Vertical Support System for Flexible Workpiece Machining
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Solution Overview
Problem
CNC machining centers struggle to precisely machine long and flexible workpieces with a high length-to-width ratio due to vertical flexure caused by the workpiece's weight and tool pressure, leading to inaccuracies in shape, size, and tolerance.
Innovation Solution
A new machining center with a vertical support system, comprising a bearing structure-frame, lower and upper supports, and an electric spindle, where the lower and upper supports can rotate synchronously around a vertical axis and translate vertically to maintain the workpiece's stability, and the electric spindle can move and rotate on multiple axes, all controlled by a programmable electronic circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If long and flexible workpieces are machined in horizontal position on conventional CNC centers, then the workpiece can be processed, but vertical flexure occurs due to workpiece weight and tool pressure causing machining inaccuracies
Solution Approach 1:
The patent inverts the conventional horizontal machining approach by implementing vertical machining. The workpiece is positioned vertically between an upper support and a lower support, with the machining tool approaching from the side. This inversion eliminates vertical flexure caused by gravity acting on the horizontally positioned workpiece, thereby resolving the contradiction between machining precision and workpiece stability.
Solution Approach 2:
The patent transitions from horizontal to vertical machining, changing the spatial dimension of workpiece positioning. By rotating the workpiece 90 degrees to a vertical orientation and machining from the side, the system eliminates the harmful vertical flexure direction while maintaining machining capability through multi-axis tool movement.
2Adaptability or versatility
If the workpiece is fixed horizontally on the support, then it can be rotated on its horizontal major axis, but the workpiece undergoes flexure due to its own weight
Solution Approach 1:
Instead of rotating the workpiece horizontally as in conventional centers, the patent inverts the workpiece to a vertical position and rotates it on its vertical major axis. This inversion allows the workpiece to be held in tension between upper and lower supports, eliminating flexure while maintaining rotation capability for multi-sided machining.
3Manufacturing precision
If the workpiece is positioned vertically with upper and lower supports, then flexure is eliminated, but the support system becomes more complex
Solution Approach 1:
The support system is segmented into distinct functional components: an upper support for holding the workpiece top end, a lower support for holding the bottom end, and independent mechanisms for each support's rotation and vertical movement. This segmentation allows each component to be optimized independently while working together to eliminate flexure and enable precise machining.
Solution Approach 2:
The patent implements dynamic capabilities in the support system, allowing the upper support to move vertically along the workpiece length and both supports to rotate synchronously. These dynamic features enable the system to adapt to different workpiece lengths and maintain precise positioning throughout the machining process, justifying the increased complexity through enhanced precision.
4Manufacturing precision
If synchronous rotation mechanisms are added to both upper and lower supports, then twisting is prevented, but the device complexity increases
Solution Approach 1:
The synchronous rotation of upper and lower supports is controlled through a programmable logic controller that coordinates both rotation mechanisms. This feedback-controlled coordination ensures both supports rotate at identical speeds and positions, preventing workpiece twisting while maintaining dimensional accuracy throughout the machining operation.
Data Source
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AI summary
A machining center includes a bearing structure-frame supporting various other parts; an electric spindle mounted on moving arms that translate it and rotate it on main axes; a lower plane or support hinged to the lower part or base of the bearing structure-frame, rotating on a vertical axis, provided with elements or mechanisms holding the lower end of the workpiece; and an upper support rotating on the vertical axis coaxially with the rotation axis of the lower plane or support, having elements or mechanisms that hold the upper end of the workpiece. The lower plane or support and the upper support are rotated simultaneously and synchronously, rotating the workpiece according to a vertical axis. Devices or mechanisms are provided for vertical translation of the upper support, thereby adapting the vertical position of the upper support to the lower plane or support depending on the length of the workpieces.