Machining Center Auto-Alignment for Bed Deformation Errors
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Solution Overview
Problem
Horizontal machining centers face misalignment issues due to bed deformation caused by load distribution, leading to installation errors in the table and spindle assembly, which affect the precision of machining processes.
Innovation Solution
A machining center with a bed structure that includes position sensors to detect bed heights and process positions, an error calculating unit to determine installation errors, and a driving unit to automatically correct these errors, ensuring accurate alignment of the workpiece and machining tool along a common central axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the bed structure is designed as a slender member to reduce size, then the overall structure becomes more compact, but the bed structure deforms under load distribution causing installation errors
Solution Approach 1:
The patent replaces mechanical alignment methods with an optical measurement system. Position sensors detect the actual positions of the table and spindle assembly, and the control unit calculates correction amounts to automatically adjust the alignment, eliminating the need for manual mechanical adjustment and compensating for bed structure deformation
Solution Approach 2:
The patent implements a feedback control system where position sensors continuously monitor the positions of the table and spindle assembly, the control unit calculates the deviation from the ideal alignment, and the system automatically adjusts the positions to correct the alignment errors, forming a closed-loop control that compensates for bed deformation
2Manufacturing precision
If manual alignment adjustment is used to correct installation errors, then alignment precision can be improved, but the operation complexity and time consumption increase
Solution Approach 1:
The patent replaces manual mechanical alignment adjustment with an automated optical measurement and control system. The position sensors detect alignment deviations, the control unit calculates correction amounts, and the system automatically adjusts the table and spindle assembly positions, eliminating complex manual operations
Solution Approach 2:
The system performs self-alignment by automatically detecting position deviations through sensors and adjusting its own components (table and spindle assembly) to correct alignment errors, eliminating the need for external manual intervention and complex operational procedures
3Manufacturing precision
If the bed structure is made more rigid to prevent deformation, then manufacturing precision is maintained, but the device complexity and cost increase
Solution Approach 1:
Instead of increasing structural complexity through heavier or more rigid bed design, the patent substitutes a measurement and control system that detects and compensates for deformation. Position sensors monitor the actual positions, and the control unit calculates and applies correction amounts to maintain alignment precision without requiring excessive structural rigidity
Solution Approach 2:
The patent changes the approach from modifying structural parameters (increasing rigidity) to modifying operational parameters (real-time measurement and active compensation). By using position sensors to detect actual positions and dynamically adjusting alignment through calculated correction amounts, the system maintains precision without increasing structural complexity
Data Source
AI summary
Disclosed is a machining center. The machining center includes a bed structure deflected along a deflection curve by a load distribution thereon, a palette structure secured to a first end portion of the bed structure, a spindle assembly to which a machining tool is secured and secured to a second portion of the bed structure, a table movably secured to the bed structure such that a table loading is applied to a load point of the bed structure and an automatic aligner automatically detecting first and second installation errors of the table and the spindle assembly and automatically correcting the first and the second installation errors such that the workpiece and the tool are aligned with each other. The misalignment between the workpiece and the tool is automatically detected and corrected in the machining center.