Mechanical Coupling for Workpiece Synchronization
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Solution Overview
Problem
Current methods for synchronizing the movement of automatic processing means with continuously moving workpieces in continuous production, such as in the automotive industry, face challenges with complexity, interface issues, and accuracy in tracking the movement, leading to suboptimal precision and reaction time.
Innovation Solution
A position sensor, or resolver, is mechanically coupled to the moving workpiece, feeding its signal directly into the control of the processing means as an additional axis, allowing direct synchronization of the processing means with the workpiece's movement, avoiding interface problems and enabling precise and quick positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If laser- or video-based measurement methods are used to continuously record distance data, then the position of the workpiece can be tracked, but the system complexity increases and interface problems occur when converting data to numerical signals
Solution Approach 1:
The patent replaces complex optical measurement systems (laser/video-based) with a simple mechanical coupling system. A coupling device mechanically connects the workpiece to the processing tool, directly transmitting position information through mechanical means. This substitution eliminates the need for complex measurement systems while maintaining synchronization accuracy.
Solution Approach 2:
The coupling device acts as an intermediary between the workpiece and the processing tool. It mechanically transmits position information from the workpiece to the processing tool, serving as a direct mediator that eliminates interface conversion problems between different measurement and control systems.
2Speed
If speed information from the conveyor is transmitted via numerical interface, then motion data can be obtained, but interface problems arise and required accuracy and reaction time are not achieved
Solution Approach 1:
The patent replaces numerical interface transmission with direct mechanical coupling. The coupling device physically connects the workpiece to the processing tool, transmitting motion information mechanically rather than through numerical interfaces. This eliminates interface conversion delays and accuracy losses.
Solution Approach 2:
The mechanical coupling ensures continuous transmission of motion information from the workpiece to the processing tool throughout the entire processing cycle. This continuous mechanical connection maintains uninterrupted synchronization without the data conversion interruptions inherent in numerical interface systems.
3Productivity
If the processing device remains stationary while workpieces are continuously conveyed, then the processing system is simple, but the processing precision deteriorates due to difficulty in adapting to workpiece movement
Solution Approach 1:
The patent merges the motion of the workpiece with the motion of the processing tool through mechanical coupling. The coupling device causes the processing tool to follow the workpiece's movement automatically, combining their motions into a synchronized system that maintains precision during continuous production.
Solution Approach 2:
The mechanical coupling creates a natural feedback mechanism where the position of the workpiece directly determines the position of the processing tool. As the workpiece moves, the coupling device automatically adjusts the tool's position in real-time, providing continuous feedback that maintains processing precision.
Data Source
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AI summary
The invention relates to a device and a method for synchronizing the movement of an automatic machining tool (BM) with the movement of a workpiece (WS) conveyed relative to the machining tool (BM) during machining, wherein the machining tool (BM) has at least one numerical control for controlling at least one primary axis (PA), and wherein a machining position of the machining tool (BM) can be continuously synchronized with the respective position of the workpiece (WS) by tracking the at least one primary axis (PA). A position sensor (LG) is mechanically coupled to the workpiece (WS), the position sensor (LG) being linked to the numerical control, and the numerical control being configured to use the signal from the position sensor (LG) to synchronize the movement of the at least one primary axis (PA) with the respective position of the workpiece (WS). With such a device, or...In this method, the workpiece's movement is converted into motion data via a direct mechanical coupling, allowing the processing equipment to synchronize directly with this movement. Mechanical deviations resulting from indirect measurement data acquisition on conveyor systems (e.g., assembly lines) can be avoided. Such a system can also be used for high-precision assembly or machining operations on workpieces with uneven movement.