Metal Panel Machining Paths for Continuous Oblique Slopes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing mechanical machining systems for metal panels, particularly in aircraft production, struggle with producing continuous slopes due to alignment constraints, leading to inefficiencies and the need for manual finishing, and are limited by complex adaptation modules that cannot handle oblique trajectories.
Innovation Solution
An automated mechanical machining system with a slope management module that determines real machining trajectories on slope using an elementary adaptation function, allowing the machining tool to be misaligned from the holding tool by an inclination angle, thereby enabling precise and efficient production of oblique slopes without manual finishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the machining tool and holding tool are aligned along the same normal axis, then the machining system maintains simple alignment and control, but it cannot produce continuous slopes and requires manual grinding
Solution Approach 1:
The patent applies asymmetry by deviating the machining tool axis from the normal axis of the holding face. The machining tool is oriented along a machining axis that forms an inclination angle with the normal axis, while the holding tool remains aligned with the normal axis. This asymmetric configuration enables the production of continuous slopes and oblique surfaces without requiring manual finishing operations.
2Manufacturing precision
If the adaptation module transforms theoretical machining trajectories into real machining trajectories, then the system adapts to the real surface geometry, but the calculation time increases and the module becomes complex
Solution Approach 1:
The patent segments the trajectory transformation process into two distinct modules: an adaptation module that handles simple theoretical trajectories and a slope management module that handles sloping trajectories. Each module performs specialized transformations, which reduces the computational complexity and calculation time compared to a single comprehensive transformation module.
Solution Approach 2:
The patent introduces an intermediary elementary adaptation function that maps simple theoretical trajectories to simple real trajectories. This elementary function serves as a building block that is then used by the slope management module to generate final machining trajectories, breaking down the complex transformation into manageable steps.
3Manufacturing precision
If a small diameter machining tool is used to form continuous slopes, then precise oblique surfaces can be produced, but the number of passes increases significantly
Solution Approach 1:
By orienting the machining tool at an inclination angle relative to the normal axis, the patent enables the use of larger diameter tools to produce continuous slopes in fewer passes. The asymmetric tool orientation allows the cutting edge to engage the workpiece in a manner that efficiently removes material while maintaining precision, eliminating the need for multiple passes with small diameter tools.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
An automated mechanical machining system (S) for machining a metal panel (P) comprising a first face (F1) and a second face (F2) which is on the opposite side from the first face (F1), the automated mechanical machining system (S) comprising at least one machining tool (1), at least one holding tool (2), a control module (5) configured to control the machining tool (1) and the holding tool (2) in a coordinated manner, a matching module (6) configured to determine simple actual machining paths TRAJr1 from, on the one hand, predetermined simple theoretical machining paths TRAJt1 and, on the other hand, measurement of the actual surface SURFr of the second face (F2) and a slope management module (9) configured to determine sloping actual machining paths TRAJr2 from sloping theoretical machining paths TRAJt2, the simple theoretical machining paths TRAJt1 and the simple actual machining paths TRAJr1.