Machining Jig Setup Using a Master Workpiece Template
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Solution Overview
Problem
Current machine tool setup changing processes are time-consuming and labor-intensive, requiring manual operation to accurately position workpieces with respect to machining jigs that deform to fit different workpiece shapes.
Innovation Solution
A method and machining system that utilize a master workpiece with a mock clamped portion matching the workpiece shape, deforming the jig's gripping parts to conform to the master workpiece's shape, allowing for automated setup changing and precise positioning of the workpiece for machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual operation is used to position workpiece and deform jig, then positioning accuracy can be achieved, but setup changing time and labor effort increase significantly
Solution Approach 1:
The patent uses a master workpiece that serves as a physical copy or template of the target workpiece geometry. The master workpiece includes a clamped portion that replicates the shape and dimensions of the actual workpiece's clamped portion, allowing the jig to be deformed and positioned accurately without manual measurement and adjustment operations
Solution Approach 2:
The master workpiece is prepared in advance with the exact geometry of the target workpiece. By using this pre-prepared master copy, the system eliminates the need for time-consuming manual positioning and jig deformation operations during actual setup changing, as the master workpiece already contains all the necessary geometric information
2Manufacturing precision
If manual operation is used to deform jig to conform to workpiece shape, then jig conformity to workpiece shape is achieved, but operator effort and setup complexity increase
Solution Approach 1:
The master workpiece serves as a physical template that copies the exact shape and dimensions of the target workpiece. The jig deforms by conforming to this master copy, automatically achieving the correct geometry without requiring operator skill or effort to manually shape the jig
Solution Approach 2:
The system enables self-service operation where the master workpiece automatically guides the jig deformation process. The jig deforms itself to conform to the master workpiece shape through the gripping mechanism, eliminating the need for manual intervention and reducing operational complexity
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
This approach enables efficient and accurate setup changing, reducing the time required for setup changes and improving machining efficiency by automating the positioning process, allowing for precise clamping and machining of workpieces with varying shapes.
Implementation Method 1
a jig (13) having a gripping part which deforms in accordance with a shape of a clamped portion of a workpiece
Data Source
AI summary
A machine tool setup changing method includes mounting a master workpiece onto a tool spindle axis, deforming a gripping part by gripping, with the gripping part of a jig, a mock clamped portion of the master workpiece mounted on the tool spindle axis, and removing the master workpiece from the tool spindle axis and mounting a tool supported on a tool support device onto the tool spindle axis, wherein the workpiece gripped at the clamped portion by the gripping part, which was deformed in accordance with the mock clamped portion, can be machined with the tool.