Rotary Machining Head With Phase-Shift Tool Selection
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Solution Overview
Problem
Existing rotary machining heads are limited to two tools due to structural constraints, making it difficult to machine small parts effectively without buckling or torsional rigidity issues, and require complex and expensive mechanical systems to accommodate more tools.
Innovation Solution
A rotary head machining unit with a control bush that axially slides and has a phase shift device, allowing up to four tools to be selectively engaged during machining without stopping rotation, using a simplified electronic phase shift system with separate motors and angular position measurement for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of tools in the machining head is increased beyond two, then the productivity and versatility of the machining system is improved, but the device complexity and construction length increase significantly
Solution Approach 1:
The invention employs a dynamic control system where a single programmable logic controller (PLC) dynamically selects and controls multiple tools based on machining requirements. The PLC receives machining parameters, determines the appropriate tool, and activates it through solenoid valves and pneumatic actuators, replacing the need for multiple fixed mechanical control systems.
Solution Approach 2:
The machining head is designed with universal tool holders that can accommodate different tool types (drills, reamers, countersinks) and a single PLC controller that can manage multiple tools through programmable logic. The pneumatic actuation system provides universal control capability for all tools, eliminating the need for tool-specific mechanical control mechanisms.
2Adaptability or versatility
If the distance between the feed system and the tool is increased to accommodate more tools, then the adaptability of the system is improved, but the torsional rigidity decreases making machining of small parts difficult
Solution Approach 1:
The invention resolves the spatial conflict by transitioning from a radial tool arrangement to an axial stacking configuration. Multiple tools are arranged along the axial dimension of the spindle rather than radially, allowing tools to be positioned close to the feed system while maintaining adequate clearance for tool operations. This dimensional reorganization enables both high tool capacity and short guide length.
3Measurement precision
If a mechanical phase shift system is used to position the control bush, then the positioning precision is improved, but the device complexity and production cost increase
Solution Approach 1:
The invention replaces complex mechanical phase shift mechanisms with an electronic control system. A programmable logic controller (PLC) electronically determines the angular position of the control bush based on machining parameters and programmatically actuates pneumatic cylinders to position the control bush at the required angular locations, eliminating the need for mechanical indexing mechanisms.
Solution Approach 2:
The system uses programmable control parameters stored in the PLC to dynamically adjust the angular position of the control bush. By changing the control parameters (machining type, tool selection), the system can reposition the control bush to different angular locations without mechanical reconfiguration, enabling flexible and precise tool selection.
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 the machining of small parts with improved rigidity and load-bearing capacity, allowing for easy tool selection and maintenance, while reducing production costs and complexity, and facilitating the use of multiple tools without the need for extensive mechanical systems.
Implementation Method 1
every guiding surface corresponding to a pivoting tool holder having the shape of a helix portion whose axis coincides with the pivoting axis of said holder
Implementation Method 2
the rotor having an axial channel and, coupled to rotational drive means, axial guiding means for said non-rotary part, these means being carried by bearings in the rotor and by the fixed support
Data Source
AI summary
A machining unit having a rotary head that bears pivoting tools for machining a non-rotating part centered on a rotational axis of the head. The supports for the pivoting tools are mounted in the head to pivot about respective axes that are parallel to the rotational axis. Each support has a transversely arranged control lever. A control bushing is mounted coaxially on the machining unit and is arranged to slide axially and adopt a first, advanced position or a second, retracted position. At one end of the control bushing bearing is arranged an ellipsoidal control surface so as to cooperate with helical directing surfaces that are connected to the tools in order to execute a plunging movement of the tools. There is provided a phase-offset device, which is arranged to move the control bushing into two, three or four different predetermined angular positions around its axis.