Automated Measurement and Correction for Inclined Slide Core Hole Machining
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Solution Overview
Problem
Machining of slide core holes in molds for large-sized resin products, such as automobile parts, is labor-intensive and inefficient due to phase misalignment between core pockets and rod holes, despite the high-speed cutting capabilities of five-axis machine tools.
Innovation Solution
A method and system for machining inclined slide core holes using a five-axis machine tool with A-axis pivoting and C-axis rotation, involving spot-facing, drilling, and precision shaping to correct reference points for accurate machining of core pockets and rod holes, enabling automated measurement and correction to ensure precise fitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate machining steps are used for core pocket and rod hole, then machining flexibility is maintained, but phase misalignment occurs resulting in poor fitting
Solution Approach 1:
The patent combines the machining of core pocket and rod hole into a single integrated process. The rod hole is machined first as a guide, then the core pocket is machined in relation to this guide hole in one setup, eliminating phase misalignment between the two features while maintaining process flexibility through automated measurement and correction.
Solution Approach 2:
The rod hole serves as an intermediary guide feature that establishes the precise position and orientation for subsequent core pocket machining. By using the rod hole as a reference intermediary, the system achieves accurate phase alignment between core pocket and rod hole without requiring complex separate positioning procedures.
2Manufacturing precision
If manual correction is performed for phase misalignment, then fitting accuracy can be adjusted, but labor intensity increases and efficiency decreases
Solution Approach 1:
The patent implements automated feedback through measurement of the machined rod hole position and use of this measurement data to correct the machining program for subsequent core pocket machining. This closed-loop feedback system automatically compensates for any deviations, achieving high fitting accuracy without manual intervention and maintaining high productivity.
Solution Approach 2:
The machining system performs self-correction by automatically measuring the rod hole position and using this information to adjust the core pocket machining parameters. The system serves itself by eliminating the need for manual measurement and correction operations, thereby maintaining both high precision and high efficiency.
3Productivity
If high-speed cutting is used for shaping machining, then machining speed increases, but manual adjustment work is still required at final stage
Solution Approach 1:
The patent replaces manual mechanical adjustment operations with automated measurement and program correction systems. The measurement device automatically detects rod hole position, and the control system automatically corrects the machining program, substituting manual operations with automated computational and control systems that maintain both high speed and high precision.
4Adaptability or versatility
If multiple machining operations are performed for slide core hole, then machining flexibility is maintained, but total machining time increases
Solution Approach 1:
The patent performs preliminary machining of the rod hole to establish a precise guide and reference position before machining the core pocket. This preliminary action enables subsequent automated measurement and program correction, allowing the main core pocket shaping to be performed efficiently in one operation without requiring multiple adjustment passes, thus reducing total machining time while maintaining flexibility.
Data Source
AI summary
A measurement/correction system for use in machining an inclined slide core hole includes means for executing a measurement program which, after machining of an intermediate pocket hole in a mold surface, measures the position of the center of a rod hole in a seating surface of the intermediate pocket and the position of the seating surface of the intermediate pocket. Arithmetic means calculates the coordinates of an actual reference point of the rod hole from the measurements. Correction means compares the measured position of the reference point with the reference point previously set in a machining program, and, if there is an error, rewrites the coordinates of the reference point in the program to the measured coordinates. The corrected machining program is executed with the rewritten reference point in order to carry out machining of the core pocket while expanding the intermediate pocket.