Stationary Cover Elements for Machine Tool Chip Management
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Solution Overview
Problem
Conventional machine tools with a cross table design face challenges in effectively managing chipfall due to the large area covered by telescopic covers, leading to early wear and increased non-productive times, as well as requiring complex and costly additional devices for chip removal.
Innovation Solution
The implementation of longitudinally continuous, stationary cover elements with a funnel-type shape to protect linear guides and drive members, allowing for efficient chip disposal without the need for movable covers, reducing the machine's setup area and cabin size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If telescopic covers are used to protect linear guides and drive members, then protection against chipfall is achieved, but the covered area increases leading to enlarged machine cabin and set-up area
Solution Approach 1:
The cover is divided into a stationary base cover element attached to the machine bed and a movable table carrier assembly. The stationary cover element remains fixed in position while the table carrier moves above it, separating the protective function from the moving components and reducing the required covered area.
Solution Approach 2:
Instead of using movable covers that travel with the table carrier, the invention uses a stationary cover element fixed to the machine bed. This inverts the conventional approach where the cover moves with the workpiece, and instead the cover remains stationary while protecting the underlying components.
2Reliability
If telescopic covers are used to protect linear guides and drive members, then protection against chipfall is achieved, but the covers experience early wear particularly in the bordering area
Solution Approach 1:
The cover system is segmented into a stationary base cover element that remains fixed and a movable table carrier. The stationary cover element is designed to remain in one position, avoiding the repetitive friction and wear that occurs with telescopic covers that expand and contract during operation.
Solution Approach 2:
The invention inverts the conventional telescopic cover design by using a stationary cover element instead of a movable one. This stationary design eliminates the bordering area wear problem that plagues telescopic covers, as there is no relative motion between the cover and the machine bed.
3Ease of operation
If the workpiece table is arranged at user-friendly height with stable machine bed, then operational comfort is achieved, but the covers cannot be arranged at favorable angle of inclination for chipfall
Solution Approach 1:
The invention addresses the chipfall angle problem by adding a vertical dimension solution. The stationary cover element includes a chip discharge chute that extends vertically downward from the cover area to the chip disposal location, allowing chips to be guided down a steep inclination path without requiring the cover itself to be at a favorable angle.
Solution Approach 2:
The chip discharge chute acts as an intermediary element between the stationary cover and the chip disposal location. It provides the necessary steep inclination for efficient chipfall while being separate from the cover structure, allowing the cover to maintain its horizontal position for user-friendly table height.
4Reliability
If conventional complex devices are used for cleaning and removing chips, then chip removal is achieved, but technical effort and costs increase
Solution Approach 1:
The stationary cover element with its integrated chip discharge chute creates a self-service chip removal system. Chips naturally fall along the inclined chute into the disposal location without requiring external cleaning devices, rinsing systems, or blowing mechanisms. The geometry of the cover itself performs the chip removal function.
Solution Approach 2:
The invention extracts the chip removal function from complex external cleaning devices and integrates it into the simple geometry of the stationary cover element. The chip discharge chute is built into the cover structure, eliminating the need for separate cleaning and removal systems.
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 enhances chip removal efficiency, reduces machine downtime, and lowers manufacturing costs by allowing for a more reliable and efficient operation with a minimized setup area and cabin size.
Implementation Method 1
The inclination of these cover sheets should be chosen to be large enough for chips which might strike to slide downwardly into the chip disposal
Data Source
AI summary
A machine tool having a machine frame which has a stand and a machine sub-structure, a workpiece carrier arrangement which can be moved on linear guides, and a machining unit which is arranged on the stand. The machining unit can be moved along at least one coordinate axis and comprises an exchangeable cutting tool. The linear guides and the linear drives of the workpiece carrier arrangement are covered by longitudinally continuous, stationary cover elements and are thus protected against chip deposits.