Robotic Cutting Body Line for Repeatable Laser-Grinding Machining
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Solution Overview
Problem
Current production systems for cutting bodies for prosthetic surgery instruments require multiple machinery, excessive time, high costs, and manual intervention, leading to inefficiencies and inconsistencies in the machining process.
Innovation Solution
A robotic working line comprising an automated three-dimensional laser cutting station, grinding station, and punching station, which automates the production process, reducing the need for manual handling and machinery, and optimizing the cutting edge geometry to eliminate subsequent sharpening steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate machines (chip removal, sharpening, grinding, punching) are used for production, then each machining operation can be performed with dedicated equipment, but the number of machines increases, production time increases, and manual intervention is required
Solution Approach 1:
The patent combines multiple separate machining operations (chip removal, sharpening, grinding, punching) into a single integrated machine that can perform all operations automatically. This merging eliminates the need for multiple separate machines and manual transfer operations, directly resolving the contradiction between machining precision and production efficiency.
Solution Approach 2:
The integrated machine is designed with multi-functionality, capable of performing chip removal, sharpening, grinding, and punching operations within a single device. This universal machine replaces multiple specialized machines, reducing production time and manual intervention while maintaining the precision of each operation.
2Manufacturing precision
If the sharpening machine operates on the entire edge of the hole, then all edges are uniformly processed, but excessive material is removed, weakening the external surface and generating excessive waste
Solution Approach 1:
The integrated machine enables selective processing where only the specific portions of the hole edges that require sharpening are processed, rather than uniformly processing the entire edge. This local quality approach maintains edge consistency where needed while preserving material in areas where it is not required, reducing waste and preventing unnecessary weakening of the external surface.
3Adaptability or versatility
If manual intervention is used for burr removal and component transport, then flexibility and adaptability are maintained, but working time increases and repeatability decreases
Solution Approach 1:
The integrated machine is designed to automatically perform all operations including burr removal and component handling without requiring manual intervention. The machine serves itself by automatically transferring components between operations, removing burrs with integrated grinding tools, and maintaining consistent processing parameters, thereby eliminating the trade-off between flexibility and productivity.
4Manufacturing precision
If multiple machines are used in sequence, then each operation can be optimized independently, but the total production time increases and operator intervention for transport is required
Solution Approach 1:
By merging multiple independent machining operations into a single integrated machine, the patent eliminates the time lost in transferring components between machines and the need for operator intervention. Each operation retains its optimization through dedicated tools and parameters within the integrated system, while overall production time is reduced through continuous automated processing.
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 robotic working line significantly reduces the number of machines and time required for production, enhances repeatability, and minimizes operator intervention, resulting in more efficient and consistent cutting body manufacturing.
Implementation Method 1
an automated three-dimensional laser cutting station (100) comprising a first automated operator (102) and a laser cutting apparatus (101)
Implementation Method 2
an automated grinding station (200) comprising a third automated operator (202) configured to place the semi-finished component (51) in cooperation with one or more grinding tools (206)
Data Source
Figure 1
Figure 2a~3c
Figure 4~6
AI summary
The invention relates to a robotic working line (10) for the production of cutting bodies (54) for prosthetic surgery instruments, in particular cutting bodies able to milling/cutting or otherwise carrying out tissue removal processes in preparation for, or in the context of, prosthetic surgery interventions, in this case in the orthopaedic field, such as acetabular cutters, patellar cutters, glenoid cutters, rasps, broaches or similar tools, starting from hollow untreated components (50) having at least one external surface (60) and one opposing internal surface (70). The invention also relates to a working method for the production of cutting bodies (54) for prosthetic surgery instruments and to a cutting body (54) made by means of a robotic working line (10) and in accordance with the method according to the invention.