Gear Shaper Cutter Control for Relieving Interference

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Solution Overview

Problem

Conventional gear shapers face relieving interference issues due to the need for a mechanism to offset the cutter and workpiece, complicating machine configuration and increasing costs.

Innovation Solution

A method of controlling the machine tool by adjusting the cutter's movement in its rotation direction upon termination of machining, without changing the relative position of the cutter's rotational axis, to prevent relieving interference, using offset control to adjust the relieving direction and magnitude.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mechanism is added to offset the cutter and workpiece to change the relieving direction, then relieving interference is prevented, but device complexity increases

Engineering Contradiction:

Improveprevention of relieving interferenceVSAvoidmachine configuration complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical offset mechanism with a control system that dynamically adjusts the relieving direction through coordinated control of cutter reciprocation and workpiece rotation. The control unit calculates and executes the optimal relieving path based on machining parameters, eliminating the need for physical offset mechanisms while preventing relieving interference.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent makes the relieving direction dynamic by continuously adjusting it during the relieving process based on the relative positions and motions of the cutter and workpiece. Instead of a fixed mechanical offset, the system dynamically determines the relieving direction to avoid interference with the workpiece surface, achieving adaptability without additional mechanical components.

Inventive Principle:

Principle #15Dynamics

2Reliability

If a mechanism is added to offset the cutter and workpiece, then relieving interference is prevented, but manufacturing cost increases

Engineering Contradiction:

Improveprevention of relieving interferenceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent substitutes expensive mechanical offset mechanisms with a control system that uses existing machine components (cutter reciprocation mechanism and workpiece rotation mechanism) to achieve the same effect. This control-based approach significantly reduces manufacturing costs while maintaining the ability to prevent relieving interference.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses the existing coordinated motion between the cutter reciprocation and workpiece rotation to automatically achieve the optimal relieving direction. The control unit leverages the already-present mechanical systems to serve the additional function of interference prevention, eliminating the need for separate dedicated mechanisms and reducing overall system cost.

Inventive Principle:

Principle #25Self-service

3Ease of operation

If the cutter is moved away from the workpiece in the conventional relieving direction, then the cutter returns to machining position, but relieving interference occurs with the workpiece surface

Engineering Contradiction:

Improvecutter return to machining positionVSAvoidrelieving interference

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The control unit monitors the relative positions of the cutter and workpiece during the relieving process and adjusts the relieving direction in real-time based on this feedback. This closed-loop control ensures that the cutter moves away from the workpiece along a path that avoids interference, while still returning to the correct machining position.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS8936417B2Method of controlling machine tool and machine tool

Publication Date: 2015.01.20 MITSUBISHI HEAVY IND MACHINE TOOL CO LTD

AI summary

To provide a method of controlling a machine tool and a machine tool which allow preventing relieving interference without using a mechanism for causing an offset between a cutter (13) and a workpiece (50), a controller (40) performs control such that the workpiece (50) is machined by repeating the steps of: machining the workpiece (50) by moving the cutter (13) for machining the workpiece (50) in a direction parallel to a rotational axis of the cutter (50) while rotating the workpiece (50) together with the cutter (13); and returning the cutter (13) to a machining start position again after termination of the machining step, and performs offset control such that the cutter (13) is moved away from the workpiece (50) in a rotation direction of the cutter (13) upon the termination of the machining step.