Vertical Milling Machine with Multi-Head Bridge
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Solution Overview
Problem
Conventional milling machines with a single head and horizontal work surface face limitations in machining capacity, especially for large parts, due to unproductive movements, material waste, and increased production costs, while machines with multiple heads on a horizontal plane are unsuitable for complex geometric parts and inefficient in space usage.
Innovation Solution
A milling machine with a vertical work surface and a C-shaped moving bridge, featuring at least three heads with independent mobility on five axes, a robust and light structure, and a vacuum table for efficient machining and waste disposal, reducing floor space occupation and material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single head is used with a horizontal work table, then the machine structure is simple, but the machining capacity is limited and the machining period is extensive for large parts
Solution Approach 1:
The machine is divided into multiple independent heads (at least three) that can operate simultaneously on different parts of a workpiece. Each head has its own spindles and cutting tools, allowing parallel machining operations that significantly increase productivity while maintaining a relatively compact overall structure.
Solution Approach 2:
Multiple heads with multiple spindles are combined on a single moving bridge that travels along the vertical work table. This merging of multiple machining units into one integrated system allows simultaneous machining of complex geometries from different angles without requiring multiple separate machines.
2Device complexity
If the work table is moved horizontally, then the machine structure is simple, but palletising cannot be performed and the load varies affecting dynamics
Solution Approach 1:
Instead of moving the work table horizontally as in conventional machines, the work table is arranged vertically and remains stationary. The moving bridge with multiple heads travels along the vertical table, inverting the traditional motion scheme. This allows workpieces to be palletised on the stationary table while the machining heads move to perform operations.
3Productivity
If multiple heads are used on a horizontal plane, then the machining capacity increases, but the structure becomes heavy and unsuitable for complex geometric parts with high velocities and accelerations
Solution Approach 1:
The arrangement of multiple heads is transitioned from a horizontal plane to a vertical configuration. The moving bridge travels along the vertical work table, and the heads are positioned vertically rather than horizontally. This dimensional change allows for lighter structure while maintaining multiple machining stations, suitable for high-velocity and high-acceleration operations on complex parts.
4Device complexity
If the work table is arranged horizontally, then the machine structure is conventional, but the occupied floor space is high and waste disposal is difficult
Solution Approach 1:
The work table is reoriented from horizontal to vertical arrangement. This vertical configuration reduces the horizontal footprint of the machine, minimizing occupied floor space. The moving bridge travels vertically along the table, and waste can be efficiently disposed of through the vertical structure, addressing both space and waste disposal issues.
5Stability of the object's composition
If the heads keep a fixed distance between them, then the structure is stable, but machining by panoplies is not possible resulting in material waste
Solution Approach 1:
The distance between the multiple heads is made variable rather than fixed. The moving bridge can position the heads at different locations along the vertical work table, allowing dynamic adjustment of head spacing. This enables machining by panoplies (simultaneous machining by multiple heads at different positions) while maintaining structural stability through precise positioning mechanisms.
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 enhances production capacity, reduces manufacturing costs, and minimizes material waste by enabling efficient machining of complex geometries with high precision and flexibility, while optimizing space usage and waste disposal.
Implementation Method 1
a vacuum table for efficient machining and waste disposal
Data Source
AI summary
A milling machine including a frame (2) having a work surface (2.1) disposed in a vertical plane and a C-shaped moving bridge (3). In addition, the machine includes: at least three heads (7), each head including a machining spindle (15); and five movement axes (X, Y, Z, A, B), such that the moving bridge (3) is moved by the frame (2) along a horizontal axis (X). Each head (7) is moved independently on the moving bridge (3) along a vertical axis (Y) in order to be moved towards or away from the work surface (2.1) along a depth axis (Z) perpendicular to both the horizontal axis (X) and the vertical axis (Y), as well as rotating independently about a first axis of rotation (A). Each spindle (15) rotates independently about a second axis of rotation (B).