GB2592949A

GB2592949A - Multi-purpose apparatus

Info

Publication number: GB2592949A
Application number: GB2003544.0A
Authority: GB
Inventors: Pearson Gary
Original assignee: Effective Cnc Solutions Ltd
Current assignee: Effective Cnc Solutions Ltd
Priority date: 2020-03-11
Filing date: 2020-03-11
Publication date: 2021-09-15
Also published as: GB202003544D0; EP4054798A1; WO2021181066A1

Abstract

The present invention relates to an apparatus 2 which incorporates standard milling, turning and grinding formats into a single machine, facilitating manufacturing of components without the need to transfer components between different machine types. The apparatus 2 comprises a workpiece mount or holder 4, a spindle 14 for milling and grinding the workpiece, and a rotatable turret 10. The workpiece holder may be mounted on a substantially vertical support structure 6. The holder may be movably in a vertical direction relative to the support structure surface. The support structure may be on a first platform 20 that is moveable towards or away from the spindle and turret, facilitated by tracks 22. The first platform may be mounted on a second platform 24 with tracks 26. The holder may attach to the workpiece 17 via a surface or table 8 that can rotate freely about one or more axes. The spindle and turret may be fixedly located opposite the holder and adjacent to each other. The apparatus may further comprise a tool changer or pallet changer, and an additive manufacturing device 16 located adjacent to the spindle and turret.

Description

Multi-Purpose Apparatus The present invention relates to an apparatus which incorporates standard milling, turning and grinding formats from different machines into a single versatile machine, facilitating the manufacture of highly complex medium and large size components without the need to transfer components between different machine types.

Machines for milling, turning and grinding for the manufacture of products, often made from metal, have been known in industry for many years. The machine tools currently on the market are traditionally divided into the three main categories of milling, turning and grinding, and are usually only able to carry out one of these functions, with a limited number of machine designs that may offer some degree of cross-over between two of these categories. For example, there are machines which are able to both mill and turn, or both mill and grind, or turn and mill.

In addition, there is also now the newer category of additive manufacturing, also called three-dimensional (3D) printing, and some machines are able to carry out both milling and additive manufacturing.

However, these machines are only able to carry out no more than two of these functions. All these cross-over designs have significant limitations to their versatilities, primarily due to the standard format of the basic machine. For example, a standard format 5-axis milling machine has limited turning capability, due to the turning tool being held in the milling spindle, or turning/milling machines being limited to milling slots or small features in turned components using a 'live' tool in the turning tool turret. Furthermore, limitations are found in many designs in the way that the tool spindle is moved around in order to achieve the full extent of the 5-axis milling capability, requiring large linear movements just to create a relatively small change in angle or rotary position.

5-axis machining refers to a machine's ability to move a tool or a part in five different axes simultaneously. Basic machining operates on three primary linear axes.

X, Y and Z* however, a 5-axis CNC (Computer Numerical Control) machining tool can rotate on two additional axes, A and B, which give a cutting tool a multidirectional approach A further major disadvantage of existing technology is that in order to carry out each of the milling, turning, grinding and additive manufacturing processes required to manufacture a product, a number of separate machines are required. Therefore, in order to carry out each of the processes, this involves first of all having sufficient space to house each of the machines, the cost, time and labour involved in purchasing and installing them all, as well as subsequently maintaining them all in good working order.

There is then the productivity aspect of using several machines. As processes requiring milling, turning, grinding and additive manufacturing processes are conventionally carried out on separate machines, any given workpiece needs to be transferred from one machine to another after each stage in the process. Depending upon the size and weight of the workpiece, this can take anything from 20-60 minutes to accomplish each time it is moved. From this alone, a machining process of 10 hours may lose about 25% of its time purely due to the time taken in moving the workpiece from one machine to another and setting it up for the next part of the process.

It would therefore be desirable to devise a functional and effective way of incorporating the ability to carry out each of the separate processes within a single machine or apparatus. Such an apparatus has never previously been developed.

Therefore, in accordance with the invention, there is provided an apparatus comprising each of: i) a holder for a workpiecei ii) a spindle for milling and grinding the workpiece; and iii) a rotatable turret.

By "workpiece", it is meant herein any object or substrate which may be worked on with a tool or machine. The workpiece may be made of any suitable material for such machining, such as metal, wood or a plastic.

According to one embodiment of the invention, the holder for the workpiece may be mounted on a surface of a support structure, which may be a substantially vertical support. The holder may also be able to move vertically upwards or downwards on the vertical support. This is a way the apparatus of the invention can control the height and distance of the workpiece relative to the spindle and rotatable turret The support structure may be mobile, and able to move in different directions, such as forwards and backwards (along the Z axis as defined herein), and from side to side (along the X axis as defined herein), or vertically up and down (along the Y axis as defined herein), in order to controllably manoeuvre the workpiece relative to the spindle and rotatable turret. For this, the support may, for example, be mounted on tracks, enabling it to slide in whichever direction it is desired to be moved, such as in the X and/or Z axes.

In one embodiment, the vertical support may be mounted on a moveable platform. The moveable platform may have parallel tracks along which the vertical support may move forwards and backwards in the Z axis, towards or away from the spindle and rotatable turret.

The moveable platform may also be mounted on a second platform, which may itself be fixed in position to another surface, or moveable. The second platform may also have parallel tracks, along which the moveable platform may move from side to side, in the X axis.

According to another embodiment of the invention, the holder may comprise a surface, on to which the workpiece may be affixed. The surface may be of any shape or size suitable. The surface may be able to rotate freely about one or more axes, such as in a horizontal and/or vertical plane. This ability of free movement enables the workpiece to be manipulated in any plane or orientation, such that it is able to approach the spindle and rotatable turret at whatever angle or orientation may be desired in order to have maximum control over the manufacturing process.

The milling and grinding operations may be performed by a high-speed spindle, and the turning may be performed by a multi-tool lathe turret. For convenience only, the spindle will be called herein a milling spindle; however, it can perform both milling and grinding operations on the workpiece, the grinding providing for very fine surface finishing. According to one embodiment of the invention, the milling spindle and rotatable turret are located adjacent each other, and on an opposite side of the apparatus to the holder and workpiece. The milling spindle and rotatable turret are typically mounted in fixed positions on the apparatus, and cannot be moved. In another embodiment, they may be movable if desired. The precise locations of the milling spindle and turret relative to each other are not of great importance, apart from that they should be sufficiently separated from each other that the workpiece may be worked on separately by each of them without interference. The milling spindle and rotatable turret are of the conventional types commonly used in the industry.

According to another embodiment of the invention, the apparatus may further comprise a device for additive manufacturing, which is used for 3D printing on the workpiece. The additive manufacturing device may typically be fixed in position on the apparatus; however, it may also be independently movable about a pivot. The additive manufacturing device is typically located adjacent the spindle and/or rotatable turret. The additive manufacturing device is typically used for laser wire-feed 3D printing or additive manufacturing, and may be performed by a fixed position Directed Energy Deposition (DED) laser printing head within the apparatus.

The present invention diverges significantly from conventional apparatuses which are separately used for milling, grinding and turning. In conventional apparatuses, the milling spindle and rotatable tool turret are mounted on moving axes on their respective apparatuses, and each move around the workpiece to create the product. In contrast, in the present invention, the milling spindle and rotatable tool turret are each typically being mounted in fixed positions, while the workpiece and holder is mounted and fully movable in three linear axes (X,Y,Z) and 2 rotary axes (A/B & C), where the A axis rotates about the X plane up to +/-180° and the C axis -which is mounted on the A axis -is infinitely rotatable about the Z and/or Y planes, permitting full freedom of movement by allowing infinite rotation of the workpiece table -the C axis -around the Z and/or Y planes, and +1-1800 rotation of the A axis around the X plane, providing unparalleled presentation of the workpiece to the spindle. In this way, the workpiece is moved around the milling spindle and rotatable tool turret to create the product.

The relative directions meant by the X, Y and Z axes herein are shown in Figure 6 hereinbelow. Essentially, movement in the X axis represents movement of the holder and workpiece across the faces of the fixed milling spindle and rotatable tool turret and running parallel with them; movement in the Y axis represents movement of the holder and workpiece in a vertical manner on the support structure; and movement in the Z axis represents movement of the holder and workpiece both towards and away from the fixed milling spindle and rotatable tool turret.

Unlike other turning machines, or milling machines with a turning capability, the apparatus of the invention uses a full rotatable tool turret in a fixed position, providing multiple tooling options and again allowing presentation of the workpiece to the tooling in any orientation. The advantage of this is that turning operations may be performed at angles of approach which are simply not achievable by conventional turning or mill/turn machines.

The full freedom of movement of the workpiece also provides presentation to the additive DED (Directed Energy Deposition) printing head in any orientation, allowing unhindered layering up of additive material.

The apparatus of the invention addresses the limitations of existing machines, by facilitating extremely versatile and flexible milling, turning, grinding and additive manufacturing capabilities in a single, highly efficient and maintainable unit, which facilitates manufacturing of highly complex medium and larger size components. This single apparatus single-handedly replaces three or four separate machines.

The benefits of the apparatus of the invention are that it requires less space and facilitates extra capacity within a workshop or factory, due to fewer machines being required; provides cost savings in that only one machine needs to be purchased and installed; allows for easier maintenance for a single machine-and provides significant savings in set-up times as there is no need to move the workpiece between separate machines.

For example, processes requiring milling, additive manufacturing and turning -which are conventionally carried out on separate machines -take anything from 20-minutes to transfer the workpiece between the different machines. A machining process of 10 hours may lose about 25% of its time purely due to the time taken in moving the workpiece and setting it up for the next part of the process The apparatus of the invention removes the need to transfer components between different machine types. Removing the need for multiple set-ups reduces this time to below 5%, consequently freeing up labour and significantly increasing productivity.

The manufacturing process can also run 'lights out', i.e. without the need for a location or building to be illuminated, due to there being no need for people to move the workpiece and set it up again, further increasing efficiency and providing energy and labour savings.

Using the apparatus of the invention, all of these processes can be completed in a single machine tool unit, which has a smaller size and a smaller cost than multiple machines, bringing about significant savings in set-up times and costs for manufacturers.

The apparatus also enables work to be carried out more easily on larger, heavier workpieces, and there is no longer the logistical problem of moving the large or heavy workpiece between different machines.

Further, due to the ability of the apparatus to move the workpiece freely, the workpiece may be moved towards and around each of the milling spindle, rotatable turret and additive manufacturing device to create the product, which enables a greater degree of control over the angle or orientation of the workpiece relative to the milling spindle, rotatable turret and additive manufacturing device, in order to have maximum control over the manufacturing process, in contrast with conventional machines. This enables more complicated workpieces to be manufactured more easily and efficiently.

The apparatus of the present invention provides multi-platform capabilities in a single machine tool platform, providing extreme manufacturing capabilities while removing the need for the transfer of workpieces between machine platforms, providing significant efficiency improvements.

The apparatus of the present invention may also have an automatic tool change capability to and from the milling spindle, and an automatic pallet change facility allowing the automated changing of the workpiece (these features are not shown in the Figures herein in order to maintain clarity in the representations).

As is conventional in this industry, the apparatus and the respective parts may be primarily constructed using steel.

The present invention also provides a method of manufacturing an article, the method comprising employing an apparatus as defined hereinabove.

The invention will now be described further by way of example with reference to the following figures which are intended to be illustrative only and in no way limiting upon the scope of the invention.

Figures 1-3 are each two-dimensional depictions of an embodiment of an apparatus of the invention from different side-on perspectives Figures 1 and 3 each show opposing side views of the apparatus of the invention while Figure 2 shows a view from a third side of the apparatus Figures 4-6 are each three-dimensional depictions of an embodiment of an apparatus of the invention from raised side-on perspectives.

In Figure 1, an apparatus 2 according to the invention is shown from a side-on perspective. A holder 4 is movably mounted on a vertical support 6, and includes a table 8, to which a workpiece is to be affixed. The table 8 is freely rotatable within the holder 4 about axes in a number of planes.

The vertical support 6 is moveable in the X and Z axes, while the holder is movable up and down in the Y-axis on the vertical support 6.

The rotatable turret 10 is located in a fixed position opposite the holder 4 and vertical support 6, and is adjacent the milling spindle 14 (not shown in Figure 1).

An additive manufacturing device 16 is also mounted in a fixed position on the same side of the apparatus as the rotatable turret 10 and milling spindle 14 In operation, the holder 4 on the vertical support 6 moves towards and manoeuvres between the rotatable turret 10, milling spindle 14 and additive manufacturing device 16, in whichever order, to be worked upon.

Figure 3 depicts the apparatus from the reverse view from Figure 1. The holder 4 is movably mounted on the vertical support 6, the holder 4 including the table 8, to which the workpiece is to be affixed, the table 8 being freely rotatable about axes in a number of planes.

The milling spindle 14 is located in a fixed position on the surface 12 opposite the holder 4 and vertical support 6, and is adjacent the rotatable turret 10.

The additive manufacturing device 16 is also mounted in a fixed position on the same side of the apparatus as the rotatable turret 10 and milling spindle 14.

In operation, the holder 4 on the vertical support 6 moves towards and manoeuvres between the rotatable turret 10, milling spindle 14 and additive manufacturing device 16, in whichever order, to be worked upon.

Figure 2 shows another side view of the apparatus of the invention, from behind the side of the apparatus where the rotatable turret 10 and milling spindle 14 are positioned. Here, the positions of the rotatable turret 10 and milling spindle 14 adjacent each other, as well as the additive manufacturing device 16, on the surface 12 opposite the holder 4 and vertical support 6, are visible.

Figure 4 depicts the apparatus 2 according to the invention from a raised side-on perspective, and from the same side as Figure 3.

The holder 4 is movably mounted on the vertical support 6, the holder 4 including the table 8, to which the workpiece 17 is to be affixed, the table 8 being freely rotatable about axes in a number of planes, as is shown by the two arrows.

The vertical support 6 has a pair of parallel tracks 18 thereon, enabling the vertical support 6 to be moveable thereon up and down in the Y axis, so the height of the holder 4 and the workpiece 17 relative to the milling spindle 14, rotatable turret 10 and additive manufacturing device 16 is able to be controllably adjusted The vertical support 6 is positioned on a moveable platform 20. The moveable platform 20 has parallel tracks 22 thereon, the tracks 22 enabling the vertical support 6 to be moveable in the Z axis, both towards and away from the fixed milling spindle 14, rotatable turret 10 and additive manufacturing device 16.

The moveable platform 20 is itself positioned on a fixed platform 24, which also has parallel tracks 26 thereon, enabling the moveable platform 20 -and thus the holder 4 and the workpiece 17 -to move in the X axis across the faces of the fixed milling spindle 14, rotatable turret 10 and additive manufacturing device 16, to manoeuvre the workpiece 17 between them during the manufacturing process. In this Figure, the moveable platform 20 is located towards one side of the fixed platform 24, where the workpiece 17 can be worked on by the milling spindle 14 In operation, the holder 4 is able to move both towards and away from, and across the faces of, the rotatable turret 10, milling spindle 14 and additive manufacturing device 16, in whichever order, so the workpiece 17 can be worked upon by all three devices Figure 5 provides a similar perspective, but from the opposite side of the apparatus, and the same side as is shown in Figure 1.

In this Figure, the moveable platform 20 is moved along the tracks 26 in the X axis so that it is located more in the middle of the fixed platform 24, where the workpiece 17 can be worked on by the rotatable turret 10 or the additive manufacturing device 16.

Figure 6 is the same as Figure 5, but including an illustration of the relative orientations of the X, Y and Z axes It can therefore be seen that the apparatus according to the invention is able to incorporate each of the milling, turning, grinding, formats, as well as an additive manufacturing device, into one single versatile machine, which is consequently able to facilitate manufacturing of highly complex medium and larger size components without the need to transfer components between different machine types It is of course to be understood that the present invention is not intended to be restricted to the foregoing examples which are described by way of example only.

Claims

Claims I. An apparatus comprising each of: i) a holder for a workpiece; ii) a spindle for milling and grinding the workpiece and iii) a rotatable turret.
2. An apparatus according to claim 1, wherein the holder for the workpiece is mounted on a support structure.
3. An apparatus according to claim 2, wherein the support structure is a substantially vertical support.
4. An apparatus according to claim 2 or claim 3, wherein the holder for the workpiece is movable relative to the surface of the support.
5. An apparatus according to claim 4, wherein the holder for the workpiece is movable in a vertical direction relative to the surface of the support structure.
6. An apparatus according to any of claims 2-5, wherein the support structure is movable towards or away from the spindle and rotatable turret.
7 An apparatus according to claim 6, wherein the support structure is mounted on a moveable platform.
8 An apparatus according to claim 7, wherein the moveable platform has tracks to facilitate movement of the support.
9. An apparatus according to claim 7 or claim 8, wherein the moveable platform is movable in a direction parallel to the spindle and rotatable turret.
10. An apparatus according to any of claims 7-9, wherein the moveable platform is mounted upon a second platform, which is either fixed to a surface or moveable itself
11. An apparatus according to claim 10, wherein the second platform has tracks to facilitate movement of the moveable platform.
12. An apparatus according to any preceding claim, wherein the holder comprises a surface on to which the workpiece can be affixed.
13 An apparatus according to claim 12, wherein the surface is able to rotate freely about one or more axes.
14. An apparatus according to any preceding claim, wherein the spindle and rotatable turret are located adjacent each other.
An apparatus according to any preceding claim, wherein the spindle and rotatable turret are located on a side of the apparatus opposing the holder.
16 An apparatus according to any preceding claim, wherein the spindle and rotatable turret are mounted in fixed positions on the apparatus.
17 An apparatus according to any preceding claim, further comprising a device for additive manufacturing.
18 An apparatus according to claim 17, wherein the device for additive manufacturing is located adjacent the spindle and/or rotatable turret.
19 An apparatus according to any preceding claim, further comprising a tool changer and/or a pallet changer.
A method of manufacturing an article, the method comprising employing an apparatus according to any preceding claim.
21. A method according to claim 20, wherein the workpiece is moved relative to fixed positions of the spindle and rotatable turret.