Profiled Bar Handling in Machine Tools with Single Door Opening
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Solution Overview
Problem
Existing machine tools require the safety door to open and close twice for unloading a machined profiled bar and loading a new one, increasing cycle time and stressing mechanical door-opening devices.
Innovation Solution
Implementing a process where the machined profiled bar is moved to a standby position within the machine tool's working space while the safety door remains closed, allowing accessory activities to be performed before unloading the bar, thus reducing the need for multiple safety door openings and closings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the safety door is opened and closed twice for unloading and loading profiled bars, then the operator can safely unload the machined bar and load a new one, but the cycle time increases and mechanical stress on door devices increases
Solution Approach 1:
The machined profiled bar is moved to a standby position before the safety door is opened, preparing the operating position in advance. This preliminary action allows the door to be opened only once, reducing cycle time while maintaining safety through automated controlled movements.
Solution Approach 2:
The machine tool performs automated movements of the profiled bar between positions and automatically positions clamps, reducing the need for repeated door openings. The system serves itself by automating the preparation and positioning operations that previously required door access.
2Reliability
If the safety door is opened and closed twice for unloading and loading profiled bars, then the operator can safely unload the machined bar and load a new one, but the mechanical devices for opening and closing the door are significantly stressed
Solution Approach 1:
The machined profiled bar is moved to a standby position and the operating position is prepared before opening the safety door. This preliminary preparation allows the door to remain closed longer, reducing the frequency of opening/closing cycles and thereby reducing mechanical stress on door devices.
Solution Approach 2:
The machine tool automates the movement of profiled bars and positioning of clamps, reducing the need for repeated door operations. This automation decreases the mechanical stress on door-opening devices by minimizing their usage frequency.
3Productivity
If the machined profiled bar is moved to a standby position before opening the safety door, then the number of door openings is reduced and cycle time decreases, but the device complexity increases
Solution Approach 1:
The working space is divided into an operating position and a standby position, allowing the profiled bar to be moved between these segmented areas. This segmentation enables automated operations to prepare the next position while the door remains closed, improving productivity with minimal added complexity.
Solution Approach 2:
A movement device acts as an intermediary mechanism between the operating position and standby position, enabling automated transfer of the profiled bar. This intermediary device facilitates the productivity improvement while keeping the overall system structure relatively simple.
4Productivity
If accessory activities are performed in the operating position while the safety door is closed, then the cycle time is reduced and productivity increases, but the automation extent must increase
Solution Approach 1:
Accessory activities such as moving the profiled bar to standby position and positioning clamps are performed as preliminary automated actions before the safety door is opened. This preliminary automation reduces cycle time by eliminating the need to open the door for these operations.
Solution Approach 2:
The machine tool performs accessory activities automatically without operator intervention, with the safety door remaining closed. The system serves itself by automating clamp positioning and bar movement, increasing productivity while requiring a corresponding increase in automation extent.
Data Source
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AI summary
A process comprises the steps of: - providing a machine tool (1) in which a work space (6) is defined, the machine tool (1) comprising a safety door (5) for closing the work space (6) or alternatively allowing access to the work space (6); - machining a profiled bar (2) on the machine tool (1) in an operating position (P1) inside the working space (6), the working space (6) being closed by the safety door (5); - opening the safety door (5) after the profiled bar (2) has been machined, for unloading the machined profiled bar (2) from the machine tool (1). Before opening the safety door (5), there is provided a step of moving the machined profiled bar (2) to a standby position (P2) distinct from the operating position (P1), the standby position (P2) being defined inside the working space (6). After opening the safety door (5), there is provided a step of loading a profiled bar (2) to be machined in the operating position (P1).