Machine Tool Balancing System with Adjustable Counterweights
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Solution Overview
Problem
Portal machine tools with large movable crosspieces face challenges in balancing the crosspiece-head assembly, leading to variable loads, elastic deformation, and inaccuracies in machining due to the weight distribution and rotation of the operating head, resulting in bulky, costly, and energy-intensive machines.
Innovation Solution
A balancing system using cable and counterweight mechanisms with adjustable compensating forces, exerted through pulleys and hydraulic actuators, to control deformation and rotation of the crosspiece, allowing for precise balancing and reduced motor power requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the crosspiece is made heavy to support the operating head, then the structural strength is improved, but the energy consumption and machine size increase significantly
Solution Approach 1:
The patent introduces counterweights that can be positioned along the crosspiece to balance the operating head's weight. The counterweights create opposing gravitational forces that compensate for the head's weight, allowing the crosspiece to be lighter while maintaining structural integrity and reducing the energy required for movement.
2Force
If the crosspiece is made heavy to support variable loads, then the load-bearing capacity is improved, but the device complexity and cost increase
Solution Approach 1:
The patent employs dynamically adjustable counterweights that can be repositioned along the crosspiece according to the operating head's position. This dynamic adjustment allows the system to maintain optimal load-bearing capacity for varying configurations without requiring an overly robust (and complex) static structure, thereby reducing device complexity and cost.
3Manufacturing precision
If the crosspiece is made heavy to prevent deformation, then the manufacturing precision is improved, but the productivity decreases due to slower movement
Solution Approach 1:
By introducing counterweights to balance the operating head, the patent reduces the net variable load on the crosspiece. This allows the crosspiece to be optimized for a more consistent load condition, reducing excessive deformation while maintaining lighter weight for faster movement, thus improving both manufacturing precision and productivity.
4Measurement precision
If overdimensioned motors are used to move the crosspiece, then the positioning accuracy is improved, but the energy consumption increases
Solution Approach 1:
The counterweights compensate for the operating head's weight, reducing the variable load that motors must overcome during positioning. This allows the use of smaller, more energy-efficient motors while maintaining positioning accuracy, as the motors only need to overcome friction and acceleration forces rather than the full weight of the head.
5Use of energy by moving object
If the crosspiece is made lighter to reduce energy consumption, then the energy efficiency is improved, but the structural strength decreases leading to deformation
Solution Approach 1:
The patent introduces counterweights to balance the operating head's weight, allowing the crosspiece to be designed with lighter weight for energy efficiency while the counterweights provide the necessary structural support through gravitational balancing, preventing deformation without requiring excessive crosspiece mass.
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 effectively balances the crosspiece and operating head, minimizing deformation and rotation, enabling precise positioning and movement, reducing machine size and energy consumption, and allowing the crosspiece to function as both a positioning and work axis.
Implementation Method 1
first and second counterweights (2, 3) generating forces in a vertical direction to compensate for the weight of the crosspiece (51) and of the operating head (54)
Implementation Method 2
first cable means (4, 5) and second cable means (6, 7) connected to the first and second counterweights (2, 3) respectively and to the crosspiece (51)
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A balancing system for a machine tool (50) provided with a crosspiece (51) that is movable along uprights (52, 53) and slidably supports an operating head (54) comprises compensating means (2, 3) connected to the crosspiece (51) by cable means (4, 5, 6, 7) and actuating means (21, 22) interposed between the cable means (4, 5, 6, 7) and the crosspiece (51) and arranged for exerting on the crosspiece (51) compensating forces (F1, F2) that are adjustable in function of a position of the operating head (54) on the crosspiece (51); the compensating means comprises first compensating means (2) and second compensating means (3) respectively connected to the crosspiece (51) by means of first cable means (4, 5) and second cable means (6, 7) of the cable means; the actuating means comprises first actuating means (21) and second actuating means (22); the first cable means (4, 5) is fixed to the crosspiece (51) in a pair of suspension points (11, 12, 13, 14), the first actuating means (21) or the second actuating means (22) being associated with one of said pair of suspension points (11, 12, 13, 14); the second cable means (6, 7) is fixed to the crosspiece (51) in a further pair of suspension points (11, 12, 13, 14), the second actuating means (22) or the first actuating means (21) being associated with one of said further pair of suspension points (11, 12, 13, 14); the balancing system enables a deformation of the crosspiece (51) to be limited and/or controlled and a lowering and/or a rotation of the operating head (54) to be limited and/or controlled.