Movable Spindles for Machining Center Waste Reduction
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Solution Overview
Problem
In automated machining centers, large tool magazines increase flexibility but lead to increased spacing between spindles, resulting in waste due to voids between tools that cannot be worked on, as spindles must be separated by a minimum distance to accommodate the size of the magazines.
Innovation Solution
A numerically controlled machining center with movable spindles that adjust their distance to operate closer together than their respective magazines, allowing for efficient tool loading, working, and debris management, with a CNC and PLC controller for coordinated movement and tool transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If large tool magazines are used to increase flexibility and tool capacity, then the ability to perform many different functions with individual spindles is improved, but the spacing between spindles increases, resulting in waste material from workpieces
Solution Approach 1:
The system divides the tool management function into two separate components: large stationary magazines for tool storage and smaller movable spindles for machining operations. This segmentation allows the magazines to maintain large capacity for versatility while the spindles can be positioned closely together to minimize waste material between them.
Solution Approach 2:
The invention introduces independent movement capability along a fourth axis (vertical/Z-axis movement of spindles relative to magazines) in addition to the traditional X-Y plane movement. This dimensional change allows spindles to approach magazines from above, enabling close spindle spacing while maintaining access to tools in large magazines, thereby reducing waste material between spindles.
2Adaptability or versatility
If magazines are made large to contain a large number of tools, then flexibility in performing many different functions is improved, but efficiency of operation on the workpiece suffers due to greater distance between spindles
Solution Approach 1:
The spindles are designed with dynamic movement capability, allowing them to adjust their position independently between magazines. This dynamic positioning enables the system to optimize spindle spacing for each specific workpiece and operation, maintaining high productivity even with large magazines that provide diverse tool options.
Solution Approach 2:
Tools are pre-loaded into the large magazines before machining operations begin. This preliminary action allows the spindles to quickly access required tools without waiting for tool changes during operation, maintaining high productivity while the large magazines provide the flexibility to handle various machining functions.
3Quantity of substance
If spindles are separated by greater distance to accommodate large magazines, then tool capacity and flexibility are improved, but the voids between spindles increase creating waste product
Solution Approach 1:
The system introduces an intermediary mechanism (the movable spindle assembly with independent positioning capability) between the large magazines and the workpiece. This intermediary allows the spindles to be positioned optimally close to the workpiece and each other, minimizing waste product, while still accessing tools from the large magazines that provide high tool capacity.
Data Source
AI summary
A numerically controlled machining center for performing work on a workpiece including a plurality of magazines holding a plurality of tools, each magazine positioned a first distance from an adjacent magazine, a plurality of spindles equal to the number of magazines and movable relative to one another independent of the positions of the magazines, the spindles movable apart from one another in a tool loading position to accommodate large magazine sizes and movable toward one another in a working position to allow the tools to work close together to minimize waste, and a table for supporting a workpiece.