Safe Mode Cross Slide System for Flange Re-machining
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Solution Overview
Problem
Conventional machining of industrial equipment, such as flange connections, is prone to operator error, safety risks, and significant production downtime due to the need for manual operation and removal of equipment to a machine shop, especially in hazardous environments.
Innovation Solution
A safe mode cross slide system with a cross slide mechanism incorporating a back plate, front plate, servo motors, and a communications hub processor that allows for precise, automated machining without the need for continuous wireless communication, ensuring safety and accuracy in re-machining surfaces like flange connections and other industrial components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manual machining is used, then operator flexibility and adaptability are maintained, but operator safety is compromised and production downtime increases
Solution Approach 1:
The patent replaces manual mechanical operation with an automated cross-slide machining system that uses computer-controlled mechanisms. The system includes a cross-slide assembly with automated tool positioning, servo motors for precise movement control, and a control system that eliminates the need for manual operation while maintaining machining capability. This substitution directly addresses the safety concern by removing operators from hazardous environments.
Solution Approach 2:
The patent introduces a communication hub as an intermediary between the control system and the machining operations. This hub receives commands, processes them, and translates them into precise mechanical movements of the cross-slide assembly. The intermediary layer allows for automated control while providing a buffer that enhances system reliability and safety by preventing direct human exposure to hazardous machining environments.
2Manufacturing precision
If equipment is removed to a machine shop for remachining, then machining quality can be maintained, but production downtime significantly increases
Solution Approach 1:
The patent segments the machining system into a portable cross-slide assembly that can be detached and transported. The cross-slide assembly includes modular components such as the tool holder, cross-slide mechanism, and support structure that can be easily assembled and disassembled. This segmentation allows the machining capability to be moved to the equipment location rather than requiring equipment removal to a machine shop, thereby reducing production downtime while maintaining precision.
Solution Approach 2:
The patent changes the spatial dimension of the machining operation by moving the machining tool to the equipment location instead of moving the equipment to the tool location. The cross-slide assembly is designed to be positioned directly at the equipment site, bringing the machining capability to where it is needed. This dimensional shift eliminates the time-consuming process of equipment transportation while preserving machining quality through precise automated control.
3Productivity
If automated cross-slide system is implemented, then productivity and precision are improved, but device complexity increases
Solution Approach 1:
The patent designs the cross-slide assembly with universal components that can perform multiple functions. The cross-slide mechanism can accommodate different tool types, the control system can handle various machining operations, and the modular design allows the same basic structure to be used for different equipment sizes and configurations. This universality reduces the need for multiple specialized components, thereby managing device complexity while maintaining high productivity and precision capabilities.
Data Source
AI summary
A safe mode cross slide system having a cross slide with a back plate, a front plate and a saddle. The back plate can have a pair of end caps, a pair of linear guides, a first ball screw, a first gear box, a first servo motor, a first drive, and a first manual feed knob and the front plate can have a pair of end caps, a pair of linear guides, a second ball screw, a second gear box, a second servo motor, a second drive, and a second manual feed knob. The system can have a power supply, a communications hub with a processor and data storage.