Pneumatic Manifold Pod Layout for Dense CNC Part Support
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Solution Overview
Problem
Existing flexible tooling systems for CNC machines are limited by high costs, minimum tooling system size, and insufficient support density, leading to deformation of parts during machining due to limited Z-axis height and actuator spacing.
Innovation Solution
A pneumatic manifold-based flexible tooling system with pods that include variable position assemblies, integrated motor and screw modules, and a pneumatic manifold, allowing for closer spacing of tooling elements and reduced cable requirements, enabling greater support density and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional flexible tooling systems use individual driven actuators for each tooling element, then positioning accuracy is achieved, but system cost increases significantly
Solution Approach 1:
The system divides the tooling table into multiple independent pods, each pod containing multiple tooling elements that share common positioning mechanisms. This segmentation allows each pod to be positioned independently while reducing the total number of actuators needed compared to individual actuation of each tooling element.
Solution Approach 2:
Multiple tooling elements within each pod share common positioning actuators and control systems. The pod structure merges the positioning functions for multiple elements, reducing the overall actuator count and system complexity while maintaining positioning accuracy through coordinated control.
2Area of stationary object
If flexible tooling systems use large tooling tables with many actuators, then support coverage is improved, but minimum tooling system height increases
Solution Approach 1:
The tooling system is segmented into multiple compact pods that can be arranged in a grid pattern on the table. Each pod is a self-contained module with integrated actuators and tooling elements, allowing dense packing to achieve large support coverage without requiring excessive vertical space.
Solution Approach 2:
The system transitions from a vertically stacked actuator configuration to a horizontally distributed pod arrangement. By spreading the tooling elements and actuators across the table plane rather than stacking them vertically, the system achieves large support coverage while minimizing the minimum usable Z-axis height.
3Device complexity
If actuator spacing is increased to reduce system complexity, then device complexity decreases, but part deformation increases due to insufficient support density
Solution Approach 1:
The table is divided into multiple small pods with tooling elements distributed throughout. This segmentation allows closely spaced tooling elements within each pod to provide dense local support, preventing part deformation while keeping each pod compact and manageable in complexity.
Solution Approach 2:
Each pod is designed as a localized support unit with tooling elements positioned to provide targeted support density where needed. The pod structure enables different spacing configurations in different regions of the table, optimizing support density for specific part geometries while maintaining overall system simplicity.
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 system allows for flexible tooling on CNC machines with varying Z-axis heights without major retrofits, providing increased support density and reducing deformation, making it suitable for machining parts with complex contours.
Implementation Method 1
The pneumatic manifold provides air and vacuum to end effectors, where the vacuum is used to secure a part to the end effectors and the air is used to release the part from the end effectors
Data Source
AI summary
The low profile of the flexible tooling system disclosed allows for flexible tooling to be added to nearly all CNC machines with an accommodating z-axis height and allows easier relocation of the system from one CNC machine to another. The system includes one or more pods, each of the pods of the system replacing the function of four independent actuators of earlier systems but operating with a shared mechanical frame. Arranging the mechanism into groups of four allows for greater density of part support spacing, minimizes cable requirements, and allows for air, vacuum, and vacuum sensor requirements be localized on each pod. The pods allow for part supports to be spaced as close as 6″ in the x and y axis. An increased variable position assembly density allows for greater flexibility to hold complicated parts.