WIRELESS CONTROL ASSEMBLY FOR CUTTING MACHINE

A technique provides for wireless control of a machine tool, e.g. a portable machine tool used on-site. According to an embodiment, a motor is connected with a tool post assembly via a gearbox. The motor is coupled with a machine controller, and the tool post assembly is mounted proximate an object to be machined. For example, the object may be machined via a cutting tool mounted to a cutter post of the tool post assembly. The machine controller operates to control movement of the cutter post along a desired axis during the cutting operation. The machine controller and thus the cutting operation, however, are controlled wirelessly according to control instructions provided via a control device, e.g. a handheld control device, which is placed in wireless communication with the machine controller.

FIELD OF DISCLOSURE

In general, the disclosure describes a control system by which a machine tool, e.g. a cutting tool, is controllable via a wireless control assembly. The wireless control assembly enables remote control of a rotational output and may be used to control the feed of a machine tool along a selected axis.

BACKGROUND OF DISCLOSURE

Various machining operations are relatively straightforward when carried out off-site and within a machine shop facility. An example of such a machining operation is flange refacing which is a process by which damaged or corroded steel flange surfaces are re-cut using lathe technology so that a flange surface may be brought back to an “as new” standard. However, such flange refacing operations and other machining operations are much more challenging when the components being machined remain on-site and connected to existing pipework or other infrastructure. A range of portable machines are available for a variety of cutting operations. When operating such portable machines, however, an operator often must reach into the machine while it is rotating to provide inputs, e.g. to adjust toolpost axial feed, and this manual interaction results in risk to the operator.

What is needed is a wireless control assembly which eliminates the direct interaction of an operator with the machine while it is rotating or otherwise operating.

SUMMARY

This summary is provided to introduce a selection of concepts that are further described below in the detailed description. However, many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

According to an embodiment, a system and methodology are provided for enabling wireless control of a machine tool, e.g. a portable machine tool used on-site. By way of example, a motor, e.g. a stepper motor, is connected with a tool post assembly via a gearbox. The motor is coupled with a machine controller, and the tool post assembly is mounted proximate an object to be machined. For example, the object may be machined via a cutting tool mounted to a cutter post of the tool post assembly. The machine controller operates to control movement of the cutter post along a desired axis during the cutting operation. The machine controller and thus the cutting operation, however, are controlled wirelessly according to instructions provided via a control device, e.g. a handheld control device, which is placed in wireless communication with the machine controller.

DETAILED DESCRIPTION

In the following description, numerous details are set forth to provide an understanding of some embodiments of the present disclosure. It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. However, it will be understood by those of ordinary skill in the art that the system and/or methodology may be practiced without these details and that numerous variations or modifications from the described embodiments are possible. This description is not to be taken in a limiting sense, but rather made merely for the purpose of describing general principles of the implementations. The scope of the described implementations should be ascertained with reference to the issued claims.

As used herein, the terms “connect”, “connection”, “connected”, “in connection with”, and “connecting” are used to mean “in direct connection with” or “in connection with via one or more elements”; and the term “set” is used to mean “one element” or “more than one element”. Further, the terms “couple”, “coupling”, “coupled”, “coupled together”, and “coupled with” are used to mean “directly coupled together” or “coupled together via one or more elements”. As used herein, the terms “up” and “down”; “upper” and “lower”; “top” and “bottom”; and other like terms indicating relative positions to a given point or element are utilized to more clearly describe some elements.

The present disclosure generally relates to a system and methodology for providing wireless control of a machine tool, e.g. a portable machine tool used on-site. According to an embodiment, a motor, e.g. a stepper motor, is connected with a tool post assembly which is used to control the movement of a tool, e.g. a cutting tool, along at least one axis. The motor may be connected with the tool post assembly via a gearbox. Additionally, the motor is coupled with a machine controller, and the tool post assembly is mounted proximate an object to be machined.

For example, the object may be machined via a cutting tool mounted to a cutter post of the tool post assembly. One type of application may involve the refacing of a flange associated with a pipe or other structure. The machine controller operates to control movement of the cutter post along a desired axis during the cutting operation. In some applications, the machine controller may be operated to control cutting depth along a linear cutting depth axis. The machine controller and thus the cutting operation, however, are controlled wirelessly according to control instructions provided via a control device, e.g. a handheld control device, which is placed in wireless communication with the machine controller. For example, an operator may provide control instructions to the handheld control device via a graphical user interface. Those control instructions may then be wirelessly relayed to the machine controller which, in turn, controls operation of the tool post assembly/cutting tool according to the inputs provided. Accordingly, an operator may control the feed along a given axis or provide other machining controls without physically interacting with the tool post assembly or cutting tool during the cutting operation.

The control scheme may be used for a variety of remote machine controls. For example, the control system may be used for indexing of a rotational output which may be used to control the feed along an axis of the machine tool. By implementing the wireless technology, an operator is able to remotely control machine output without the need for wired connections or interaction between man and machine while the machine is rotating or otherwise operating. The control system also may be used to enable system monitoring and interaction of safety protocols in the event of a signal loss. If the tool post assembly is used on-site with a lathe type cutter for refacing flanges, the flange being operated on may be held static while the lathe rotates within or outside the flange. However, the wireless system enables cut depth controls to be sent to the machine controller, thus allowing an operator to remain at a distance while controlling the cutting operation.

Referring generally toFIG.1, an embodiment of a wireless control system20is illustrated. In this example, the wireless control system20comprises a motive unit22having, for example, a motor24coupled to a gearbox26secured to a mounting bracket28. The motor24may be in the form of a stepper motor or other suitable motor providing a rotational output to gearbox26which, in turn, provides a rotational output via output shaft30. A machine controller32, e.g. a cut depth controller, is coupled with the stepper motor24(or other suitable motor) via a connection lead34which may be in the form of a cable or other suitable connection lead for transferring control commands from machine controller32to the motor24.

However, control instructions may be provided to the machine controller32wirelessly from a handheld control device36. By way of example, the handheld control device36may be in the form of a tablet, smart phone, or other remote, handheld computer type device. The handheld control device36comprises a mobile operator interface38, such as a graphical user interface (GUI), by which an operator may enter commands/instructions and receive data. The commands/instructions are transferred from handheld control device36to machine controller32and data is received from machine controller32via a wireless transmission protocol40. This enables an operator42to control motor24and to thus control a machining operation at a distance from the actual operation while also receiving pertinent data related to the machining operation.

With additional reference toFIG.2, the motor24may be connected to a tool post assembly44via the gearbox26and output shaft30. By way of example, the motor24and gearbox26may be secured to the tool post assembly44by the appropriately configured mounting bracket28. The tool post assembly44(along with motive unit22) is readily movable to a desired location, e.g. a worksite location, and is mountable proximate an object45, e.g. mountable directly to object45, to be machined or otherwise operated on. As further illustrated inFIG.3, the tool post assembly44may comprise a cutter post46on which an appropriate tool48, e.g. a cutting tool, is mounted for controlled movement with respect to object45according to the operation of motor24and corresponding rotational output of shaft30.

It should be noted the tool post assembly44may have a variety of configurations depending on the machining operation or other operation to be performed on object45. For example, the tool post assembly44may have a variety of gears, shafts, and/or mounting brackets configured to accommodate the intended machining operation or other operation on object45. In some machining operations, the tool post assembly44may have an output shaft/gear and appropriate mounting features for mounting and driving the tool post assembly44linearly along a supporting tool post structure. For other machining operations, the tool post assembly44may have cooperating components50(seeFIG.2) which enable mounting, positioning, and precisely controlled movement of tool48along a desired axis in response to operation of stepper motor24. For example, controlled operation of stepper motor24may be used to precisely control movement of cutter post46and thus cutting tool48along a cutting axis, e.g. to precisely control cut depth. These are just a few examples of various tool post assembly configurations which may be constructed to enable a given, controllable machining operation.

According to a specific example, cutting tool48is in the form of a lathe and the tool post assembly44is constructed as a portable unit which may be mounted on or adjacent object which, in this example, is in the form of a metal flange in need of refacing. The cooperating components50may be in the form of components which can slide or shift relative to each other to enable control over the depth of cut based on inputs from stepper motor44. The machine controller32provides signals to stepper motor24via connection lead34to precisely control the stepper motor24for achieving a desired depth of cut. However, an operator is able to select and adjust the control signals output by machine controller32according to instructions provided remotely via handheld device36. These control instructions are sent wirelessly from handheld device36to the machine controller32which then converts them into appropriate control commands for stepper motor24so as to precisely control the depth of cut on the flange or other object45.

InFIG.4, an exploded view is provided of one example of machine controller32which is able to wirelessly receive control commands/instructions from handheld device36and to wirelessly output data to the handheld device36. In this example, machine controller32comprises a stepper motor controller52configured for providing the machine control commands to stepper motor24. The stepper motor controller52may be mounted in a housing54.

Additionally, the machine controller32comprises a microcontroller56having a wireless transceiver58able to receive the wireless commands/instructions from handheld device36and to output data to handheld device36. The microcontroller56also is mounted within housing54. In this example, the machine controller32also comprises a battery pack or other self-contained power source for powering controllers52,56. By way of example, the battery pack60may be a rechargeable battery pack which is also mounted within housing54and closed in via a suitable housing cover62.

Depending on the specifics of the machining operation or other operation to be performed on object45, the operator interface38and corresponding control software and wireless communication software may have a variety of configurations suitable for use on handheld device36. InFIGS.5-8, examples of functionality that may be provided via operator interface38are shown although many other types of graphical user interfaces and many other types of control functionality may be implemented.

In the example illustrated inFIG.5, the operator interface38provides a startup screen having a screen header64which may comprise screen navigation buttons and a battery status monitor. Additionally, the operator interface38provides data entry and display fields66through which control data may be entered, e.g. cut depth and other cutting related data. The illustrated operator interface38also comprises main control buttons68. Examples of main control buttons68include a start button which initiates movement of the cutting tool48; a cut tool direction button (e.g. cutting tool in or cutting tool out); and an enable/disable button for selectively enabling the machine controller32.

InFIG.6, a settings screen of the operator interface38is illustrated. The settings screen may be used to provide various data/information70to the operator. Examples of such information include gearbox ratio, metric/imperial units, stepper motor pulse/revolution data, distance traveled data, speed data, and/or other desired data. The operator interface38also may be used to provide a device information screen72, as illustrated inFIG.7. Such a screen may be used to provide wireless interface data, project data, system power data, specific application data, and/or other desired data that may be useful to an operator.

InFIG.8, another screen example of operator interface38is illustrated. In this example, the screen may be used to output customer data74and cutting history data76. However, the operator interface38may be configured for enabling many types of command/instruction entry and for providing many types of data related to a given cutting operation or other operation.

Depending on the parameters of a machine operation, the configuration and use of overall wireless control system20may be adjusted. For example, the wireless control system may utilize various wireless interfaces for use between handheld device36and machine controller32. Additionally, various types of machine controllers32may be utilized according to the type of machine being controlled and the desired control functionality. Similarly, the tool post assembly44and the cutting tool48(or other type of tool) may be constructed and selected according to a variety of machining operations. Regardless of the specifics of the operation, however, the wireless control system20enables an operator to remotely control a desired operation on object45.

Although a few embodiments of the disclosure have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this disclosure. For example, the pipe isolation device of the present disclosure may be modified by adding additional sealing heads to become a triple, or more, block and bleed apparatus. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims. The scope of the invention should be determined only by the language of the claims that follow. The term “comprising” within the claims is intended to mean “including at least” such that the recited listing of elements in a claim are an open group. The terms “a,” “an” and other singular terms are intended to include the plural forms thereof unless specifically excluded.