Tool Exchange Shutter Control for Faster Machine Tool Changes
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Solution Overview
Problem
Current machine tools face challenges in shortening tool exchange time, which is crucial for reducing lead time in machining processes.
Innovation Solution
A machine tool design that incorporates a shutter position detector, motors for precise control of a shutter and arm movements, and a controller to optimize the timing of arm motions based on shutter positions, allowing for synchronized and efficient tool exchange operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cam mechanism is used to synchronize the side door and tool exchange arm motions mechanically, then the motions are synchronized reliably, but the device complexity increases and tool exchange time cannot be optimized flexibly
Solution Approach 1:
The patent replaces the mechanical cam mechanism with an independent control system using sensors to detect shutter position and a controller to generate arm motion commands. This substitution eliminates complex mechanical linkages while maintaining synchronization reliability through electronic control, directly resolving the contradiction between reliability and device complexity.
Solution Approach 2:
The patent implements a feedback mechanism where sensors detect the real-time position of the shutter and feed this information to the controller. The controller uses this feedback to generate appropriate arm motion commands, ensuring synchronized operation without requiring complex mechanical pre-synchronization mechanisms.
2Ease of operation
If the shutter is fully open during tool exchange, then the arm has sufficient space to move, but coolant and swarf may scatter outside the machining chamber
Solution Approach 1:
The patent makes the shutter position dynamic rather than fixed, allowing it to be partially open during tool exchange. The control system adjusts the shutter opening degree based on the arm's position and tool exchange requirements, providing sufficient movement space while minimizing coolant and swarf scattering. This dynamic adjustment resolves the contradiction between ease of operation and harmful factors.
3Productivity
If the tool exchange arm moves quickly to shorten exchange time, then productivity increases, but the precision of positioning and synchronization with the shutter decreases
Solution Approach 1:
The patent uses sensors to detect the real-time position of both the shutter and tool exchange arm, providing feedback to the controller. This feedback enables the controller to adjust motion commands dynamically, ensuring precise positioning even at high speeds. The electronic control system can react faster than mechanical systems, maintaining precision while enabling higher exchange speeds.
Solution Approach 2:
The patent implements dynamic motion control where the arm's speed and position are continuously adjusted based on real-time feedback. This allows the system to move quickly when possible while maintaining precise positioning when needed, resolving the contradiction between productivity and manufacturing precision.
Data Source
AI summary
This machine tool is provided with an arm for exchanging a tool between a main shaft in a machining chamber and a secondary tool standby position in a tool holding chamber, a shutter which is provided in an opening defined in a wall which partitions between the machining chamber and the tool holding chamber, a first motor for opening and closing the shutter, a shutter position detector which can detect the position of the shutter in the entire range between the fully open position and the fully closed position, a storage device which stores a prescribed position of the shutter associated with a prescribed operation of the arm and a control device which is configured to perform a prescribed operation of the arm on the basis of the position of the shutter detected by the shutter position detector and the prescribed position of the shutter stored in the storage device.