Non-round Hole Boring Device Using Cam-Driven Tool Projection
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Solution Overview
Problem
The existing methods for boring non-round holes in cylinder blocks are inefficient due to complex machine tool structures, high data volume issues, and precision problems caused by bore deformation and high-order noise, leading to decreased productivity and processing speed.
Innovation Solution
A device with a cylindrical arbor and shaft system, using cams to adjust the processing tool's projection, combined with frequency analysis and phase correction to generate analytical shape parameters, allowing for high-speed and precise processing without shaft advancement and retraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the shaft is caused to advance and retract at high speed to process non-round bores, then processing speed is improved, but the machine tool structure becomes complex due to requiring linear guides, rotary joints, or linear motors
Solution Approach 1:
Instead of advancing and retracting the shaft to control the processing tool's position, the invention inverts the approach by rotating the processing tool itself around the bore. The tool's rotation, combined with controlled radial movement, achieves the same non-round bore formation without requiring complex shaft advancement mechanisms. This transforms a linear motion problem into a rotational motion problem, simplifying the overall machine tool structure.
Solution Approach 2:
The invention employs dynamic control of the processing tool's rotation speed and radial position during the boring operation. By dynamically adjusting these parameters, the system can create various non-round bore shapes while maintaining high processing speeds. The processing tool rotates at controlled speeds and its radial position is dynamically adjusted to match the desired bore profile, eliminating the need for complex mechanical advancement systems.
2Manufacturing precision
If all measured inner-diameter shape data is used to generate NC data, then manufacturing precision is improved, but data volume becomes enormous and processing speed declines
Solution Approach 1:
The invention extracts only the essential features from the measured inner-diameter shape data by performing frequency analysis. Instead of using all raw measurement data, the system identifies and extracts the dominant frequency components that define the bore's non-round shape characteristics. This extraction process significantly reduces data volume while preserving the critical geometric information needed for accurate NC data generation.
Solution Approach 2:
The invention transforms the measured bore shape data from spatial domain measurements to frequency domain parameters through spectral analysis. By converting the data into frequency components (amplitudes and phases), the system reduces the data representation from numerous individual measurement points to a compact set of frequency parameters. This parameter transformation maintains manufacturing precision while enabling rapid data processing and NC code generation.
3Measurement precision
If high-order noise is included in the measured data, then measurement precision is maintained, but vibration occurs during machine tool operation
Solution Approach 1:
The invention converts the harmful high-order noise components into useful information by analyzing their frequency characteristics. Through spectral analysis, the system identifies which frequency components correspond to actual bore shape features versus those that represent measurement noise or vibrations. By selectively filtering and reconstructing the bore profile using only the beneficial frequency components, the system eliminates vibration-causing high-order noise while preserving measurement precision for the essential geometric features.
Data Source
AI summary
A non-round hole boring device capable of machining a work in a desired cross sectional shape by a simple configuration. The non-round hole boring device (1) comprises cylindrical arbors (11, 21), shafts (12, 22) stored in the arbors (11, 21), respectively, a cutting tool (13) attached to the outer peripheral surface of the arbor (11), a cam (121) formed on the shaft (12) and pressing the cutting tool (13), a first rotary encoder (252), a second rotary encoder (241), an arbor motor (23) for rotatingly driving the arbors (11, 21), a shaft motor (24) for rotatingly driving the shafts (12, 22), and a controller (40). The controller (40) advances or retards the phases of the rotating angles of the shafts (12, 22) relative to the phases of the rotating angles of the arbors (11, 21), respectively, while rotating the arbors (11, 21) and the shafts (12, 22) in synchronism with each other, respectively. Consequently, the cutting tool (13) is pressed by the cam (121) to adjust the projecting dimension of the cutting tool (13).