Hybrid Machining Centre Coupling for Faster Additive-Subtractive Switching
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Solution Overview
Problem
Machining centers face inefficiencies in switching between subtractive and additive configurations due to high operational complexity, lengthy downtime, and material deterioration when transitioning between modes, particularly due to the manual connection of energy supplies and disconnection of transit pipes, leading to increased production times and costs.
Innovation Solution
A machining center design that incorporates a coupling mechanism between the subtractive and additive units, allowing for simplified and rapid switching between configurations, with automatic energy supply management and sealed transit pipes to maintain material integrity, reducing operational complexity and downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the extrusion/3D printing unit is manually connected to the energy supplying means, then the additive machining can be performed, but the connection time and heating time increase the production downtime
Solution Approach 1:
The system performs self-service through automatic connection of energy supplies via coupling mechanisms and pre-heating of the extrusion unit before machining operations, eliminating manual intervention and reducing downtime
Solution Approach 2:
The extrusion unit is pre-heated to operating temperature before the actual additive machining begins, and energy connections are established in advance through automated coupling, preventing time loss during the machining process
2Adaptability or versatility
If the transit pipes are disconnected when switching to subtractive configuration, then the subtractive machining can be performed, but the material inside the pipes deteriorates due to exposure to air and humidity
Solution Approach 1:
The transit pipes are sealed with closures that prevent air and humidity from entering when the pipes are not in use, protecting the material inside from deterioration while allowing the system to switch between additive and subtractive configurations
Solution Approach 2:
The system dynamically adapts by automatically opening pipe closures only when additive machining is required and keeping them sealed during subtractive machining, maintaining material quality while enabling configuration flexibility
3Adaptability or versatility
If the machining centre is equipped with both subtractive and additive units, then the versatility is improved, but the structural complexity and operational costs increase
Solution Approach 1:
The machining centre uses a universal portal structure and conveying unit that can accommodate both subtractive spindle units and additive extrusion units, allowing a single system to perform multiple machining functions without requiring completely separate machines
Solution Approach 2:
The system is segmented into modular components (portal structure, conveying unit, interchangeable tool units) that can be independently configured and replaced, reducing overall system complexity while maintaining versatility
4Manufacturing precision
If the conveying unit moves the additive unit along the axes, then the positioning is improved, but the coordination and control complexity increases
Solution Approach 1:
The conveying unit uses the same multi-axis movement system already present for the subtractive unit, allowing it to move additive units along the X, Y, and Z axes with the same precision control mechanisms, avoiding the need for separate control systems
Data Source
AI summary
A machining centre comprising a machining plane; a subtractive unit for performing chip removal on a workpiece positioned on the machining plane; the subtractive unit comprising a first carriage that is slidable parallel to an operating axis; an additive unit arranged to perform machining by additive production techniques on the machining plane; the additive unit comprising a second carriage that is slidable along the operating axis. The additive unit is provided with a first coupling portion and said subtractive unit is provided with a second coupling portion couplable with the first coupling portion. In one step, the subtractive unit adopts a pick-up configuration in which the first coupling portion is coupled with the second coupling portion to connect the subtractive unit to the additive unit at least along the operating axis. In the pick-up configuration, the subtractive unit, connected to the additive unit, is configured to move the additive unit.