Machine Tool Disk Magazine Segmentation for Rapid Exchange
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Solution Overview
Problem
Existing machine tools face inefficiencies in tool exchange processes, leading to prolonged chip-to-chip times, especially during complex machining operations that require multiple tool changes.
Innovation Solution
The implementation of a machine tool design featuring two types of tool stores: a storage device on the machine frame as a background magazine and disk bearings as a secondary magazine, allowing for direct tool exchange and synchronous operation of tool spindles, with a circulating conveyor system and transfer stations for efficient tool transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If a single tool magazine is used, then the device complexity is reduced, but the tool exchange time increases leading to prolonged chip-to-chip times
Solution Approach 1:
The tool storage system is segmented into two distinct magazines: a first tool magazine with a larger number of tools and a second tool magazine with a smaller number of tools. This segmentation allows the system to optimize for both storage capacity and rapid tool exchange by distributing tools across multiple specialized storage units rather than using a single generalized magazine.
Solution Approach 2:
The system pre-positions required tools in the second tool magazine in advance of when they are needed. The control unit monitors tool requirements and proactively transfers tools from the first magazine to the second magazine before they are needed for machining, ensuring that frequently needed tools are immediately accessible and eliminating waiting time during tool changes.
2Adaptability or versatility
If tools are transferred between magazines, then tool availability is improved, but the tool exchange process complexity increases
Solution Approach 1:
A tool transfer mechanism acts as an intermediary between the first and second tool magazines. This intermediary system includes transfer arms or conveyors that automatically move tools between magazines based on control unit instructions, simplifying the overall process by providing a dedicated intermediary structure rather than requiring direct access to both magazines simultaneously.
Solution Approach 2:
The control unit implements a feedback system that monitors the tool inventory in both magazines, tracks current machining requirements, and automatically determines when tools need to be transferred. This closed-loop control ensures tools are transferred at the optimal time based on actual usage patterns, maximizing tool availability while minimizing unnecessary transfer operations.
3Productivity
If multiple tool spindles are operated synchronously, then productivity is improved, but the coordination complexity increases
Solution Approach 1:
Multiple tool spindles are merged into a single coordinated system under one control unit. The control unit synchronizes the operation of all spindles, tool magazine transfers, and tool spindles as an integrated system, allowing parallel machining operations while centralizing control to manage the complexity rather than requiring separate control systems for each spindle.
Data Source
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AI summary
Disclosed is a machine tool comprising a machine frame, at least one tool spindle that is arranged on the machine frame and can be moved in relation thereto, a workpiece holder, and a storage device for tools that is arranged on the machine frame. The disclosed machine tool is characterized in that at least one rotatable disk-type storage unit for tools which communicates with the storage device and with the at least one tool spindle is arranged on the machine frame, each tool spindle being associated with its own disk-type storage unit, and in that the storage device comprises a continuous conveying device.