US2314499A - Apparatus for reproducing threedimensional patterns and the like - Google Patents

Description

March 23, 1943. D. E. HQwARb 2,314,499

APPARATUS FOR REPRODUCING THREE-DIMENSIONAL PATTERNS AND THE LIKE Filed June' 15, 1941 2 Sheets-Sheet l I l 1 '1 L g1" 20 6 4 fo o 70-m 6'5 6 78 7619 25 H 71 I I 2.9 I] 74 3 I I 27 o 72 i I d2 March 23, 1943. D. E. HOWARD 2,314,499

APPARATUS FOR REPRODUCING THREE-DIMENSIONAL PATTERNS AND THE LIKE Filed June 13, l941 2 Sheets-Sheet 2 Patented Mar. 23, l 943 NITED STATES PATENT OFFICE:

APPARATUS FOR REPRODUCING' THREE- DIMENSIONAL PATTERNS AND TH LIKE Darnley'E. Howard, Washingtom-D. C. Application June 13, 1941, Serial No. 397,984

7 Claims. (01. 90-131) The invention relates to apparatus for repro- I ducing patterns and other articles and objects, and is particularly useful in reproducing threedimensional objects. It is applicable to use in die sinking and inthe reproduction of structures such A further aim is to enable the reproduction of an extremely intricate and peculiarly contoured object with great exactitude bythe exercise of care in the manipulation of the apparatus, and

with great rapidity.

Another importantaim of the invention is to enable the use oforiginals which may be readily made by-modeling manually orotherwise in soft materials if desired, including moist clay, as well 1 A fur-- ,Additional objects, advantages "and features of invention [reside in the construction; arrangement, and combination'fof parts involved inthe embodiment of the, invention, as will be understood" from the following description and accompanying drawings, wherein; v

Figure 1 is an elevational view of a system embodying the necessary apparatus for carrying out my invention as to method and mechanism, Figure 2 is a top view thereof Figure-31s a cross sectional viewof the pattern table on the line 3-3 of Figure 1, looking toward the right:'

\ Figure 4 is an enlarged vertical section through the optical system, at right angles to the plane ofFigure 3; I

Figure 5 is adiagram of the system for controlling electrically the valves by which the fluid level is established onthe pattern table;

Figure 6 is 'a detail 'elevational view .jective lensmounting; o

Figure 7 is a detail of the diaphragm or slide for'fo'rming the image, of the tool, or, in other as patterns made of harder materials,v so that expensive metal casts or machined originals in hard materials-are not essential, andthe production of finished work mayb effected from models or patterns made by persons unskilled in the operation ofmachinery or in pattern making, casting,

.etc. a f

A further important aim of the invention is to enable the production of a contour in any given plane of anoriginal piecein-a novel way. A still further important object is. to make it possible for the oper-ator to guide a tool in conformity with such contours without requiring any rigid or-solid guide to. contact the surface of the pattern.

.Yet another important aim of this invention. is to present a novel coordination of a work-engaging tool. and an optical system operative in connection with a pattern contour for the reproduction of a solid having -the* same contour, whether in the same size, or-larger or smaller in a definite scale relation, with great exactitude. It is also anobject to present novel apparatus and operative means for effectingthe necessary relative movements of a pattern and toolcontrolling means and of the 'tool and the work in scaled relatio n, adapted to actual size reproduction and to largeor small scale reproductions.

words the diameter and shape of a light beam to be projected beside the pattern piece.

Referring more particularly to the drawings,

' there is illustrated a pattern table 10,- supported rotativelyupon a non-rotating screw ,l l, mounted upon a suitable footing l2, which may be secured upon a floor l3 in any'usual way. Over worm sleeve or nut H in which the screw l I is l threaded, the nut having a ring gear 15 fixed thereon driven by means of a worm l5, mounted ina suitable bracket l'l secured'upon the side of the foot piece I2. The table I0 is rotatable independently upon the screw H by means of a worm l8 mounted upon a bracket I9, fixed on 'thescrew I l, and meshed with a gear 20 fixed on the under side of'thetable. v

The table lll'is formed with a basin 2| in which a liquid 22 is ,maintained at a variable level independently of the level of the table and the basin,

this liquid preferable being opaque and of a dis-- tinctive color contrasting with the color of the pattern to-be reproduced,'preferable white orgray. White. is used where the pattern may be painted black or is of a very dark material, but a. gray may be found preferable Where the pattern is white.- 3 I -Set upon the table Ill within the basin 2|, there is a pattern 23 to be reproduced, a formal representaiion of a relief image of a human face being indicated in the present instance although various other forms of patterns may be used.

of the ob Means is provided for supplying the liquid 22, which in the present instance consists of a reservoir'24 at a higher level than the highest level to which the liquid is to be raised in the basin with suitable duct connection 25, leading through the table l and discharging within the basin, the fiow of liquid through this duct being controlled by an electrically operated normally closed valve 26 arranged to open on closing of the circuit thereto. Also connected to the same duct at its low part there is a discharge duct 21, having a control valve 28 therein similar to the one 26 except that the effluent outlet of the valve has a discharge or.drain pipe 29, which leads downward to a receiver 30 at a convenient point or may discharge elsewhere, as preferred.

- For operating the valves 26 and 28, a float 3| is mounted pivotally upon a suitable fixed support 3201' any suitable kind, the float operating a rigid arm 33 fixed with respect to the float and movable at its extremity between two sets of switches each including a movable contact operable by the arm 33 on movement of the latter in respective directions. One' of these switch devices 34. is en a ed in circuit with the valve 26, while the other switch, 35. is connected in the circuit with the valve 28. These switches are spring loaded and normally open; being closed by movement of the lever in respective directions from a medial position. Thus. in case of the raising of the table '0 as will be subsequently described. the float 3| will be caused to operate the switch 35 by action of the arm 33 thereon, causing a decant ng of liquid from the basin 2|. so that the liquid is restored to its original relation to the switch, at which time the switch 35 will be opened by return of the float and arm 33 to its initial or neutral position clearing both switch On the other hand, when the table I0 devices. is lowered. the lowering of the float 3| will close the switch 34, causing opening of the valve 26 by which an accretion of liquid in the bowl is effected from the supply'in the reservoir 24. raising the level of the liquid 22 to that at which it stood in relation to the float mounting before the lowering of the table. The return of the float to' its neutral position will open the switch and permit closing of the valve again, which will occur automatically.

An objective lens 36 is mounted on a fixed vertical axis coincident with the axis of the rotation of the table III by means of an arm 31, fixed on a work table base frame 55 to be described, and a bracket 31 mounted on an elevatable arm 61 ad- .iustable on said frame, as will be described. The lens mounting in the present instance includes an outer barrel portion 38, fixed upon a telescopic extension 39 of the arm 31, and held in adjusted positions by a set screw 40. Within the barrel there is.a lens-carrying sleeve 4| vertically slidable in the barrel. and held adjustably on its vertical axis by an adjusting device 42 of any desired kind, which may include in the present instance the separate support bracket 31' and lower rigid bracket arm 43 attached to the arm 61 of the work table device, which also serves to support the float mounting 32. A light beam source 44 is provided above the lens barrel, this being fixed upon a bracket 45, which is secured rigidly upon a, sliding work table base 46 presently to be described, and movable in a fixed line toward and away from the table In. The light beam source 44 in the present instance may include any approved electric lamp 41, condensers 43 and a photographic image slide 49 removably engaged in the lower part of the lamp mounting.

A rotary work table 50 is provided, mounted revolubly on the work table base 46 before referred to, the table being mounted for movement with the base 46 horizontally and being elevatable with the arm 61 by means of a screw 5| operable by a worm 52 mounted on a bracket 53 secured upon the foot 54 of the work table frame 55 having an upper arm 56 of fixed position carrying a milling head 51, the spindle of which carries the die sinking cutter or thelike 58. Means is provided for rotating the table 50, consisting of a gear 59with which a worm 60 is meshed, mounted upon a bracket 6| fixed on the work table base 46. The worm 60 is driven by a shaft 62 coupled to the shaft of a motor 63 fixed on the table base 46, and the worm 60 is also connected by a flexible shaft 64 to the worm l6 by which the pattern table in is rotated. The pitches of the worm and sizes of the gears 59 and 20 are so proportioned as to rotate the two tables in synchronism, so that thepattern will be always oriented on a horizontal axis extending inthe same direction as the corresponding axis'of the work.

The work table base 46 has a usual dovetail spline '65 engaged slidably in a carriage 66 mounted slidably upon a lower arm 61 in a dimotion at ri ht angles to the direction of movement of the base 46 on the carriage, The arm 61 is vertically adiustabl upon the frame as at 66, by means of the screw 52 and its operating means before described. The table base 46 may be 7 moved upon the carria e by means ofa hand screw 69 or any-other approved means. and the carriage 66 is movable by mean of a ha d screw 10, both shown in Figure 1. The worm 52 by which the table 50 is raised and lo ered is nerated b means of a hand c ank a d this worm and the worm |6 are connected by a flexible shaft 12, so that operation of the crank will turn both screws simultaneously. The pitches of the worms and number of teeth on the gears by which the screws II and 5| are tu ned are such that the ratio of elevating movemen of the t bles I 0 and 50 will be the same as the ra o or scale of size of the reproduction desired. The difference in the len th of the incident beam '13 of light from the slide image 14 to the lens and the length of the projected portion of the beam at 15 from the lens to the surface of the li uid 22 is also in the same proportion: so that if the work is to be produced one-fifth the size of the original. the distance between the slide and lens is one flfth the distance from the lens to the liquid 22, and

the table 50 is elevated one fifth as much as the table ID on a given movement of the crank 1|.

A piece of work 16 is indicated as being fixed on the table 56, in position to be engaged by the tool 56.

In the practice of my invention, the pattern 23 being suitably set in place on the table "I, and a piece of material 16 for the work being flxed on the table 50 in the same relation to the axis of rotation of the table 50 as the pattern is to the. ax s of rotation of the table l0. the screw 66 is operated to draw the table and base 46 to one limit of movement, or soas to clear the tool from the work. The work being reduced to a height nearly or quite corresponding to the height of level in the basin 2| with respect to the pattern when the float is in neutral position and bothvalves closed. this level being approximately at the apex or highest point of the pattern 23. The crank H is then operated to raise the table l0 and the table 50' softhat the level of liquid-fan cl thepattern are raised a distance, and the work alsoelevatedone fifth the distance. This causes'theliquidlevel to overtake' the'floatwhich was elevated-the; same distance as thework, and causes raising-of the float andoperation of the valve 28'until lowering of the. liquid returns the fioat to neutral position where the valve again closes and establishes a liquid level in the basin fixedfor the time being. This exposes a part of the pattern and discloses the contour of the base of the exposed part byits junction with the liquid 22.- The tool 58 isnow at a level to engage the work when the, latter is moved into engagement with the tool. The screw 69 is now operated to move the work toward the tool, but the operator observes the location of the spot of light .on the surface of the liquid caused by the incidence of the beam I5 thereon. By the proper proportioning of the image It, the diameter of the light spot will correspond to an image of the cross section of thetool 58 enlarged in the same proportion which the pattern bears to the work to be produced. The operator now moves the base 6 inward while the motor 63is-in constant operati n, so'that all portions of material on the work are removed until the edge of the beam approaches or contacts the contour line at the junction of the liquid and pattern. Moving the base 46- also moves the, bracket 45 and light source, so that the beam 15 swings in a direction opposite that in which the work is moved, and over a distance fivetimes as great in the assumed ratio or scale of reproduction above indicated. The work is moved so as to swing the spot or image into recessed parts of the contour, and draws the work backward when the convexities of the contour are approaching the beam under rotation of the table ill, the corresponding rotation of the table 50, results in the tool 58 cutting the work 16 in corresponding form. After one or more turns of the tables so as to remove all material on the work beyond the finished contour at a given level attained by. operation of t e crank 1|, the screw 69 is operated to draw the work away from the tool 58 again, while the crank II is again operated to raise the tables 10 and 50 to new levels. This brings the work to where it may again engage the tool outwardly of the contour to be produced, and causes the liquid to again function with the float and valves so that its level is lowered further. aroundthe pattern as before described, producing a new contour to be reproduced on the work in .the man- 'ner already described. These steps are repeated until the complete'reproduction of the pattern is effected, when the liquid level will be close to or at the base of the pattern.

After operation with a large diameter tool and corresponding slide 49, where there are contours involved having indentationstoo narrow for the spot or image to enter, another tool of smaller diameter and a new slide with correspondingly smaller image 14 are introduced, and the tooling of the work repeated as before beginning at such upper parts as require the smaller tool work. A final treatment, with a pointed tool may be carried out.

In this way original works of high value and delicate finish may be reproduced without liability of injury, as well as more rugged pieces duplicated, or reproduced to scale.

Paper drawings of desired contours may be utilized by mounting them at the levels corresponding to the liquid levels referred to, or the table I0 maybe disconnected from the elevating.

drive 12 and the table 50 only elevated in the necessary successive degrees as respective contours on a drawinglaid on thetable ID are followed; producing a three dimensional work from flat drawings.

- When it is desired to change the scale 'of reproduction, the height of the arm 31 and light source are'cor'respondingly adjusted and in reproducing from patterns the ratio of the drives atlfiand 52 changed similarly.

Itwill be understood that the 1iquid22 may includean oil or the like to reduce surface tension, and may also includelaqueous solutions or mixtures adapted to theuses contemplated; Also if desired in certain work the screw'il and crank H 1 may be coupled for simultaneous operation in conventional ways. Y w

. While I have disclosed myiinvention in the'best forms which I have thus. far constructed, ,it' will be understood that this is purely exemplary, and

that further improvements may be found objvious, includin'gvariations in the-proportions of parts, substitution of materials, and. mechanical equivalents, arrangement and construction ofparts, allwithout departing from the spirit of z the inventiomas more particularly set forth and indicated by the appended claims.

I claim: I g

l. In a machine of the character described, a pattern table, means to establish a body of liquid thereon, means to vary the level of the liquid; a

pointer device over the table movable universally,

a Work table, a tool mounted thereover, means to move the tool and work table relatively in a given direction, means to move said pointer and operative connections between the means to move the work table and tool relatively and said means to move the pointer, means to move the work movement of the work table:

3. Means for establishing a contour around a pattern consisting of a table support, means to establish a body of liquid around a pattern on the support, means to vary the level of said liquid at will,v the means for varying the level of I the liquid consisting of a liquid supply. a basin on the support, duct connections between said supply and the basin, a feed valve therein, a drain duct from said basin, a drain valve therein, a float adapted to float on the liquid in the basin and having a mounting independent of the table support and basin, means to move the float mounting and table support vertically relatively at will, and operative connections between said float andsaid valves, for alternative operation on respective opposite vertical relative movements.

4. Means for establishing a contour around a pattern consistingof a table support, means to establish a body of liquid around a pattern on the support, means to vary the level of said liquid at will, the means for varying the level of liquid consisting of a liquid supply, a basin on the support, a duct connection between said supply and the basin, a feed valvetherein, a drain duct from said basin, a drain valve therein, a float adapted to float on the liquid in the basin and having a mounting independent or the table support and basin, means to move the float mounting and table support vertically relatively at will, operative connections between said float and said valves, for alternative operation on respective, opposite vertical relative movements, said valves being normally closed, electrical means to open them, an arm movable by said float under variation of liquid level relatively, respective electrical circuits for said valves each including a circuit closer operatively associated with said arm and operable thereby alternately onmovement of the arm in respective directions.

5. Means for establishing a contour around a pattern consisting of a table support, means to establish a body of liquid around apattern on the support, means to vary the level of said liq:

iiid at, will, the means for varying the level 0! liquid consisting of a liquid supply, a basin on the support, duct connections between said supply and the basin, a feed valve therein, a drain duct from said basin, a drain valve therein, a

float adapted to float on the liquid in the basin and having a mounting independent of the table support and basin, means to move the float mounting and table support vertically relatively at will, and operative connections between said float and said valves, for alternative operation on respective opposite vertical relative movements, a work table and tool relatively vertically movable, means to move the table and tool vertically relatively to each other and operative connections between the last named means and-:said means to establish the liquidlevel. f 6. Means for establishing a contour around a. pattern consisting of a table support, means to establish a body of liquid around a. pattern on the support, means to vary the level of said liquid at will, the means for varying the liquid level consisting of a liquid supply, a basin on the support, duct connections between said supplyand the basin, a feed valve therein, a drain duct from said basin, a drain valve therein, a float adapted to float onthe liquid in the basin and having a mounting independent of the table support and basin, means to move the float mounting and table support vertically relatively at will, and operative connections between said float and saidvalves, for alternative operation on respec-- tive opposite vertical relative-movements, a work 20 table, a tool thereover, means tomove the table and tool relatively and operative connections between the last named means and said mounting of the float.

7. The structure of claim 1 in which said 25 pointer device consists of a lens over the pattern table, a light beam source over the lens and one being horizontally movable with respect to the other, the operative connection between the means to' move the work table and tool relatively 30 being connected with the movable one of the two elements consisting of lensand light beam source.

DARNLEY E. HOWARD.

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