Shaping Device Tool Carrier Adjustment for Hollow Body Accuracy
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Solution Overview
Problem
Existing forming devices for cup-shaped hollow bodies face challenges in maintaining processing accuracy due to elasticity and bearing play-related tolerances, requiring adjustable stroke lengths and minimum distances between the tool carrier and workpiece rotary table to ensure optimal manufacturing quality, while minimizing downtime and rejects.
Innovation Solution
A forming device with a threaded spindle and non-rotatable, linearly displaceable spindle nuts connected via a servomotor and linear adjusting device, allowing real-time adjustment of stroke length and minimum distance during operation, controlled by a machine controller using sensor data and a control algorithm to compensate for tolerances and deformations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the stroke length and minimum distance are adjusted to compensate for tolerances, then processing accuracy is improved, but device complexity increases
Solution Approach 1:
The adjustment device is nested within the existing linear movement mechanism. The threaded spindle integrates with the driver assigned to the tool carrier, and the spindle nuts are mounted within the driver structure. This nesting approach allows stroke length and minimum distance adjustment without adding external complex mechanisms, thereby improving processing accuracy while minimizing device complexity.
Solution Approach 2:
The adjustment device enables dynamic modification of stroke length and minimum distance during operation. The servomotor-driven threaded spindle allows real-time adjustment of the tool carrier's linear movement parameters, transforming a static system into a dynamic one that can adapt to tolerance variations, thus improving processing accuracy without requiring complete system redesign.
2Loss of time
If adjustment is made while the device is in operation, then downtime is reduced, but control complexity increases
Solution Approach 1:
The adjustment device allows the forming device to maintain continuous operation while adjusting stroke length and minimum distance. The adjustment can be performed during linear movement cycles without stopping the intermittent rotary movement or the overall forming process, ensuring continuous productive action and minimizing downtime for adjustments.
Solution Approach 2:
The system uses a control algorithm that processes sensor data to automatically adjust the threaded spindle position. This feedback mechanism enables the machine controller to monitor processing conditions and automatically modify stroke length and minimum distance parameters in real-time, reducing the need for manual intervention and simplifying the control process despite the added adjustment capability.
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
This solution ensures improved processing accuracy and reduced downtime by allowing for precise adjustments of stroke length and minimum distance between the tool carrier and workpiece rotary table, adapting to changing operating conditions and maintaining high-quality hollow body formation.
Implementation Method 1
the adjusting device comprises a threaded spindle and a first and a second spindle nut arranged at a distance from one another, which each engage in an external thread of the threaded spindle
Implementation Method 2
the second spindle nut is assigned a linear adjusting device and a servomotor, the second spindle nut being displaceable by the servomotor by rotation along the threaded spindle
Data Source
Figure 1
Figure 2
AI summary
The shaping device (1) comprises a machine controller (2), a drive device (6), a workpiece rotary table (3) for receiving hollow body, a tool carrier (4) for receiving processing tools, and an adjustment device. The workpiece rotary table and the tool carrier are opposite to each other, mutually rotatable about a rotation axis and adjustable along the rotation axis. The drive device is: controllable by the machine controller; and formed to provide a rotary step movement and a cyclic linear motion between the rotary table and the tool carrier for the transformation of the hollow body. The shaping device (1) comprises a machine controller (2), a drive device (6), a workpiece rotary table (3) for receiving hollow body, a tool carrier (4) for receiving processing tools, and an adjustment device. The workpiece rotary table and the tool carrier are opposite to each other, mutually rotatable about a rotation axis and adjustable along the rotation axis. The drive device is: controllable by the machine controller; and formed to provide a rotary step movement and a cyclic linear motion between the rotary table and the tool carrier for the transformation of the hollow body by the machining tools. The adjustment device is formed: to set a stroke length of a cyclic linear movement and/or a minimum distance between the tool carrier and the rotary table; and such that the stroke length of the linear movement and/or the minimum distance between the tool carrier and the rotary table are set during the execution of the linear motion. The machine controller is: formed such that the adjustment of the cyclic linear movement and/or the minimum distance between the tool carrier and the rotary table occurs as a function of a state value of the drive device; and associated with a sensor unit for determining the state value of the drive device. The sensor unit is formed as a length sensor, a distance sensor, a speed sensor, an acceleration sensor, a deformation sensor and/or a temperature sensor and coupled with the machine controller. A control algorithm is stored in the machine controller to permit an adjustment of the adjustment device as a function of the state value. The adjustment device is formed for the linear adjustment of the tool carrier relative to the drive device. An independent claim is included for a method of operating a shaping device.