Universal-Joint Workpiece Adapter for Non-Round Rotary Machining
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Solution Overview
Problem
Conventional rotary machines face challenges in efficiently and accurately rotating large and non-round workpieces due to issues with clamping, support, and alignment, requiring complex and costly adjustments and specialized equipment.
Innovation Solution
A workpiece adapter system incorporating a universal joint assembly and adapter rings that securely attach to a rotary machine's chuck, allowing for flexible support and rotation of irregularly shaped workpieces without direct clamping, using adapter rings to maintain rotational accuracy and reduce sagging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a chuck and bearing system is made large enough to handle increased size and weight of workpieces, then the workpiece can be supported, but the rotational mass increases and more powerful drive motors are required
Solution Approach 1:
The system divides the workpiece support function into multiple independent roller supports distributed along the workpiece length, rather than using a single large chuck-bearing system. This segmentation allows each support element to be smaller and lighter, reducing the overall rotational mass while still supporting large workpieces
Solution Approach 2:
Motorized rollers act as intermediary elements between the drive system and the workpiece. These rollers transfer rotational motion to the workpiece without requiring the workpiece to be directly clamped in a large chuck, thereby reducing the rotational mass that the drive motor must accelerate
2Measurement precision
If supports are placed at the ends of the workpiece to limit wobble, then rotational accuracy improves, but the system becomes more complex and difficult to operate
Solution Approach 1:
The roller supports are designed to be adjustable in position and height, allowing dynamic adaptation to different workpiece sizes and shapes. This dynamic adjustability maintains rotational accuracy without requiring a fixed complex support structure
Solution Approach 2:
The motorized roller system serves multiple functions: it supports the workpiece, provides rotational drive, and acts as a bearing surface. This multi-functionality reduces the need for separate specialized components, simplifying the overall system while maintaining rotational accuracy
3Stability of the object's composition
If non-round workpieces are clamped directly to the chuck, then the workpiece can be held, but clamping and positioning become difficult
Solution Approach 1:
The motorized rollers serve as an intermediary between the chuck and non-round workpieces. Instead of directly clamping the irregular workpiece to the chuck, the rollers provide a flexible contact surface that can accommodate various shapes while maintaining stable rotation
Solution Approach 2:
The system changes the contact parameters between the holding mechanism and workpiece by using distributed roller contact points rather than fixed chuck jaws. This allows the contact geometry to adapt to different workpiece shapes, making clamping and positioning easier while maintaining stability
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
Enables efficient and accurate rotation of large and non-round workpieces by minimizing the need for motorized rollers and reducing the load on the rotary machine's drive system, preventing workpiece loosening and ensuring precise machining operations.
Implementation Method 1
a universal joint assembly arranged between the first drive member and the adapter mount, the universal joint assembly comprising a first fork member coupled to the first drive member, and a second fork member coupled to the adapter mount
Data Source
AI summary
A workpiece adapter system to support a workpiece rotated by a rotary machine, the system including a first drive member having a proximal end configured to be secured in a chuck of a rotary machine, at least one workpiece adapter configured to secure at least a portion of an end of a workpiece in a central opening of the workpiece adapter, an adapter mount configured to be connected to the at least one workpiece adapter, and a universal joint assembly arranged between the first drive member and the adapter mount, the universal joint assembly comprising a first fork member coupled to the first drive member, and a second fork member coupled to the adapter mount. An adapter ring may be provided to rotatably support a workpiece being machined.