Spindle-Mounted Chip Removal Using Pressure-Actuated Fluid Channels
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Solution Overview
Problem
Manual removal of chips from machine tool surfaces interrupts part production processes, leading to inefficiencies and increased costs due to operator involvement in chip removal during machining operations.
Innovation Solution
An automated machine tool chip removal device utilizing machine tool fluid (coolant or air) to direct pressurized fluid for chip removal, with a coupling interface to rotate with the spindle and valves actuated by fluid pressure and rotational speed to control fluid delivery channels, allowing for targeted and efficient chip clearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual chip removal by operators is used, then chips can be removed from part surfaces, but operator involvement interrupts part production processes and increases costs
Solution Approach 1:
The system enables self-service chip removal by utilizing the machine tool's own fluid supply (coolant or air) to automatically clear chips from part surfaces. The fluid delivery system is integrated into the machine tool's existing infrastructure, allowing the system to service itself without external operator intervention while maintaining continuous production operations
Solution Approach 2:
The manual mechanical chip removal process performed by operators is replaced with an automated fluid-based system. Pressurized fluid delivered through controlled channels substitutes for manual air blowing, eliminating the need for operator involvement and enabling continuous uninterrupted production
2Productivity
If automated fluid-based chip removal is implemented, then operator intervention is eliminated and production continuity is maintained, but system complexity increases due to fluid delivery channels and control valves
Solution Approach 1:
The system utilizes the machine tool's existing fluid supply infrastructure for dual purposes: primary coolant delivery during machining and secondary chip removal fluid delivery. This multi-functional approach leverages already-present fluid lines and pressure systems, avoiding the need for entirely separate automated chip removal equipment and reducing overall system complexity
Solution Approach 2:
The control system acts as an intermediary between the machine tool's existing fluid supply and the chip removal process. By utilizing already-present fluid lines and pressure systems as intermediaries, the system integrates chip removal functionality without requiring completely new infrastructure, thereby managing complexity while achieving automation
3Productivity
If pressurized fluid is used for chip removal, then chip clearance efficiency is improved, but fluid pressure control requirements increase system complexity
Solution Approach 1:
The system utilizes the machine tool's existing pressurized fluid supply (coolant pump or air compressor) to provide the necessary pressure for chip removal. The existing fluid delivery infrastructure and pressure generation systems service the chip removal function without requiring separate pressure control equipment, eliminating the need for additional complexity while maintaining efficient chip clearance
Solution Approach 2:
The machine tool's primary fluid supply system serves multiple functions: cooling/lubrication during machining and pressurized chip removal during or between operations. This multi-functional use of existing pressurized fluid infrastructure eliminates the need for dedicated chip removal pressure systems, achieving efficient chip clearance without increasing overall system complexity
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
Eliminates operator intervention in chip removal, enhancing manufacturing efficiency by enabling continuous operation and precise control over chip removal processes, reducing production costs and improving part inspection reliability.
Implementation Method 1
direct fluid onto the workpiece in one or more directions
Implementation Method 2
direct pressurized fluid for chip removal
Data Source
AI summary
A machine tool chip removal device including a coupling interface to couple with a rotatable spindle of a machine tool to facilitate rotation of the machine tool chip removal device about an axis at a rotational speed. The chip removal device can also include a main fluid channel with an opening to receive pressurized fluid from the machine tool. The chip removal device can further include a first fluid delivery channel and a second fluid delivery channel to direct fluid in different directions. Each fluid delivery channel can be in fluid communication with the main fluid channel. In addition, the chip removal device can include one or more valves associated with the first and second fluid delivery channels to selectively allow fluid passage from the main fluid channel to the fluid delivery channels. The one or more valves can be actuated by varying fluid pressure and/or rotational speed.