Receiving Device Dimensioning for Dynamic Clamping Loads
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Solution Overview
Problem
Existing methods for dimensioning receiving devices in industrial processes, such as clamping devices in machine tools, fail to adequately account for dynamic process variables like forces and torques, leading to suboptimal resilience, handling, and manufacturing efficiency.
Innovation Solution
A method involving simulation by a virtual controller to determine dynamic process variables, which are then used to dimension the receiving device, combining virtual controller outputs with FEM simulations to optimize the device for static and dynamic loads, ensuring precise and reliable setup for machining processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the receiving device is made more resilient and rigid to withstand dynamic forces, then the mechanical strength and reliability improve, but the weight increases and handling becomes more difficult
Solution Approach 1:
The patent applies preliminary action by performing virtual commissioning and dynamic simulations before actual manufacturing to determine optimal dimensioning parameters. The receiving device is designed with predetermined dimensions that account for expected dynamic loads, allowing the device to achieve necessary strength without excessive material usage. This preliminary design phase enables optimization of the strength-weight ratio before physical prototyping.
Solution Approach 2:
The patent utilizes parameter changes by varying dimensional parameters of the receiving device based on results from virtual commissioning and FEM simulations. The dimensioning parameters are adjusted to achieve optimal mechanical properties while minimizing weight. This includes optimizing wall thickness, reinforcement placement, and overall geometry based on simulated dynamic load analysis.
2Ease of manufacture
If traditional dimensioning methods are used without dynamic simulation, then the manufacturing process is simpler and faster, but the receiving device may not adequately withstand dynamic process forces leading to workpiece detachment
Solution Approach 1:
The patent applies copying by creating virtual models and digital twins of the receiving device and manufacturing process. Instead of physically testing multiple prototypes, the design is replicated and tested in virtual environments through FEM simulations and virtual commissioning. This digital copying allows thorough validation of clamping reliability under dynamic loads before actual manufacturing, ensuring the physical device will perform reliably without requiring iterative physical prototyping.
Solution Approach 2:
The patent performs preliminary validation through virtual commissioning and dynamic simulations before actual manufacturing. The receiving device design is tested in advance under simulated dynamic process conditions to verify clamping reliability. This preliminary action identifies potential failures and allows design optimization before committing to manufacturing, ensuring reliability without adding manufacturing complexity.
3Manufacturing precision
If the receiving device is optimized for dynamic loads through simulation, then the precision and reliability of workpiece positioning improve, but the device complexity and manufacturing costs increase
Solution Approach 1:
The patent replaces complex physical testing and trial-and-error manufacturing with virtual simulation systems. FEM simulations and virtual commissioning digitally replicate the mechanical behavior of the receiving device under dynamic loads, eliminating the need for multiple physical prototypes and extensive bench testing. This substitution of mechanical experimentation with computational analysis achieves high positioning precision while managing device complexity through virtual rather than physical means.
Solution Approach 2:
The patent applies universality by using the same virtual commissioning and simulation framework for multiple purposes: validating receiving device design, optimizing dimensioning parameters, predicting dynamic behavior, and verifying workpiece positioning accuracy. This multi-functional simulation approach consolidates what would otherwise require separate testing procedures, managing complexity through a unified virtual validation system that serves multiple design objectives.
Data Source
AI summary
In a method for dimensioning a receiving device for use in an industrial process, control of the industrial process is simulated by a virtual controller. A dynamic control variable based on the simulation of the virtual controller is outputted and a dynamic process variable is determined based on the dynamic control variables. The receiving device is dimensioned by taking into account the determined dynamic process variable.