Sander Machine with Profile-Adaptive Abutment Roller
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Solution Overview
Problem
Existing sander machines fail to effectively and precisely finish flat surfaces of panels with opposing curvilinear profiles, often resulting in non-conforming machined parts and safety risks due to uneven force application during sanding.
Innovation Solution
A sander machine with a control unit and adjustable components, including pneumatic pistons and rollers, ensures precise sanding by adapting to the panel's profile and shape, using a sanding roller and abutment roller system to maintain constant contact and control material removal, preventing excessive force and surface defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed sanding roller system is used, then the sanding operation is simple, but the machine cannot adapt to different panel profiles resulting in poor manufacturing precision
Solution Approach 1:
The patent implements a movable abutment roller supported by a pneumatic piston that can dynamically adjust its position along the Z-axis to follow the panel's curvilinear profile. This dynamic adjustment allows the sanding roller to maintain optimal contact with the panel surface while adapting to varying profiles, thereby achieving high manufacturing precision without requiring a completely complex reconfigurable system
Solution Approach 2:
The control unit receives information about the panel profile and automatically adjusts the abutment roller position accordingly. This feedback mechanism ensures that the sanding operation adapts to the specific geometry of each panel, maintaining precise planarity achievement while automating the adjustment process to manage system complexity
2Reliability
If pneumatic pistons are used to press the panel against the conveyor belt, then the panel remains constantly adherent during transport, but the device complexity increases
Solution Approach 1:
The patent employs pneumatic pistons to provide controlled downward force on the abutment roller, ensuring the panel remains constantly adherent to the conveyor belt during transport. This pneumatic system offers reliable and consistent force application that can be easily controlled and adjusted, achieving high reliability while keeping the mechanism relatively simple compared to alternative mechanical pressing systems
3Manufacturing precision
If the abutment roller is movable along Z-axis according to panel profile, then the sanding precision is improved, but the control system complexity increases
Solution Approach 1:
The control unit automatically adjusts the abutment roller position based on the panel profile information, creating a closed-loop feedback system. This automation improves sanding precision by ensuring the roller follows the exact panel geometry while reducing the need for manual intervention and simplifying operation
Solution Approach 2:
The system is designed to automatically adapt to different panel profiles without requiring manual reconfiguration. The control unit self-adjusts the abutment roller position based on the detected panel shape, making the system self-servicing and reducing operational complexity despite the sophisticated control capabilities
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
The machine efficiently achieves a higher degree of planarity on flat surfaces while minimizing defects and ensuring safe operation by dynamically adjusting to the panel's shape and profile during sanding.
Implementation Method 1
each roller of the second plurality of accompanying rollers 15 is mounted on a respective pneumatic piston 16, oriented in such a way as to push the relative roller of the accompaniment 15 against the shaped upper surface U of the panel P
Implementation Method 2
An abrasive surface is provided on the external surface of the sanding roller 10 to abrade or smooth the lower surface L of the panel P
Implementation Method 3
a first conveyor belt 7 is also provided for transporting the panel P to be treated from the inlet 4 to the operating unit 6
Data Source
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AI summary
The present invention relates to a sander machine (1) for machining at least one panel (P) or other workpiece where are provided a first surface (L) which is substantially flat and a second surface (U), which is shaped, opposite said first surface (L), said sander machine (1) comprising: first moving means (7) for moving, in use, said at least one panel (P) or other workpiece to an operative zone according to an advancing direction (A); sanding means (10) placed at said operative zone and configured to sand, in use, said first surface (L) of said at least one panel (P) or other workpiece; a abutment member (11) which is movable according to an axis (Z) being transversal to said advancing direction (A) and placed above said sanding means (10) such that when said at least one panel (P) or other workpiece advance according to said advancing direction (A), said at least one panel (P) or other workpiece pass through the space comprised between said sanding means (10) and said abutment member (11) with said first surface (L) facing said sanding means (10) and with said second surface (U) facing said abutment member (11); actuating means for moving said abutment member (11) along said axis (Z); and a control unit which is configured to know the profile of said at least one panel (P) or other workpiece according to said axis (Z), which at any moments is between said sanding means (10) and said abutment member (11) when said at least one panel (P) or other workpiece advance along said advancing direction (A); said control unit being operatively connected with said actuating means such that said control unit controls, by said actuating means, the movement of said abutment member (11) along said axis (Z) based on the value of said profile, such as to allow said sanding means (10) to sand, in use, said first surface (L) in such a way as to achieve a higher planarity level of the first surface (L).