Tool Magazine Brake and Angle Sensing for Precise Tool Disc Stopping
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Solution Overview
Problem
Conventional tool machine magazines face issues with smooth rotation and accurate stopping of the tool disc due to inertia with regular motors and wear-related errors with servomotors, leading to inefficient tool changes and high maintenance costs.
Innovation Solution
A tool machine magazine with a driver device comprising a motor, brake structure, cam, angle sensor, and control terminal that accurately senses the rotation angle and controls the brake to stop the tool disc smoothly, mimicking servomotor functionality while reducing maintenance costs.
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 and cost are reduced, but the tool disc cannot stop at the appropriate position due to rotation inertia causing temporary waver
Solution Approach 1:
A brake structure is introduced as an intermediary component between the motor and the rotating tool disc. The brake structure includes a brake disc connected to the motor rotation shaft and a brake component that can clamp the brake disc. This intermediary allows the simple regular motor to achieve precise stopping by applying braking force to counteract rotation inertia, enabling the tool disc to stop accurately at the appropriate position without requiring a complex servomotor.
2Manufacturing precision
If an idling design is imposed on the cam outline to enable stopping, then the stopping position can be achieved, but the rotating tool disc generates intermittent exercise between static and rotating statuses
Solution Approach 1:
The brake structure is activated in advance before the tool disc reaches the stopping position. The control system receives a tool change command and controls the brake component to clamp the brake disc, creating a braking effect that gradually reduces the rotation speed. This preliminary action allows the tool disc to decelerate smoothly and stop precisely at the target position without requiring the cam idling design, thereby eliminating intermittent exercise and enabling continuous smooth rotation for higher productivity.
3Productivity
If a servomotor is used to control the rotation of the rotating tool disc, then the intermittent exercise issue is improved, but the cost increases and the servomotor is more susceptible to wear-related errors
Solution Approach 1:
Instead of using an expensive servomotor with encoder for detecting rotation angle and controlling stopping, the patent uses a simple regular motor combined with a brake structure that copies the essential functionality. The brake structure mechanically achieves the positioning function that the servomotor would provide electronically, eliminating the need for encoders and complex control systems while maintaining the ability to stop at appropriate positions and enable smooth continuous rotation.
4Productivity
If the rotation speed of the rotating tool disc is increased to improve tool change efficiency, then the tool change time is reduced, but the existing cam-driven mechanism cannot achieve smooth continuous rotation
Solution Approach 1:
The brake structure provides dynamic control over the rotation process. By adjusting the braking force applied to the brake disc, the system can control the deceleration of the tool disc smoothly. This dynamic braking allows the tool disc to rotate at higher speeds during the main rotation phase and then decelerate smoothly as it approaches the stopping position, enabling both high productivity and rotation smoothness that were previously contradictory.
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
Ensures accurate and efficient tool changes by preventing intermittent rotation and wear-related errors, enhancing tool change operation efficiency and reducing manufacturing and maintenance costs.
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
the motor driving the cam to operate
Implementation Method 4
the roller pillar of the rotation disc operates along the outline of the cam
Data Source
AI summary
A tool machine magazine includes a base, a tool disc disposed on the base, tool sleeves disposed on a periphery of the tool disc through a bearing, a motor, a brake structure, a cam, a driver shaft, an angle sensor, and a control terminal. The motor drives the cam to operate. Each bearing orderly operates along the outline of the cam, driving the tool disc to continuously rotate without intermittence. The angle sensor is disposed on one end of the driver shaft or a rotation center of the tool disc. When the rotation angle of the tool disc matches the tool change command, the control terminal controls the brake structure to stop the motor, so as to stop the tool disc for facilitating the tool change operation.