Intelligent tool system

• US 4,778,313 A
• Filed: 05/18/1987
• Issued: 10/18/1988
• Est. Priority Date: 05/18/1987
• Status: Expired due to Term

• Current Assignee: Robert A. Lehmkuhl
• Original Assignee: Manuflex Corporation
• Inventors: Lehmkuhl, Robert A.
• Primary Examiner(s): Briggs, William R.
• Application Number:
  US07/050,941
• Time in Patent Office: 519 Days
• Field of Search: 409/80, 409/187, 409/194, 409/196, 409/127, 409/218, 409/134, 409/193, 29/56.5, 29/26 A, 279/1 ME, 408/3, 408/10, 408/6, 408/11, 408/12, 408/13, 33/558, 33/561, 33/559, 33/556, 33/505, 364/560
• US Class Current: 409/127
• CPC Class Codes: B23B 29/03457 by pivoting the tool carriers or by elastic deformation
• CPC Class Codes: B23B 31/083 axially
• CPC Class Codes: B23B 31/208 with a tool positioning stop axial positioning of the tool being adjustable B23B31/028
• CPC Class Codes: B23B 31/261 clamping the end of the toolholder shank
• CPC Class Codes: G05B 19/182 characterised by the machine tool function, e.g. thread cutting, cam making, tool direction control G05B19/21 - G05B19/40 take precedence
• CPC Class Codes: G05B 19/401 characterised by control arrangements for measuring, e.g. calibration and initialisation, measuring workpiece for machining purposes G05B19/19 takes precedence
• CPC Class Codes: G05B 19/404 characterised by control arrangements for compensation, e.g. for backlash, overshoot, tool offset, tool wear, temperature, machine construction errors, load, inertia G05B19/19, G05B19/41 take precedence
• CPC Class Codes: G05B 2219/37175 Normal encoder, disk for pulses, incremental
• CPC Class Codes: G05B 2219/37207 Verify, probe, workpiece
• CPC Class Codes: G05B 2219/37245 Breakage tool, failure
• CPC Class Codes: G05B 2219/37402 Flatness, roughness of surface
• CPC Class Codes: G05B 2219/37405 Contact detection between workpiece and tool, probe, feeler
• CPC Class Codes: G05B 2219/43152 Feed in, transfer line, rapid traverse to work, grip speed
• CPC Class Codes: G05B 2219/45129 Boring, drilling
• CPC Class Codes: G05B 2219/45145 Milling
• CPC Class Codes: G05B 2219/45216 Tapping
• CPC Class Codes: G05B 2219/49219 Compensation temperature, thermal displacement
• CPC Class Codes: G05B 2219/50171 Machine, machining centre, center
• CPC Class Codes: G05B 2219/50252 Replace, change tool with tracer head, probe, feeler
• CPC Class Codes: G05B 2219/50293 Radial setting of tool
• CPC Class Codes: Y10T 29/5176 : including machining means
• CPC Class Codes: Y10T 408/08 : with means to regulate operation by use of templet, tape, card, or other replaceable information supply
• CPC Class Codes: Y10T 408/17 : to control infeed
• CPC Class Codes: Y10T 409/303528 : Adapted to trigger electrical energy
• CPC Class Codes: Y10T 409/30728 : In response to cutter condition
• CPC Class Codes: Y10T 409/308624 : with limit means to aid in positioning of cutter bit or work [e.g., gauge, stop, etc.]

Abstract

An intelligent tool system used with computer numerical controlled machining centers consisting of an internal spindle machanism and a variety of spindle mounted devices.

The spindle mechanism provides CNC communicating and operating means with spindle mounted devices such as; telescoping tool holders for determining work surface locating with random length tools and for sensing tool condition; automatic boring tools for high precision boring and contouring; probing devices for work surface location, measurement and definintion; combination boring and probing tools for boring and measuring a hole without removing the tool from the spindle.

Claims

1. A tooling device for computer numerically controlled machining centers having a spindle, a control rod passing through said spindle, a sliding element, said control rod connected to said sliding element, a linear motor and transducer connected to said sliding element to control the position and force of said sliding element, a spring loaded telescoping tool holder, an actuating rod in said tool holder adapted to engage said control rod, said actuating rod displacing said control rod to displace said sliding element to displace said transducer, said transducer having electronic coupling means to the axis feed rate of the computer numerical control for controlling spindle deceleration from rapid traverse to zero traverse, said transducer producing a signal to transmit work surface location to the computer numerical control to feed the spindle to a programmed depth at a programmed feed rate.

2. The device as described in claim 1 having a spring loaded telescoping tool holder that will unseat during drilling operations if said drill breaks, said unseating displaces said transducer before said programmed depth is reached signaling said computer numerical control that a malfunction has occurred.

3. The device described in claim 1 wherein said spring loaded telescoping tool holder is arranged to drive taps and is partially compressed during deceleration to a predetermined position of the transducer, whereby a in-position signal is transmitted to said computer numerical control, said in-position signal determines work surface location and starts spindle rotation, said spindle rotation will cause said tap to feed into said work piece causing said tap holder to displace transducer, said displacement will signal computer numerical control to feed said spindle at the tap feed rate to a programmed depth, reversing said spindle rotation at said programmed depth causing said tool holder to move said transducer to a position past the predetermined position, said spindle feed will reverse following said tap from hold, said spindle will retract to a programmed position relative to said work piece.

4. The device as described in claim 3 having a spring loaded telescoping tool holder that will change its operating position during a tapping operation if said tap should break or stall, said change in operating position will displace said transducer before said programmed depth is reached signaling said computer numerical control that a malfunction has occurred.

5. The device described in claim 1 wherein said telescoping tool holder is adapted to drive milling cutters and is seated solidly in said tool adapter body during milling operations and is retained in the seated position independent of machining loads by means of a spring loaded ball locking mechanism comprising an internal cam groove in said adapter body, a series of balls located in a series of holdes in said telescoping tool holder, an external cam surface with a locking angle working in conjunction with said balls, said external cam surface being located on a spring loaded cam secured to a tool actuating rod and slidably mounted in an internal bore of said sliding tool holder, said spring load on said locking angle forces said balls against said internal groove in said adapter body forcing said tool holder to be rigidly seated during machining operation.

6. The device described in claim 5 wherein said telescoping tool holder has a self releasing external taper on the lower portion arranged to seat securely in a matching internal taper of said adapter body when said tool holder is in the fully telescoped position, said tool holder also has the center of said holes for said balls located at an angle less than 90°

from the centerline of said tool holder, said angle of said holes provides radial stability to said tool holder at end of said tool holder opposite said taper by balls being forceably locked between internal cam groove in said adapter body and angle of said holes by locking angle of said spring locaded sliding cam whereby said tool holder is rigidly locked both axially and radially to eliminate any looseness between said tool adapter body and said tool holder during machining operations.

7. The device in claim 5 wherein said servo motor moves said spindle control rod against said tool actuating tod, when said machining operation is complete with sufficient force to overcome said spring force on said sliding cam, moving said locking angle of said sliding cam away from said balls allowing and assisting tool holder spring to return to said tool holder to the work sensing cycle position.

8. A boring device for computer numerical controlled machining centers having a spindle, a control rod, said control rod passing through said spindle, a sliding element, said control rod connected to said sliding element, a linear motor and transducer connected to said sliding element to control the position and force of said sliding element, an adjustable boring tool mounted in said spindle, said adjustable boring tool having a main operating body secured in said spindle, a preload adjustable boring bar, a cam bar, said cam bar secured to one end of said boring bar, said boring bar pivotly secured to said operating body, a linear cam for controlling the position of said cam bar slidably mounted in said support body, a tool actuating rod secured to said linear cam, an actuating rod spring, said actuating rod spring maintains said actuating rod and said linear cam in a fully retracted position, a boring head, said boring head secured to end of said boring bar opposite said cam bar, a cutting tool mounted in said boring head, said spindle control rod contacts said tool actuating rod during operations and overcomes the force of said actuating rod spring to determine the position of said tool actuating rod and said linear cam, a preload spring, said preload spring mounted on one end of said operating body to pivot said boring bar in a direction to oppose the force of said linear cam engaging with said cam bar to pivot said boring bar to a preselected position to locate said cutting tool for controlling the diameter of said bored hole.

9. A probing device for computer numerically controlled machining centers having a spindle, a control rod passing through said spindle, a sliding element, said control rod connected to said sliding element, a linear motor and transducer connected to said sliding element to control the position and force of said sliding element, said probing device mounted in said spindle comprising a spindle mounted support body, a stylus mounted head secured to a spring biased center shaft slidably mounted in said support body, a tool actuating rod secured to said center shaft, a stylus in said stylus mounting head, said stylus, mounting head, center shaft and actuating rod movable relative to said support body, an object, said tool actuating rod is displaced when said stylus is deflected by said object while said probing device is moving in a minus direction parallel to the axis of said spindle, said displacement of said tool actuating rod displaces said spindle control and said sliding element, said transducer is displaced by said sliding element, said transducer having electronic coupling means to the axis feed rate of the computer numerical control for controlling the spindle advance from rapid traverse to zero feed rate, said transducer to trigger position detection circuits of said computer numerical control when relative motion begins between said stylus mounting head and said support body to track said relative motion until zero velocity is reached, whereby said output of said detection circuit is processed by said computer numerical control to determine relative position of said object to said stylus when said probing device is moved in a minus direction parallel to the axis of said spindle until said stylus is deflected by said object.

10. The device described in claim 9 for defining the contour of an object relative to a plane perpendicular to the axis of said spindle when said stylus is moved along said object in a direction perpendicular to the axis of said spindle.

11. A probing device for computer numerically controlled machining centers having a spindle, a control rod passing through said spindle, a sliding element, said control rod connected to said sliding element, a linear motor and transducer connected to said sliding element to control the position and force of said sliding element, said probing device mounted in said spindle comprising a spindle mounted support body, a stylus mounting head secured to a spring biased center shaft slidably mounted in said support body, a means for retaining opposed preload forces to provide positive neutral position of said stylus mounting, a tool actuating rod secured to said center shaft, a stylus in said stylus mounting head, said stylus, mounting head, center shaft and actuating rod movable relative to said support body, an object, said tool actuating rod is displaced when said stylus is deflected by said object while said probing device is moving in a plus or minus direction parallel to the axis of said spindle, said displacement of said tool actuating rod displaces said spindle control and said sliding element, said transducer is displaced by said sliding element, said transducer having electronic coupling means to the axis feed rate of the computer numerical control for controlling the spindle advance from rapid traverse to zero feed rate, said transducer to trigger position detection circuit of said computer numerical control when relative motion begins between said stylus mounting head and said support body to track said relative motion until zero velocity is reached, whereby said output of said position detection circuit is processed by said computer numerical control to determine relative position of said object to said stylus when said probing device is moved in a plus or minus direction parallel to the axis of said spindle until said stylus is deflected by said object.

12. A probing device for computer numerical controlled machining centers having a spindle, a control rod passing through said spindle, a sliding element, said control rod connected to said sliding element, a linear motor and transducer connected to said sliding element to control the position and force of said sliding element, said probing device mounted in said spindle comprising a spindle mounted support body, a stylus mounting head movable relative to said support body in a direction perpendicular to the axis of said spindle, a stylus in said mounting head, an object, a means for displacing said spindle control rod, said sliding element and said linear transducer when said stylus is deflected by said object when said probing device is moved in a direction perpendicular to the axis of said spindle, said transducer having electronic coupling means to the axis feed rate of said computer numerical control for controlling the spindle advance from rapid traverse to zero feed rate, said transducer to trigger position detection circuits of said computer numerical control when relative motion begins between stylus mounting head and said support body and to track said relative motion until zero velocity is reached, whereby said output of said position detection circuit is processed by said computer numerical control to determine relative position of said object to said stylus when said probing device is moved in a direction perpendicular to the axis of said spindle until said stylus is deflected by said object.

13. A probing device for computer numerically controlled machining centers having a spindle, a control rod passing through said spindle, a sliding elemet, said control rod connected to said sliding element, a linear motor and transducer connected to said sliding element to control the position and force of said sliding element, said probing device mounted in said spindle comprising a spindle mounted support body, a center shaft, a spring to bias said center shaft, said center shaft mounted to slide axially in said support body, a tool actuating rod secured to said center shaft, a rigid disc type stylus mounting head movable relative to said support body in a direction perpendicular to the axis of said spindle, a cam in said stylus mounting head, a ball carried in said cam of said mounting head, a ball carried in said cam of said mounting head, a cam in said center shaft for receiving said ball, said spring of said center shaft applies pressure on said ball and said cam surfaces to determine a neutral position of said stylus mounting head, a stylus in said stylus mounting head, an object, any displacement of said stylus when moved in a direction perpendicular to the axis of said spindle against said object causes said ball operating in said cam surfaces to displace said center shaft and said tool actuating rod an amount equal to the displacement of said stylus, said stylus remains parallel to the axis of said spindle during stylus displacement, a floatably mounted orientation retention ring keying said rigid disc to said fixed support body, said displacement of said tool actuating rod displaces said spindle control rod and said sliding element, said transducer is displaced by said sliding element, said transducer having electronic coupling means to the axis feed rate of said computer numerical control for controlling the spindle advance from rapid traverse to zero feed rate, said transducer to trigger position detection circuits of said computer numerical control when relative motion begins between said stylus mounting head and said support body and to track said relative motion until zero velocity is reached, whereby said output of said position detection circuit is processed by said computer numerical control to determine relative position of said object to said stylus when said probing device is moved in a direction perpendicular to the axis of said spindle until said stylus is deflected by said object.

14. A probing device for computer numerically controlled machining centers having a spindle, a control rod passing through said spindle, a sliding element, said control rod connected to said sliding element, a linear motor and transducer connected to said sliding element to control the position and force of said sliding element, said probing device mounted in said spindle comprising a spindle mounted support body, a stylus mounting head movable relative to said support body in a plus direction parallel to the axis of said spindle and in a direction perpendicular to the axis of said spindle, a stylus in said stylus mounting head, an object, a means for displacing said spindle control rod, said sliding element and said linear transducer when said stylus is deflected by said object when said probing device is moved in a minus direction parallel to the axis of said spindle or in a direction perpendicular to the axis of said spindle, said transducer having electronic coupling means to the axis feed rate of said computer numerical control for controlling the spindle advance from rapid traverse to zero feed rate, said transducer to trigger position detection circuits of said computer numerical control when relative motion begins between said stylus mounting head and said support body and to track said relative motion until zero velocity is reached, whereby said output of said position detection circuit is processed by said computer numerical control to determine relative position of said object to said stylus when probing device is moved in a minus direction parallel to the axis of said spindle or in a direction perpendicular to the axis of said spindle until said stylus is deflected by said object.

15. A probing device for computer numerically controlled machining centers having a spindle, a control rod passing through said spindle, a sliding element, said control rod connected to said sliding element, a linear motor and transducer connected to said sliding element to control the position and force of said sliding element, said probing device mounted in said spindle comprising a spindle mounted support body, a center shaft, a spring to bias said center shaft, said center shaft mounted to slid axially in said support body, a tool actuating rod secured to said center shaft, a rigid disc movable relative to said support body in a direction perpendicular to the axis of said spindle, a stylus mounting head, said rigid disc arranged to locate said stylus mounting head in a steep tapered hole in said disc with said stylus mounting head having a matched taper to fit said hole, a cam in said stylus mounting head, a ball carried in said cam in said stylus mounting head, a cam in said center shaft for receiving said ball, said spring of said center shaft applies pressure on said ball and said cam surfaces, said pressure locates said stylus mounting head axially in said tapered hole and locates said stylus mounting head and rigid disc radially in a neutral position, a stylus in said stylus mounting head, an object, any displacement of said stylus when moved in a minus direction parallel to the axis of said spindle or in a direction perpendicular to the axis of said spindle against said object causes said ball operating in said cam surfaces to displace said center shaft and said tool actuating rod an amount equal to the displacement of said stylus, said stylus remains parallel to the axis of said spindle during stylus displacement, a floatably mounted orientation retention ring keying said rigid disc to said fixed support body, said displacement of said tool actuating rod displaces said spindle control rod and said sliding element, said transducer is displaced by said sliding element, said transducer having electronic coupling means to the axis feed rate of said computer numerical control for controlling the spindle advance from rapid traverse to zero feed rate, said transducer to trigger position detection circuit of said computer numerical control when relative motion begins between said stylus mounting head and said support body and to track said relative motion until zero velocity is reached, whereby said output of said position detection circuit is processed by said computer numerical control to determine relative position of said object to said stylus when said probing device is moved in a minus direction parallel to the axis of said spindle or in a direction perpendicular to the axis of said spindle until said stylus is deflected by said object.

16. A probing device for computer numerically controlled machining centers having a spindle, a control rod passing through said spindle, a sliding element, said control rod connected to said sliding element, a linear motor and transducer connected to said sliding element to control the position and force of said sliding element, said probing device mounted in said spindle comprising a spindle mounted support body, a stylus mounting head movable relative to said support body in a plus and minus direction parallel to the axis of said spindle and in a direction perpendicular to the axis of said spindle, a stylus in said stylus mounting head, an object, a means for displacing said spindle control rod, said sliding element and said linear transducer when said stylus is deflected by said object when said probing device is moved in a plus or minus direction parallel to the axis of said spindle or in a direction perpendicular to the axis of said spindle, said transducer having electronic coupling means to the axis feed rate of said computer numerical control for controlling the spindle advance from rapid traverse to zero feed rate, said transducer to trigger position detection circuits of said computer numerical control when relative motion begins between said stylus mounting head and said support body and to track said relative motion until zero velocity is reached, whereby said output of said position detection circuit is processed by said computer numerical control to determine relative position of said object to said stylus when said probing device is moved in a plus or minus direction parallel to the axis of said spindle or in a direction perpendicular to the axis of said spindle until said stylus is deflected by said object.

17. A probing device for computer numerically controlled machining centers having a spindle, a control rod passing through said spindle, a sliding element, said control rod connected to said sliding element, a linear motor and transducer connected to said sliding element to control the position and force of said sliding element, said probing device mounted in in said spindle comprising a spindle mounted support body, a center shaft, a spring to bias said center shaft, said center shaft mounted to slid axially in said support body, a tool actuating rod secured to said center shaft, a rigid disc movable relative to said support body in a direction perpendicular to the axis of said spindle, a stylus mounting head, said rigid disc arranged to locate said stylus mounting head in a counter bore in said rigid disc, a preloaded spring assembly secured to said stylus mounting head, said spring assembly axially positions said mounting head in said counter bored hole, a cam in said stylus mounting head, a ball carried in said cam in said stylus mounting head, a cam in said center shaft for receiving said ball, said preload spring assembly of said stylus mounting head having a preload value greater than the value of said center shaft spring, said center shaft spring locates said stylus mounting head and spring preload assembly axially and said rigid disc radially in a neutral position, a stylus in said stylus mounting head, an object, any displacement of said stylus when moved in a plus or minus direction parallel to the axis of said spindle or in a direction parallel to the axis of said spindle against said object causes said ball operating in said cam surfaces to displace said center shaft and said tool actuating rod an amount equal to the displacement of said stylus, said stylus remains parallel to the axis of said spindle during stylus displacement, a floatably mounted orientation retention ring keying said rigid disc to said fixed support body, said displacement of said tool actuating rod displaces said spindle control rod and said sliding element, said transducer is displaced by said sliding element, said transducer having electronic coupling means to the axis feed rate of said computer numerical control for controlling the spindle advance from rapid traverse to zero feed rate, said transducer to trigger position detection circuit of said computer numerical control when relative motion begins between said stylus mounting head and said support body and to track said relative motion until zero velocity is reached, whereby said output of said position detection circuit is processed by said computer numerical control to determine relative position of said object to said stylus when said probing device is moved in a plus or minus direction parallel to the axis of said spindle or in a direction perpendicular to the axis of said spindle until said stylus is deflected by said object.

18. A combination probing-boring device for computer numerically controlled machining centers having a spindle, a control rod, said control rod passing through said spindle, a sliding element, said control rod connected to said sliding element, a linear motor and transducer connected to said sliding element to control the position and force of said sliding element, a combination probe and adjustable boring tool mounted in said spindle for boring, measuring, and correcting the diameter of a bored hole without removing said combination tool from said spindle, said combination tool having a main operating body secured in said spindle, a preloaded adjustable boring bar, a cam bar, said cam bar secured, to one end of said boring bar, said boring bar pivotally secured to said operating body, a linear cam for controlling the position of said cam bar slidably mounted in said support body, a tool actuating rod secured to said linear cam, an actuating rod spring, said actuating rod spring maintaining said actuating rod and said linear cam in a fully retracted position, a boring head, said boring head secured to the end of said boring bar opposite said cam bar, a cutting tool mounted in said boring head, a probe stylus mounted in said boring head opposite said cutting tool, whereby said spindle control rod contacts said tool actuating rod during operation and overcomes the force of said actuating rod spring thereby determining the position of said tool actuating rod and said linear cam, a preload spring, said preload spring mounted at one end of said operating body to pivot said boring bar in a direction to oppose the forces of said linear cam operating on said cam bar, said linear cam engaging with said cam bar to pivot said boring bar to a preselected position to locate said cutting tool for controlling the diameter of said bored hole, said linear cam having two distinct cam angles, a lower cam angle, said lower cam angle being gradual to operate against said cam bar for the boring operations, an upper cam angle, said upper cam angle being steep and in a direction opposite lower cam angle to operate against said cam bar for the probing operation, whereby said spindle control rod positions said linear cam to engage said upper cam angle with said cam bar after a hole has been bored and combination tool has been retracted from said hole, the position of said linear cam determines an angle of said boring bar that provides clearance in said bored hole for said cutting tool and said probe stylus, said combination tool is advanced into said bored hole, said spindle control rod advances said linear cam to a point determined in a previous calibration procedure allowing said preload spring to pivot said boring bar until said stylus contacts the inside diameter of said bored hole, at this point said cam bar will not be in contact with any cam surface, current to said linear motor is reduced allowing actuating rod spring to position said linear cam until said upper cam makes contact with said cam bar but not causig said stylus to lose contact with bored hole. said linear cam position determines the position of said tool actuating rod, said spindle control rod, said sliding element and said transducer, said transducer position is then processed by said computer numerical control and compared to a position determined in a previous calibrating procedure to determine actual size of the bored hole.