Segmented Tool Path Exit Strategy for Collision-Free Automatic Tool Changes
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Solution Overview
Problem
In aircraft construction, the automatic tool change process for cutting tools, especially in complex shapes like aircraft center arch panels, is prone to collisions, leading to damage and inefficiencies due to standard retraction methods, resulting in reduced tool life and increased engineer workload and costs.
Innovation Solution
A method and apparatus that specify tool paths with defined exit and entry points and paths for cutting tools, allowing for safe and efficient tool changes by avoiding collisions, utilizing a processor-controlled system to manage tool life and automate the tool change process, even for complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If standard retraction methods are used to change cutting tools, then tool change operation is simplified, but the risk of collision between cutting apparatus and workpiece/fixture increases
Solution Approach 1:
The tool path is divided into multiple segments, each with defined entry and exit points. This segmentation allows the system to plan safe entry and exit paths separately from the machining path, enabling tool changes without collision while maintaining operational simplicity.
Solution Approach 2:
Entry and exit paths are pre-defined for each tool path segment before machining begins. This preliminary planning ensures that when tool changes are needed, the apparatus can follow pre-calculated safe paths without requiring complex real-time collision avoidance calculations.
2Reliability
If cutting tools are changed before failure, then tool reliability is improved, but useful tool life is wasted
Solution Approach 1:
The system monitors tool life parameters continuously during machining operations. Based on this feedback, the system can determine the optimal moment to initiate tool change procedures, ensuring tools are replaced just before failure without unnecessarily discarding useful tool life.
Solution Approach 2:
The tool change timing is made dynamic rather than static. Instead of following a fixed schedule, the system adapts tool change decisions based on actual tool condition and usage, allowing maximum utilization of each tool while maintaining reliability.
3Ease of manufacture
If pre-programmed tool change processes are implemented, then engineer workload and cost decrease, but system complexity increases
Solution Approach 1:
The system is designed to automatically manage tool changes using pre-programmed paths and embedded logic. Once the entry and exit paths are established, the apparatus performs tool changes autonomously without requiring engineer intervention, reducing workload while the initial programming complexity is amortized over many automatic operations.
Data Source
AI summary
Disclosed is a method and apparatus for machining a workpiece (2). The method comprises specifying a path along which a cutting tool (6) is moved during machining the workpiece (2), the path comprising segments (26); defining, for each segment (26), an exit point on that segment (26); defining, for each segment (26), an exit path (38) from the exit point of that segment (26) to a point remote from the workpiece (2); performing a machining process including moving the cutting tool (6) along the tool path and machining the workpiece (2); and, during the machining process, when one or more criteria are satisfied: interrupting the machining process and, without machining the workpiece (2), moving the cutting tool (6) to the exit point of the current segment (26) and then along the exit path (38) of the current segment (26).