Reconfigurable Hybrid Kinematics Machine for Large-Structure Machining

Solution Overview

Problem

Machining and welding large structures in the field is challenging due to inaccuracies in manual methods, joint errors in serial kinematics machines, low stiffness at extended arm configurations, and limited workspace in parallel kinematics machines.

Innovation Solution

A reconfigurable hybrid kinematics machine (HKM) combining parallel and serial modules, allowing for adjustable degrees of freedom and modular reconfiguration to adapt to different machining tasks and workpiece geometries, featuring a base, frame, arms, actuators, and a platform that can translate and rotate relative to the workpiece.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If serial kinematics machines are used for machining large structures, then the machine can reach extended positions, but joint errors accumulate and stiffness decreases

Engineering Contradiction:

Improvereach distanceVSAvoidmachining accuracy

Core Design Contradiction:

Length of moving objectVSManufacturing precision

Solution Approach 1:

The machine is divided into multiple modular units (base module, arm modules, platform modules) that can be connected in series. Each module contains its own actuators and joints, allowing the system to achieve extended reach while maintaining precision through modular error isolation. The segmentation allows the machine to be configured for specific task lengths without compromising overall accuracy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The machine employs dynamic reconfiguration capabilities where modules can be added, removed, or repositioned based on the specific machining task. The system can adjust its degree of freedom and modular configuration dynamically to optimize both reach and precision for different workpiece sizes and geometries, transforming from a static fixed-configuration machine to an adaptable system.

Inventive Principle:

Principle #15Dynamics

2Strength

If parallel kinematics machines are used for machining large structures, then the machine maintains high stiffness, but rotational and translational workspace sizes are limited

Engineering Contradiction:

Improvestructural stiffnessVSAvoidworkspace size

Core Design Contradiction:

StrengthVSArea of stationary object

Solution Approach 1:

The machine is divided into multiple modular units (base module, arm modules, platform modules) that can be connected in series. Each module contains its own actuators and joints, allowing the system to achieve extended reach while maintaining precision through modular error isolation. The segmentation allows the machine to be configured for specific task lengths without compromising overall accuracy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The machine is designed with universal modules that can function in multiple configurations. The same base module and arm modules can be arranged in different sequences and configurations to handle various workpiece sizes and geometries. This multi-functionality allows a single machine design to serve multiple machining tasks across different workspace requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If manual machining methods are used on large structures in the field, then the machine can be simple and portable, but machining accuracy and quality are compromised

Engineering Contradiction:

Improvesystem simplicityVSAvoidmachining accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The machine is divided into multiple modular units (base module, arm modules, platform modules) that can be connected in series. Each module contains its own actuators and joints, allowing the system to achieve extended reach while maintaining precision through modular error isolation. The segmentation allows the machine to be configured for specific task lengths without compromising overall accuracy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The machine incorporates self-contained modules with integrated actuators, sensors, and control systems that can operate autonomously. Each module is designed to be self-sufficient with its own power and control, reducing the need for complex external support systems and enabling portable operation in field conditions while maintaining high machining precision.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20250326111A1Reconfigurable hybrid kinematics machine

Publication Date: 2025.10.23 KHALIFA UNIV OF SCI & TECH

AI summary

A system for machining a workpiece. The system includes a rotatable frame mounted to a base and arms which can translate relative to the rotatable frame. The arms are attached directly or indirectly to a machining tool which can be moved to various points around the workpiece and include tools for various machining operations.