Modular Deburring Machine with Rotatable Brush Drum
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Solution Overview
Problem
Existing abrasive finishing and deburring tools are limited in geometry handling, require high labor and cost, and lack flexibility to accommodate complex shapes and larger widths, making them unsuitable for aerospace manufacturing and other industries with diverse part features.
Innovation Solution
A modular, automated deburring machine with a hexagonal housing and rotatable brush drum featuring a helical groove and adjustable abrasive filament, allowing for customizable configurations and CNC capabilities, reducing labor and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional abrasive finishing tools are used, then material removal and surface finishing can be achieved, but the tools are limited in handling complex geometries and varying heights of part features
Solution Approach 1:
The patent employs a robotic arm with multiple degrees of freedom that can dynamically position and orient abrasive tools to access complex geometries and varying heights of part features. The robotic system allows real-time adjustment of tool position, orientation, and motion paths to adapt to different workpiece configurations, thereby achieving high adaptability without requiring complex fixed tooling arrangements.
Solution Approach 2:
The robotic deburring system is designed as a universal platform that can handle multiple workpiece types, geometries, and deburring requirements through programmable motion control and interchangeable abrasive tools. A single robotic system can perform various deburring operations on different parts by changing toolpaths and tool configurations, eliminating the need for dedicated fixtures for each part geometry.
2Productivity
If conventional deburring machinery is used, then deburring operations can be performed, but the machinery is labor intensive and costly
Solution Approach 1:
The robotic deburring system operates autonomously with programmable control that enables automatic tool positioning, motion execution, and process parameter adjustment. The system can independently complete deburring operations without continuous human intervention, significantly reducing labor requirements and associated costs while maintaining high productivity through automated cyclic operation.
Solution Approach 2:
The patent replaces manual mechanical deburring operations with an automated robotic system controlled by computer programs. This substitution eliminates the need for skilled manual labor and reduces operational costs while increasing productivity through consistent, repeatable automated processes that can operate continuously without fatigue or downtime.
3Productivity
If Fladder type machines are used, then high efficiency deburring can be achieved, but the machine width is limited to 1.8-2 m and flexibility is reduced
Solution Approach 1:
The robotic deburring system features dynamic positioning capabilities with multiple axes of motion that allow the tool to reach various positions and orientations on workpieces of different sizes and shapes. The robotic arm can extend to accommodate larger widths beyond 2 meters and adjust its configuration dynamically, providing both high deburring efficiency and the flexibility to handle diverse part geometries that fixed Fladder machines cannot accommodate.
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
The machine provides a cost-effective, flexible solution for deburring operations on parts of any size and shape, enhancing manufacturing efficiency and reducing costs, making it suitable for both small and large machine shops across various industries.
Implementation Method 1
abrasive filament inserted by its edge into it and secured thereof. The abrasive filament is prepared from a precursor abrasive tape or sheet's
Data Source
AI summary
An abrasive deburring machine comprised of a plurality of individually controlled abrasive modules, each having a rotatable drum type brush with flexible bristles, the drum is mounted on a rotatable support with axis of rotation generally perpendicular to the rotational axis of the drum. Each support with brush and support drive are mounted inside of a housing therefore creating a module. Plurality of such modules can be combined in a desired configuration to form a deburring machine or finishing/polishing machine tailored to a specific geometry of the work piece or part to be deburred, finished or polished. Each drum and drum support, including its axial angular position are controlled independently, which for a pre-programmed movement of all brushes in order to conform to a complex shape of the part to be deburred, optimize the process of deburring and maximize the durability of abrasive brushes. The drum type brush is preferably made of polystyrene foam with helical groove along its outer shape containing a continuous abrasive filament secured inside the groove and having bristle or strap like abrasive extremities. The invention includes a variety of modes of use being mostly applicable for deburring and finishing operations in Aerospace sector as well as in finishing operations in other metal, plastic and woodworking industries.