling elements within pods, allowing elements to move in the Z-axis to conform to complex part geometries. This dimensional addition allows fewer pods to provide adequate support across the table by leveraging vertical adjustment capability, reducing the need for dense horizontal actuator spacing.
3Adaptability or versatility
If flexible tooling systems are designed with minimum tooling system height, then adaptability to different CNC machines is improved, but support capability for thin parts is reduced
Solution Approach 1:
The tooling elements within each pod are designed to be dynamically adjustable in position, allowing them to adapt to different part geometries and machining requirements. This dynamic positioning capability compensates for the reduced number of pods, ensuring adequate support for thin parts while maintaining a compact system height that fits various CNC machines.
Solution Approach 2:
The system allows adjustment of tooling element parameters including position, orientation, and spacing within pods. This parametric flexibility enables the same compact pod structure to provide appropriate support for different part types and thicknesses, maintaining part support capability while keeping the overall system height adaptable to different machine tools.
4Measurement precision
If flexible tooling systems use numerous individual actuators, then positioning precision is maintained, but cable requirements and control complexity increase
Solution Approach 1:
Multiple tooling elements within each pod share common actuators and control systems, merging what would otherwise require separate cables and controllers. This consolidation dramatically reduces the total cable quantity and control complexity while maintaining positioning precision through coordinated control of the shared actuator system serving multiple elements.
Solution Approach 2:
The shared actuators and control systems within pods are designed to serve multiple tooling elements simultaneously, providing multi-functionality. A single actuator can position multiple elements, and the control system can manage all elements within a pod, reducing cable requirements and control complexity while maintaining the precision needed for each individual element.
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 system allows for flexible tooling on nearly all CNC machines with accommodating z-axis heights, reducing deformation risks and installation costs, while enabling more precise and stable support for thin parts with increased density of tooling elements, enhancing the practicality and efficiency of CNC machining operations.
Implementation Method 1
Each of the motor assemblies includes a plurality of motors, each of the motors co-axial with one of the pass through shaft guides
Implementation Method 2
an encoder configured to detect the motor being in one of a plurality of positions
Implementation Method 3
a drive screw mechanically coupled to an output of the motor, wherein the drive screw is moved upon the motor moving from one of the positions to another one of the positions; a plurality of anti-rotation linear guides, each including a nut element that mounts onto one of the drive screws and a linear guide element that is attached to the nut element and that prevents rotation of the nut element, wherein the movement of that drive screw causes a linear motion of the nut element along a length of that drive screw
Data Source
AI summary
The low profile of the flexible tooling system disclosed allows for flexible tooling to be added to nearly all CNC machines with an accommodating z-axis height and allows easier relocation of the system from one CNC machine to another. The system includes one or more pods, each of the pods of the system replacing the function of four independent actuators of earlier systems but operating with a shared mechanical frame. Arranging the mechanism into groups of four allows for greater density of part support spacing, minimizes cable requirements, and allows for air, vacuum, and vacuum sensor requirements be localized on each pod. The pods allow for part supports to be spaced as close as 6″ in the x and y axis. An increased variable position assembly density allows for greater flexibility to hold complicated parts.