Tool Holder Escape Mechanism Using Integrated Bellows
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Solution Overview
Problem
Existing tool holders with escape mechanisms are complex, expensive, heavy, and not suitable for all machines due to their large size and high production costs, as well as susceptibility to damage from sudden forces.
Innovation Solution
A tool holder with an integrated escape mechanism using a tubular holder and bellows or springs, produced in one piece via rapid prototyping methods like selective laser sintering, allowing for compact, lightweight, and reliable operation with defined deflection and centering capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-part construction is used for tool holder with escape mechanism, then functional requirements are met, but manufacturing cost and complexity increase significantly
Solution Approach 1:
The housing and bellows are merged into a single integrated component produced by selective laser sintering. This eliminates the need for separate assembly of housing and bellows, reducing the number of parts while maintaining the escape mechanism's functional reliability. The additive manufacturing process allows complex geometries to be created in one piece, resolving the contradiction between reliability and complexity.
Solution Approach 2:
The invention changes the manufacturing parameter from traditional subtractive or assembly-based methods to additive manufacturing (selective laser sintering). This parameter change enables the production of complex integrated structures that would be difficult or expensive to manufacture using conventional methods, thereby reducing part count while maintaining functional integrity.
2Strength
If traditional manufacturing methods are used for tool holder, then structural strength is achieved, but production cost and time increase
Solution Approach 1:
The invention transitions from traditional manufacturing parameters to additive manufacturing (selective laser sintering). This enables cost-effective production of complex geometries including integrated bellows and housing structures, reducing production time and cost while maintaining structural strength through optimized material deposition and layer-by-layer construction.
Solution Approach 2:
The additive manufacturing process inherently segments the construction into layers, allowing for optimized material usage and reduced waste. This layer-by-layer construction method maintains structural integrity while reducing material costs and production time compared to traditional manufacturing of equivalent complex structures.
3Force
If conventional tool holder design is used, then load-bearing capacity is sufficient, but weight becomes excessive for some applications
Solution Approach 1:
The invention uses plastic material with optimized structural parameters achieved through additive manufacturing. This allows reduction of density parameter compared to metal alternatives, decreasing weight while maintaining load-bearing capacity through geometric optimization inherent in the 3D printing process.
Solution Approach 2:
The bellows structure incorporates curved and flexible geometries that are naturally suited for additive manufacturing. These curved structures provide mechanical flexibility and load distribution while using minimal material, reducing weight compared to rigid straight-line constructions that would require more material to achieve the same functional outcome.
4Manufacturing precision
If precise dimensional accuracy is required for escape mechanism, then manufacturing difficulty and cost increase
Solution Approach 1:
The invention adopts selective laser sintering technology which provides inherent dimensional accuracy for complex geometries. This manufacturing parameter change enables precise control of critical dimensions for the escape mechanism components without increasing production complexity, as the additive process naturally maintains tolerances through controlled material deposition.
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
The solution results in a cost-effective, lightweight, and reliable tool holder that is less prone to failure, capable of easy assembly and compact design, with the ability to withstand sudden forces and maintain precise dimensional accuracy.
Implementation Method 1
The holder (3) can be centered by means of at least three bellows (10) by applying a pneumatically or hydraulically generated pressure
Implementation Method 2
This is possible in particular with a so-called rapid prototyping method, in particular by means of selective laser sintering
Data Source
Figure 1
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AI summary
The holder (1) has a holding part (3) receiving a tool with a drive spindle. The holding part is arranged in a housing (4), and is displaced opposite to the housing. The holding part is centered by three bellows (10) under application of a pneumatic or hydraulic produced pressure such that the bellows are formed with a casing section as a single piece, where the bellows are formed by a plastic i.e. polyamide. The housing comprises a housing base part (6) and a housing upper part (7), where the housing upper part is connected with the housing base part by multiple arms (11). An independent claim is also included for a method for manufacturing a tool holder.