Machining Construction Elements Without Turning
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Solution Overview
Problem
Existing machining devices for construction elements require complex handling operations to turn elements, leading to increased construction time, workforce requirements, and tolerance issues in height irregularities, which complicates the assembly process and increases costs.
Innovation Solution
A machining device that allows construction elements to be machined from their original position on pallets without the need for delicate handling, featuring a fixed table with a machining tool that supports the elements during machining, and a second tool for machining the upper face, with offset machining surfaces to ensure efficient machining of both faces without manual reorientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If construction elements are machined from their original position on pallets without turning, then handling operations are simplified and productivity is improved, but the machining device complexity increases due to the need for multiple machining tools and offset arrangements
Solution Approach 1:
The patent combines multiple machining operations (machining of lower face and upper face) into a single processing step by arranging multiple machining tools on the same machining center. The lower face is machined by a first machining tool while the upper face is machined by a second machining tool simultaneously or sequentially without removing the construction element from the pallet, thus eliminating the need for turning operations and improving productivity.
Solution Approach 2:
The patent introduces a vertical dimension to the machining process by arranging machining tools at different heights and positions. The machining plane is offset with respect to the support surface, and multiple tools are positioned at different vertical levels to access both the lower and upper faces of the construction element, enabling multi-face machining from a single horizontal position.
2Ease of operation
If support surfaces are arranged horizontally with construction elements stacked on pallets, then the elements remain in their original position during machining, but additional handling operations are required to reorient elements for machining their faces
Solution Approach 1:
The patent merges the machining of both lower and upper faces into a single operational cycle. By equipping the machining center with multiple tools positioned to access different faces, the system performs what would traditionally require separate handling and reorientation operations all within one continuous process, thereby improving productivity without compromising ease of operation.
3Ease of manufacture
If height irregularities of construction elements are within loose tolerances (plus or minus 2 mm), then manufacturing is easier and faster, but the assembly process requires thicker mortar layers and more quality checks
Solution Approach 1:
The patent performs preliminary machining of the construction elements to achieve precise height and surface flatness tolerances before assembly. By machining both the lower and upper faces with high precision on the same element, the system ensures that elements meet strict tolerance requirements (reducing height irregularities to within 0.5 mm) prior to stacking, thereby eliminating the need for thick mortar compensation layers and reducing quality check requirements during assembly.
Data Source
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AI summary
The device has a machining station with machining tools (12, 13) that machines lower and upper faces (7, 8) of a construction element (1). The machining tool (12) e.g. bell tool, is disposed at a level of a lower bearing surface and rotated around a rotational axis (A) perpendicular to the lower bearing surface. The machining tool (12) has a machined surface of appreciably annular form. A circular shaped fixed table (15) supports the lower face and is disposed at a center of the machining tool (12). Additional bearing surfaces are provided perpendicular to upper and lower bearing surfaces.