APPARATUS, METHOD, SYSTEM AND COMPUTER PROGRAM FOR MACHINING A WORKPIECE
FIELD OF THE INVENTION
Embodiments of the present invention relate to machining a workpiece. In particular, though without prejudice to the foregoing, various but not necessarily all embodiments relate to an apparatus, method, system and computer program for working a metallic workpiece, for example repairing a section of rail track.
BACKGROUND TO THE INVENTION
Typically, when a defect in a workpiece needs repairing, for example a wheel burn in a rail track, such a repair would be carried out manually. A cavity in the track would be by manually machined out with a cutting tool. Then the cavity would be manually filled in with a welding tool. Such a process is laborious, time consuming and requires personnel having a high degree of skill. Also, such a manual repair process cannot be accurately and reliably repeated to give a consistent repair. Any discussion of a prior-published document or any background in this specification should not necessarily be taken as an acknowledgement that the document or background is part of the state of the art or is common general knowledge.
One or more aspects/embodiments of the present disclosure may or may not address one or more of the background issues. For example, various but not necessarily all embodiments seek to provide an improved apparatus, method and system for machining a workpiece which is simpler to use thereby reducing the manpower and skill level required in a machining process as well as reducing the time taken which consequently reduces downtime of the workpiece. Also, various embodiments seek to provide a more consistent and accurately repeatable machining process.
BRIEF DESCRIPTION OF VARIOUS EMBODIMENTS OF THE INVENTION
According to various, but not necessarily all, embodiments of the invention there is provided an apparatus for machining a workpiece comprising: means for securing the apparatus to a workpiece; means for detachably mounting a tool to the apparatus such that a first tool detachably mounted is replaceable with a second tool; means for moving a detachably mounted tool; a controller for controlling the means for moving the detachably mounted tool, wherein the controller is configured to cause movement of the second tool, when detachably mounted, that is at least partly dependent upon movement performed by the first tool when detachably mounted.
Advantageously, the same apparatus can be used for different machining tools and thus the same apparatus can be used for performing different machining tool operations on the workpiece e.g. cutting and welding in a repair process.
The same means for moving may be used for movement of the tool and the other tool. Accordingly, the same frame of reference, can be
used for both fools which helps †o simplify fhe repair process and improve fhe consistency of the repair.
The movement and a functional operation of a fool may be computer controlled so as to improve fhe accuracy, repeatability and consistency of a machining process.
The apparatus may comprise means for controlling a function or operation of af least one of the fools. Movemen function and/or operation of at least one of fhe fools may be controllable by a programmable device. Control of: a movement, a function and/or an operation of a second defachably mounted tool may be af least partly dependent upon: a movement, a function and/or an operation previously carried out by fhe first fool when defachably mounted.
According to various, but not necessarily all, embodiments of fhe invention there is provided a method for machining a workpiece comprising: securing an apparatus to a workpiece; mounting a first detachable fool†o fhe apparatus; controlling movement of fhe first fool; replacing fhe first detachable tool with a second detachable tool; and controlling movement of the second fool based af least partly on fhe movement of fhe first fool.
According †o various, but not necessarily all, embodiments of fhe invention there is provided a system comprising: the apparatus as set out above, a first tool; and a second fool.
According †o various, but not necessarily all, embodiments of fhe invention there is provided a computer program that, when run on a
computer, causes the apparatus as set out above, when mounted with a tool, to machine a workpiece.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of various examples of embodiments of the present invention reference will now be made by way of example only to the accompanying drawings in which: Figure 1 schematically illustrates an apparatus according to an embodiment on the invention;
Figure 2 schematically illustrates an apparatus according to a further embodiment;
Figure 3 schematically illustrates an apparatus according to a further embodiment;
Figure 4 schematically illustrates an apparatus according to a further embodiment;
Figure 5 schematically illustrates a method according to a further embodiment of the invention; and
Figure 6 schematically illustrates a controller for use with embodiments of the invention.
DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS OF THE INVENTION The Figures illustrate an apparatus 100 for machining a workpiece 101 comprising: means 102 for securing the apparatus to the workpiece; means 103 for detachably mounting a tool 104 to the apparatus such that the tool is replaceable with another tool 105; means 10ό for moving a detachably mounted tool; and means 107 for controlling the means for moving.
Figure 1 schematically illustrates an apparatus 100 for machining a workpiece 101 according to an embodiment of the invention. The apparatus 100 comprises a fixing device 102 such as clamps or any other suitable means for securing and attaching the apparatus to the workpiece 101 that is to be worked on. The workpiece may, itself, be fixed, i.e. is of itself held firm and in a constant stable position independently of the apparatus. For example the workpiece may be fixed due to the fact that it is installed in position and/or in due to the substantiality of the size and weight of the workpiece, e.g. a metallic workpiece such as a rail track, pipe or a cylindrical vessel. Since the workpiece is fixed, it is the apparatus that is secured to the fixed workpiece to secure and stabilize the apparatus with respect to the workpiece, rather that the workpiece that is secured and fixed with respect to the apparatus.
The apparatus 100 may be configured such that it is portable and conveyable to the location of the fixed workpiece and attachable to the workpiece to enable in-si†u repair of the workpiece. Such portability can be achieved, for example, by the size and materials of the components of the apparatus being selected such that the weight of the apparatus enables its portability (e.g. under 20kg to be able to be manually carried by users or under 100kg to be conveyable via a user operable machine) or alternatively by the apparatus being configured such that it is able to be assembled on site on the workpiece.
The apparatus 100 comprises a tool mount 103 for detachably mounting a tool 103. The tool mount is configured so that the tool is
detochably mountable and replaceable with another detachably mountable tool 105. This enables a plurality of machining tools 104 and 105 to be used with the apparatus. The mount may accommodate a single tool at a time, i.e. each tool may be detachably mounted and able to be replaced separately with another detachably mountable tool. Alternatively, the mount may accommodate two or more tools at the same time. Advantageously, the same apparatus and securing means can be utilized during operation of each different tool without requiring a further additional apparatus or repositioning and re- securing of the entire apparatus. Therefore the same fixed points of reference relative to the workpiece can be used.
The apparatus 100 also comprises means 10ό for moving a detachably mounted tool with respect to the workpiece. The movement means, such as an actuator may provide linear translational movement of the mount 103 (and corresponding movement of any tool mounted thereon) along a first (x) axis. The movement means may further be configured to provide translational movement in an orthogonal (y) axis (see Figure 2). Furthermore, the movement means, or additional movement means may provide translational movement in a third orthogonal (z) axis so as to enable movement of the mount/tool with 3 degrees of freedom. Optionally, movement means may also be provided on the mount, for example so as to enable z axis translational movement (depth control of the tool) and/or rotational movement such as: yawing, pitching and rolling of the tool. Advantageously, the same movement means can be utilized during operation of each different tool without requiring separate dedicated movement means per tool or the re-alignment of movement means for each tool.
Means for controlling the movement means are provided, for example via a by controller, 107. Although in Figure 1 the controller is shown as being attached to the apparatus, it is to be appreciated that the controlling means of the apparatus could equally well comprise means for receiving control signals from a physically separate or remote controlling device. Computer Numerical Control (CNC) may be utilized in the control of the movement means to ensure programmable, accurate, repeatable and reliable movement of the mount/tool. Automated computer control enables predetermined precise movement of the mount/tool to be effected and a consistent machining process to be carried out on each workpiece.
The workpiece 101 may be machined so as to repair a defect (not shown) in the workpiece such as an indentation, deformation, or fracture. A detachably mountable tool 104 may be attached to the mount which removes material at and around the vicinity of the defect. The tool 104 for removing material from the workpiece may comprise for example: a cutting tool, an oxy-acetylene torch, a milling tool, a profiling tool or a grinding tool to: cut out, melt away, mill out, profile or grind a section of the workpiece. Then, this tool would be replaced with another tool 105 for adding filler material to replace the material removed from the workpiece. The tool 105 for adding material may comprise for example: a welding tool, a cladding tool, a casting tool, or a tool for depositing sintered metal.
The controller 10ό may additionally be configurable to control operation of the tool, i.e. a function or operational parameter of the tool. For example, where the tool is a milling tool the rotation rate, speed, and penetration depth, feed, can be adjusted, where the tool is a welder the output rate of filler material can be controlled. The
controller 10ό may additionally monitor/track movements and operations carried out with a first tool and store information related to the movement and operations performed by the first tool. This information can then be used in the control of movement and operation of a second tool. The combined computer controlled movement of a tool as well as computer controlled operation of the tool enables the machining/repair process to be substantially automated with pre-programmable movements and tool operations appropriate to: the machining/repair process to be effected, the workpiece and the tool currently mounted. For example, movement and operation of a detachable mounted tool can be automated so as to remove a set amount of material to create a cavity in the workpiece having pre-determined parameters of shape and dimensions. Then, having replaced the removal tool with a tool for adding material such as a welding gun, movement and operation of the welding gun can be controlled, at least partly based on the movement and operation previously performed by the first tool, so as to provide a pre-determined requisite amount of filler material into the cavity. Computer controlled movement and operation of the welding gun enables a precise and consistent welding operation to be performed whereby welding parameters can be set and predetermined based on the cavity parameters, and such welding parameters can be accurately controlled and executed. This may assist in performing a specific type of weld repair having certain particular parameters and characteristics, for example, where it is necessary to maintain a weld bead at a temperature above a Martensite Start temperature.
The apparatus may be provided in a module. As used here 'module' refers to a unit or apparatus that excludes certain parts/components that would be added by an end manufacturer or a user. Figure 2 schematically illustrates an apparatus 200 for machining a workpiece 101 according to another embodiment on the invention. The apparatus comprises: clamps 202 for securing the apparatus to the workpiece 201 , mount 203 for detachably mounting a plurality of replaceable tools 204 and 205 to the apparatus, and movement system 206a and 206b configured to move the mount in at least two orthogonal (x, y) directions. The mount itself also comprises further means for moving the tool in a third orthogonal (z) direction and may also optionally be configured so as to enable rotational movement of the tool. A controller 207 controls the movement and functional operation of the mounted tool. The controller can provide control signals to the movement means and the mounted tool via any suitable means such as via wired or wireless communication 208.
The means for movement 206a and 206b may be modular and expandable such that the range of movement afforded by the means for movement may be increased by the additional or expansion modules. For example, with reference to figure 2, the means for movement 206b provides linear translational movement by causing the means 206a, which the mount 203 is connected to, to move along guide path members 209. Additional guide path members 210 could be provided to increase the length of the guide path. The movement means may comprise a gantry moveable on rails wherein additional rails can be attached to increase the range of movement possible.
Optionally, the apparatus may comprise one or more sensors 21 1 for mapping and measuring characteristics and parameters of the workpiece or movement and operation of the tool. For instance, sensor information relating to: the position, orientation and shape of the workpiece as well as the location of a defect on the workpiece could be determined. Signals related to sensor measurements can be used in controlling the movement and operation of tool.
Optionally, the apparatus may further comprise means for heating the workpiece to a desired temperature, such as a heater or burner (not shown).
In Figures 1 and 2, only the functional components that are necessary for describing the operation of the apparatus are described. The functional components and the functions described may or may not be performed by a single physical entity as described. It should be appreciated that any number or combination of intervening components can exist (including no intervening components) . Although each of the apparatuses is described in terms of comprising various functional components, it should be understood that the functional components may be controlled by a processing element or processor of the apparatus. In this regard, each of the functional components described may be any combination of device, means and circuitry embodied in hardware, software or a combination of hardware and software that is configured to perform the corresponding functions of the respective components as described.
Figure 3 schematically illustrates an apparatus 300 of an embodiment suitable for repairing rail track workpiece 301 a.
Means for securing the apparatus to the rail track workpiece is provided by sub frame 302. This support structure clamps on to rail tracks 301 a and 301 b by means of profiled clamps. Mounted onto the sub frame is a carriage 320. The carriage can be suitably positioned on the sub frame, i.e. so as to be proximal to either track 301 a or 301 b, dependent upon which rail track is to be repaired, and clamped into its respective position on the sub frame. Mounted on to the carriage is a sliding positioning system 306a which provides means for movement along a first (x) direction. Another slide system 306b provides movement means along a second (y) direction.
Cutting and welding head 303 provides means for detachably mounting a first tool 304 and a second tool to the apparatus. The head also provides movement means along a third (z) direction as well as rotational yaw, pitch and roll movement. Attached to the welding and cutting head 303 is either a cutting tool 304 or welding torch 305 depending on the mode of operation of the apparatus. If necessary, the effective range of movement of the cutting and welding head 303, with respect to the rail 301 a, may be increased by re-positioning the carriage 320 on the sub frame 302.
The operation of the apparatus 300 is controlled by means of a computing device (not shown) which controls: twin servo drives 321 , on axis control motors and spindle drive motor 322 to give movement, positioning and rotational control. Pre programmed software allows the speed, feed and position of the cutting tool to be controlled during a cutting process to enable machining of a predetermined profile 323. Then, the cutting tool is replaced with the welding torch 305 to commence the welding process. The same apparatus is thus capable
of controlling the welding torch position, speed and feed to ensure the correct weld parameters are met and that the weld process and position is directly correlated to the machined profile. The Χ,Υ,Ζ platform carriage 320 is configured to be able to clamp to the rail tracks 301 a and 301 b via the sub structure 302 in a predetermined position with the cutting and welding head 303 mounted to the Z axis. Movement on each axis is computer controlled and the twin servo drives 321 enable the apparatus to cut the rail track 301 a with a predefined profile 323 by means of the cutter 304 attached to the cutting and welding head 303 and pre programmed control software. The apparatus is positioned by markings over the centre of the rail track deformation and clamped. The software controls the position, speed, feed, length and depth of machining. The cutter is then removed from the cutting and welding head and the welding torch installed. The software then controls the depth, step and speed of the welding process.
The portable apparatus 300 seeks to enable the machining and welding of rail track to repair the track so as to be as hot rolled without any metallurgical defects that lead to stress fractures. The apparatus provides consistent and semi autonomous repair of a rail track which is particularly advantageous for repairing rail defects such as wheel burns since they are typically of a relatively consistent size, shape and location on a rail track (e.g. 100mm x 10mm in the centre of the track) and thus involve a consistent repair process.
The apparatus enables an at least semi-automated repair process to be programmed and executed by the apparatus. This reduces the manpower and operator skill level required in carrying out a repair as
compared†o previous manual repairs. Also, the down time of the rail track is reduced.
Whilst the above embodiment has described the apparatus with respect to repairing a workpiece, embodiments of the invention are no so limited and may well be used to work a metallic workpiece.
Figure 4 schematically illustrates an apparatus 400 according to a further embodiment for working a workpiece, in this case preparing a vessel to receive a nozzle.
The portable apparatus 400 enables the cutting and machining of a vessel nozzle weld preparation in situ and provides an accurate method for angular weld preparations on cylindrical vessels 401 .
The apparatus 400 comprises an Χ,Υ,Ζ platform 402 securing means that clamps to the vessel 401 in a predetermined position with a cutting head 404 mounted to the Z axis. Movement on each axis is controlled by computer and twin servo drives 421 enable the apparatus to cut a nozzle hole in the vessel to a predefined profile by means of a cutter 404 attached to the cutting head 403 and pre programmed control software. The apparatus may be positioned by markings over the centre of the vessel nozzle hole position and clamped to the vessel. The software controls the position, speed, feed, diameter and depth of cutting tool. The cutting tool is then removed from the cutting head and replaced with a profile cutting tool (not shown) which is installed. The software then controls the operation of the profile cutter such as its speed and feed is based on the parameters of the previously machined profile.
The apparatus 400 consists of a sub frame 402 that can be clamped on to the cylindrical vessel 401 by means of profiled clamps 430. Mounted onto the sub frame is a positioning system 406a to give X directional movement. The range of movement may be expanded, for example by means of additional slides and jointing in a rack and pinion type movement arrangement. Another slide system 406b provides Y directional movement and a cutting head 403 gives Z axis movement as well as rotational movement. Attached to the cutting head is either a cutter 404 or a profiled cutter (not shown) depending on a mode of operation. The operation is controlled by means of a computer (not shown) that is able to control twin servo drives 421 , on the axis control motors and spindle drive motor 422 to give positioning and rotational control. Preprogrammed software loaded in the computer controls the speed, feed and position of the cutting tool during the process to enable machining of a pre determined profile. The cutting head is then replaced with a profiling cutter to commence the profiling process. The same apparatus is thus capable of controlling the profiling tool position and speed to ensure the correct profile parameters are met and the profiling process is directly correlated to the machined profile.
Figure 5 schematically illustrates a method 500 according to a further embodiment of the invention.
In block 501 , an apparatus is secured to a workpiece. In block 502, a first detachable tool is mounted to the apparatus. In block 503, movement of the mounted first detachable tool is controlled. In block 504, the first detachable tool is replaced with a second detachable tool. In block 505, movement of the second tool is controlled. The movement of the second tool is at least partly based on the movement performed by the first tool.
The method may also further include the following:
controlling operation of the first tool;
controlling operation of the second tool based on the operation performed by the first tool;
operating the first tool to remove material from the workpiece and
operating the second tool to add material to the workpiece. The illustration of a particular order to the blocks does not necessarily imply that there is a required or preferred order for the blocks and the order and arrangement of the block may be varied. Furthermore, it may be possible for some steps to be omitted. Figure 6 schematically illustrates a controller 607 for use with various but not necessarily all embodiments of the invention to control the movement, and also optionally the functional operation, of a detachably mounted tool. The controller 607 comprises: a processor 61 1 and a memory 612 including a computer program 613 comprising machine readable code/ computer program instructions 614. The code is configured to, with the processor, control the movement and functional operation of a tool detachably mounted on the apparatus 100, 200, 300 or 400.
The processor 61 1 is configured to read from and write to the memory 612. The processor 61 1 may also comprise an output interface 615 via which data and/or commands are output by the processor and an input interface 616 via which data and/or commands are input to the processor. For example, the input and output interfaces may enable
communication with the apparatus and the sending control signals to control the movement and operation of the tool.
The memory 612 stores the computer program 613 comprising computer program instructions 614 that control the operation of the apparatus 100, 200, 300, 400 when loaded into the processor 61 1 . The computer program instructions provide the logic and routines that enables the apparatus to control the movement, positioning and operation of a tool as well as monitor and store information related to the movement, position and operation of the tool. The processor, by reading the memory, is able to load and execute the computer program.
Implementation of controller can be in hardware alone (a circuit, a processor...), have certain aspects in software including firmware alone or can be a combination of hardware and software (including firmware). The controller 607 may be any suitable apparatus or collection of apparatuses. It may, for example, be a hand-portable device or a desk-top device, general-purpose or special-purpose device. The program may be stored on a computer readable storage medium (disk, memory etc) or carried by a signal carrier to be executed by a processor.
The controller may be physically separate and remote from the apparatus. The controller is able to provide control signals to control the movement and function of the tool. The control signals may arrive at the apparatus via any suitable delivery mechanism 208. The delivery mechanism may be, for example, a non-transitory computer-readable storage medium, a computer program product, a memory device, a record medium or an article of manufacture that tangibly embodies
computer program instructions. The controller may propagate or transmit control signals to the apparatus as a computer data signal.
References to computer program, instructions, code etc. should be understood to encompass software for a programmable processor or firmware such as, for example, the programmable content of a hardware device whether instructions for a processor, or configuration settings for a fixed-function device, gate array or programmable logic device etc.
Although functions have been described with reference to certain features, those functions may be performable by other features whether described or not. Although features have been described with reference to certain embodiments, those features may also be present in other embodiments whether described or not. Features described in the preceding description may be used in combinations other than the combinations explicitly described. Although various embodiments of the present invention have been described in the preceding paragraphs with reference to various examples, it should be appreciated that modifications to the examples given can be made without departing from the scope of the invention as claimed.
Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.