Profiled Bar Machining Head With Stepped End-Face Reorientation
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Solution Overview
Problem
Existing machine tools with four controlled axes are inadequate for performing mechanical operations on the transversal end sections of profiled bars, requiring either additional machines or expensive five-axis machines.
Innovation Solution
A machine tool with four controlled axes, featuring an operating head that is displaceable along a longitudinal and transversal direction, and rotatable about a first axis for working longitudinal surfaces, with an actuator for rotating the operating head in steps about a second transversal axis to access and work the transversal end sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a machine tool with four controlled axes is used, then the machine structure remains simple and cost-effective, but mechanical operations on transversal end sections cannot be performed
Solution Approach 1:
The operating head is made dynamically rotatable about a second rotation axis (transversal axis) in addition to its normal operations. This dynamic addition allows the head to reorient itself to access transversal end sections, transforming a static 4-axis system into a versatile system that can perform operations on both longitudinal surfaces and transversal ends without requiring a permanently complex 5-axis structure
Solution Approach 2:
The operating head is designed to perform multiple functions: it can work on longitudinal surfaces using the standard four axes, and it can also work on transversal end sections by rotating about the additional second rotation axis. This multi-functionality allows a single machine structure to handle diverse machining requirements without needing separate dedicated machines
2Adaptability or versatility
If a machine tool with five controlled axes is used, then mechanical operations on transversal end sections can be performed, but the machine becomes expensive and complex
Solution Approach 1:
Instead of providing continuous rotational capability about two axes (which would constitute a full 5-axis system), the invention implements a dynamic solution where the operating head can rotate about a second rotation axis only when needed to access transversal end sections. This selective dynamic rotation reduces structural complexity compared to a dedicated 5-axis machine while maintaining the required versatility
Solution Approach 2:
The rotational capability is segmented into distinct functional modes: the primary four axes handle longitudinal surface operations, while the secondary rotation about the second rotation axis is activated specifically for transversal end section operations. This segmentation allows the machine to maintain simplicity for the majority of operations while gaining enhanced capability when needed
3Reliability
If mechanical operations on transversal end sections are performed on a different machine tool, then the operations can be completed, but production time increases
Solution Approach 1:
The invention merges the capability to work on both longitudinal surfaces and transversal end sections into a single integrated machine tool. The operating head, by rotating about the second rotation axis, can access and machine transversal end sections without requiring the workpiece to be transferred to or repositioned on a different machine, thereby eliminating transfer time and improving overall production efficiency
Solution Approach 2:
A single machine tool is designed with universal capability to perform all required mechanical operations - both on longitudinal surfaces and on transversal end sections. This eliminates the need for multiple specialized machines and the associated setup, transfer, and repositioning operations, thereby reducing total production time while maintaining operational completeness
Data Source
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AI summary
An apparatus for working a profiled bar (2) having a main dimension, comprises an operating head (3) having at least one working tool (8) and a support (11) which supports the operating head (3). The operating head (3) is displaceable along a longitudinal direction (X) in order to be brought to a desired position along the profiled bar (2). The operating head (3) is furthermore displaceable transversely to the longitudinal direction (X) along a first transversal direction (Z) and along a second transversal direction (Y). The operating head (3) is rotatable about a first rotation axis (R1) for working distinct longitudinal surfaces (16) of the profiled bar (2). The apparatus further comprises an actuator (14) for rotating discretely the operating head (3) about a second rotation axis (R2) arranged transversally to the first rotation axis (R1), so that the working tool (8) can act on transversal end sections (15) of the profiled bar (2).