Machine Tool Handle Layout for Power-Assisted Float Control
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Solution Overview
Problem
Industrial machine tools lack an efficient and ergonomic handle system that assists operators in power-assisted movement and precise control during machining processes, potentially leading to operator fatigue and safety hazards due to the lack of integrated distance sensing and power-assisted mechanisms.
Innovation Solution
A handle apparatus integrated with industrial machine tools, featuring a housing with strategically placed switches and a servomechanism, a distance sensor, and a processor that limits machining actuation when the moveable portion is within a threshold distance from the workpiece, allowing for power-assisted movement and precise control through ergonomic design and safety features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operation of industrial machine tools is used, then device complexity is reduced, but operator fatigue increases and safety hazards occur due to lack of power assistance
Solution Approach 1:
The patent combines multiple functions into the handle apparatus: power assistance control, distance sensing, machining actuation, and safety monitoring are all integrated into a single handle system. This merging provides comprehensive operator support while maintaining a unified, manageable interface rather than separate complex systems.
Solution Approach 2:
The handle apparatus serves multiple functions simultaneously: it provides power assistance for moveable portion movement, acts as a control interface for machining operations, incorporates distance sensing for safety, and includes emergency stop capabilities. This multi-functionality reduces the need for separate control mechanisms and improves ease of operation.
2Ease of operation
If power-assisted movement mechanism is added, then operator fatigue is reduced, but device complexity and cost increase
Solution Approach 1:
The handle apparatus serves as an intermediary control interface between the operator and the servomechanism. The operator interacts with the handle switches rather than directly controlling the complex servomechanism, simplifying the operator's task while the servomechanism handles the complex power-assisted movement automatically.
Solution Approach 2:
The servomechanism operates autonomously based on handle switch signals, automatically providing power assistance for moveable portion movement without requiring continuous manual intervention. The system self-regulates the assistance based on operational mode and distance sensing feedback.
3Reliability
If distance sensor and safety features are integrated, then operator safety is improved, but device complexity increases
Solution Approach 1:
The distance sensing system, safety monitoring, and machining actuation control are merged into the handle apparatus. This integration provides comprehensive safety functionality within a unified control interface, avoiding the need for separate distributed safety systems and reducing overall system complexity.
Solution Approach 2:
The distance sensor provides continuous feedback to the processor, which automatically limits machining actuation when the moveable portion is within a threshold distance from the workpiece. This feedback mechanism ensures safety without requiring complex manual monitoring systems or additional safety infrastructure.
4Measurement precision
If multiple switches are placed on the handle, then control precision is improved, but ease of operation deteriorates due to finger coordination requirements
Solution Approach 1:
Different switches are positioned on opposite sides of the handle to be actuated by different body parts: the second switch (machining actuation) is positioned for thumb actuation, while the first switch (float mode) is positioned for finger actuation. This local differentiation optimizes each control element for its specific function, improving both precision and ease of operation.
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 handle system enhances operator safety and efficiency by providing power-assisted movement and precise control, reducing the risk of accidents and improving productivity by allowing operators to focus on the machining process without manual strain.
Implementation Method 1
The industrial machine tool comprises a servomechanism to power assist in the movement of the moveable portion of the industrial machine tool
Implementation Method 2
The distance sensor senses a distance between the moveable portion of the industrial machine tool and the workpiece
Implementation Method 3
the distance sensor is a linear variable differential transformer (LVDT)
Data Source
AI summary
A handle is coupled to an industrial machine tool, along with a method of operating the industrial machine tool via the handle. The handle comprises a housing, a first switch, and a second switch. The housing includes a first side, a second side, a top end, and a bottom end, the first side facing toward the industrial machine tool and the second side facing away from the industrial machine tool. The first switch actuates a float mode for the industrial machine tool, the float mode being a mode in which movement of a moveable portion of the industrial machine tool is power assisted for an operator of the industrial machine tool. The second switch actuates a machining portion, coupled to the moveable portion of the industrial machine tool, to perform a machining process on a workpiece.