Robotic Machining Tool With Conductive Sensing Wheels
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Solution Overview
Problem
Manual operation of existing machine tools with endless abrasive belts for machining complex workpieces, such as turbine engine exhaust casings, is slow, expensive, and hazardous, with no precise control over machining distance and frequent belt slippage issues.
Innovation Solution
A robotic machining tool with an endless machining belt, featuring two pulleys and idly rotating wheels made of electrically conducting material, which maintain constant contact with the workpiece to define and maintain machining distance, prevent belt slippage, and adjust to misaligned surfaces using electrical current detection and control mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operation of machine tool is used, then operator can handle complex workpieces, but machining speed is slow and operation is hazardous
Solution Approach 1:
The machine tool automatically guides itself along the workpiece surface using the sensing wheel that detects surface contours and controls the ram mechanism to follow the surface profile, eliminating the need for manual operator guidance and enabling continuous automated operation
Solution Approach 2:
The patent replaces manual mechanical guidance with an automated sensing system where a sensing wheel detects surface geometry and electronically controls the ram mechanism to maintain proper tool positioning, substituting human operation with automated sensor-controlled mechanics
2Manufacturing precision
If manual guidance is used, then operator can adapt to complex geometries, but machining distance cannot be precisely defined
Solution Approach 1:
The patent replaces manual measurement and judgment with an automated sensing wheel that electronically detects surface contours and provides feedback to the control system, enabling precise automated control of machining distance based on actual surface geometry
Solution Approach 2:
The sensing wheel continuously detects the workpiece surface profile and provides feedback signals to the control mechanism, which automatically adjusts the ram positioning to maintain the correct machining distance, ensuring precise and consistent material removal
3Reliability
If manual operation is used, then flexible handling is possible, but belt slippage requires frequent operator intervention
Solution Approach 1:
The ram mechanism automatically maintains proper belt tension by self-adjusting its position based on feedback from the sensing wheel and control system, eliminating the need for manual belt retensioning and ensuring continuous reliable operation
Solution Approach 2:
The control system receives feedback from the sensing wheel about surface position and automatically adjusts the ram mechanism to maintain both proper belt tension and correct tool positioning, preventing belt slippage through automated real-time control
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
Enables precise, efficient, and automated machining operations with consistent machining distance and reduced operator intervention, improving safety and reducing operational costs by maintaining constant contact and adjusting to complex geometries.
Implementation Method 1
the wheels are made of an electrically conducting material and are each connected by a conducting element to one terminal of a source of electrical energy whose other terminal is connected to the workpiece. When a wheel is in contact with a surface to be machined of an electrically conducting part, and is rolling for example along a weld bead, an electric current passes between the wheel and this surface and is detected by appropriate means provided on the tool
Data Source
AI summary
A robotic machining tool employing an endless machining belt is disclosed. The tool includes a front pulley and a rear pulley which guide the machining belt, a drive unit which turns the rear pulley, a spindle about which the front pulley is free to rotate, and two wheels which flank the front pulley and are mounted idly on the spindle of the front pulley. The two wheels have an outside diameter greater than that of the front pulley in order to roll over a surface to be machined and in order to define a machining distance between the machining belt guided around the front pulley and the surface to be machined.