Tool Machine Magazine Continuous Rotation via Brake Structure
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Solution Overview
Problem
Conventional tool machine magazines face issues with intermittent rotation and reduced efficiency due to the use of regular motors and servomotors, which lead to inaccurate positioning and increased maintenance costs.
Innovation Solution
A tool machine magazine with an angle sensor and brake structure that accurately detects the rotation angle and stops the tool disc at the desired position, using a deceleration motor and a cam mechanism to ensure continuous rotation without intermittence, similar to a servomotor's control function.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a regular motor is used to drive the rotating tool disc, then the device complexity is reduced, but the tool disc produces intermittent motion and cannot stop at the appropriate position due to rotation inertia
Solution Approach 1:
The patent introduces a brake structure as an intermediary component between the motor and the tool disc. This brake structure includes a brake disc connected to the motor shaft and a brake caliper that can clamp the brake disc to stop rotation. The brake structure acts as a mediator that enables the simple regular motor to achieve precise stopping control, resolving the contradiction between device simplicity and positioning accuracy.
2Reliability
If an idling design is imposed on the cam outline to allow the tool disc to stop at the appropriate position, then positioning is achieved, but the tool disc generates intermittent exercise between static and rotating statuses
Solution Approach 1:
The patent eliminates the idling design in the cam outline by introducing a brake structure that provides continuous rotational control. Instead of relying on the tool disc to coast through an idling portion of the cam, the brake structure allows the motor to maintain continuous engagement with the cam while providing active braking control. This enables the tool disc to rotate continuously without intermittent stopping and starting, improving tool change efficiency while maintaining positioning accuracy through the brake control system.
3Productivity
If a servomotor is applied to control the rotation of the rotating tool disc, then the intermittent exercise issue is improved, but the cost increases and the system becomes more complex with multiple elements that wear over time
Solution Approach 1:
The patent replaces the expensive and complex servomotor system with a simpler, more economical approach using a regular motor combined with a brake structure. Instead of using a high-cost servomotor with encoder and complex control electronics, the invention uses inexpensive components (regular motor plus brake mechanism) that can achieve the same functional result of smooth rotation control and precise positioning. This resolves the contradiction by choosing a more economical solution that maintains productivity while reducing device complexity and cost.
4Adaptability or versatility
If the distance between the used tool and the target tool is relatively long, then more tools are available for selection, but the time duration for the tool change operation becomes longer
Solution Approach 1:
The brake structure enables continuous rotational motion of the tool disc without intermittent stopping, allowing the disc to rotate smoothly and quickly to the target position. This continuous motion capability reduces the time required to traverse longer distances on the tool disc, thereby reducing tool change time while maintaining the ability to select from multiple tools arranged at different positions.
Solution Approach 2:
The patent incorporates an angle sensor that detects the rotation angle of the tool disc and provides feedback to the control system. This feedback mechanism allows the control system to monitor the disc's position and control the brake structure to stop precisely at the target tool position. The feedback system enables accurate positioning even when the target tool is located far from the current position, reducing the time required to reach and accurately position at distant tools.
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
Enhances tool change operation efficiency by ensuring accurate positioning and reducing maintenance costs through precise angle detection and continuous rotation, while maintaining smooth operation and preventing accidental rotation.
Implementation Method 1
the angle sensor sensing a rotation angle of the tool disc
Implementation Method 2
the brake structure accurate stops the tool disc at the desirable angle
Implementation Method 3
a driver device comprising a motor, a brake structure, a cam, a driver shaft
Implementation Method 4
the cam, a driver shaft, an angle sensor, and a control terminal, the brake structure disposed in the motor, the motor driving the cam to operate, each bearing contacting an outline of the cam
Data Source
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AI summary
A tool machine magazine includes a base (10), a tool disc (20) disposed on the base (10), tool sleeves (30) disposed on a periphery of the tool disc (20) through a bearing (40), a motor (51), a brake structure (52), a cam (53), a driver shaft (54), an angle sensor (57), and a control terminal (58). The motor (51) drives the cam (53) to operate. Each bearing (40) orderly operates along the outline (531) of the cam (53), driving the tool disc (20) to continuously rotate without intermittence. The angle sensor (57) is disposed on one end of the driver shaft (54) or a rotation center of the tool disc (20). When the rotation angle of the tool disc (20) matches the tool change command, the control terminal (58) controls the brake structure (52) to stop the motor (51), so as to stop the tool disc (20) for facilitating the tool change operation.