Hybrid Machine Tool Layout for Low-Vibration Profile Machining

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Solution Overview

Problem

Existing machine tools face inefficiencies due to the need for frequent tool changes, wear, and compatibility issues between laser and rotary tools, particularly when machining elongate workpieces like extruded aluminum profiles, which can deform or vibrate during machining, leading to poor quality and increased cycle times.

Innovation Solution

A machine tool design incorporating both laser and rotary tools, with a workpiece support that allows pivoting and multiple tool carriers displaceable along orthogonal axes, enabling simultaneous or sequential machining of multiple workpieces, optimizing tool usage and minimizing downtimes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple tool carriers with different tools are used for machining elongate workpieces, then machining versatility is improved, but tool change frequency and cycle time increase

Engineering Contradiction:

Improvemachining versatilityVSAvoidcycle time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent applies universality by designing a single tool carrier that can accommodate both rotary tools and laser tools through interchangeable tool holders. This multi-functional design allows the same tool carrier to perform different machining operations (drilling, milling, cutting) without requiring separate specialized carriers, thereby reducing the number of tool changes needed while maintaining machining versatility

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If rotary tools are used for machining elongate workpieces, then material removal efficiency is improved, but workpiece deformation and vibration increase

Engineering Contradiction:

Improvematerial removal efficiencyVSAvoidworkpiece quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent introduces laser tools as an intermediary method for machining elongate workpieces. Instead of directly applying rotary tools that cause vibration and deformation, the laser beam serves as a non-contact intermediary that removes material through melting and vaporization, thereby achieving material removal efficiency without inducing mechanical vibration or workpiece deformation

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If laser tools are used for machining, then workpiece deformation is minimized, but tool life and reliability decrease due to lens soiling

Engineering Contradiction:

Improveworkpiece qualityVSAvoidtool life

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent applies the disposable principle by using inexpensive protective screens or sacrificial barriers that can be easily replaced. These screens are positioned between the laser beam and the workpiece to prevent direct contact with debris, and when they become soiled, they are simply replaced rather than attempting to clean the expensive laser lens, thus protecting the laser tool's reliability while maintaining low cost

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Adaptability or versatility

If frequent tool changes are performed to handle different machining operations, then machining adaptability is improved, but productivity decreases

Engineering Contradiction:

Improvemachining adaptabilityVSAvoidproductivity

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent merges multiple tool functions into a single tool carrier system. By combining rotary tool capabilities and laser tool capabilities in one interchangeable carrier, the system allows operators to switch between different machining operations (drilling, milling, cutting) by changing only one tool carrier rather than multiple specialized carriers, thereby maintaining adaptability while reducing tool change frequency and improving productivity

Inventive Principle:

Principle #5Merging (Combining)

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

Enhances productivity and quality by reducing tool changes, minimizing wear, and efficiently handling diverse machining operations without compromising on tool life or precision, especially for elongate workpieces.

Implementation Method 1

at least one of the tools is a laser tool adapted for removal of material from the at least one workpiece

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

removal of material from the at least one workpiece by heating the material with a laser beam

Methodology Applied

Scientific EffectThermal heating: Heating

Data Source

PatentUS20250345892A1Machine tool and method of operating the machine tool

Publication Date: 2025.11.13 ETXE TAR SA

AI summary

A machine tool is provided with a workpiece support (1000) for supporting at least one workpiece (2001, 2002) for allowing machining of the workpiece, and a plurality of tools (11A, 12A, 21A, 22A) adapted for machining of the at least one workpiece. The machine tool being adapted for positioning the tools in relation to the workpiece support. At least one of the tools is a laser tool (21A, 22A) adapted for removal of material from the at least one workpiece. Another one of the tools may be a rotary tool (11A, 12A) adapted for removal of material from the at least one workpiece.