PATENT DOCUMENT

Publication Number: US-10040153-B2
Application Number: US-201314078085-A
Country: US
Kind Code: B2

Title: Retrofit for current CNC machines to allow for ‘shaping’ style machining process

Abstract:
An apparatus configured to convert a rotary machine to a non-rotary machine is provided. The apparatus may include a tool body that engages a rotary head of a CNC mill and a rotation restraint member that is fixed at a stationary position relative to a rotational axis of the rotary head. An arm of the tool body may engage the rotation restraint member to prevent rotation of the tool body. A cutting tool may be coupled to the tool body such that rotation thereof is also fixed. The arm of the tool body may include an elongated aperture that allows for slight pivoting of the tool body and the cutting tool to facilitate chip removal and cutting in opposing directions. Related methods are also provided.

Claims:
What is claimed is: 
     
       1. A tool configured to be coupled to a rotary machine and to remove material from a substrate, the rotary machine including a rotary head and a rotation restraint member, the tool comprising:
 a tool body, comprising:
 a machine connector configured to engage the rotary head, and 
 an arm configured to extend substantially perpendicularly to a rotational axis of the rotary head, the arm including an elongated aperture arranged to accept a protrusion of the rotation restraint member, wherein during a cutting operation, the arm pivots about the rotational axis according to (i) a first angular limit that corresponds to a position where the protrusion contacts a first end of the elongated aperture, and (ii) a second angular limit that corresponds to a position where the protrusion contacts a second end of the elongated aperture that is opposite to the first end; and 
 
 a cutting tool that is arranged to (i) pivot along with the arm about the rotational axis, and (ii) be detachably connected to the tool body. 
 
     
     
       2. The tool of  claim 1 , wherein the cutting tool includes first and second cutting edges. 
     
     
       3. The tool of  claim 2 , wherein when the first cutting edge is cutting the substrate, the second cutting edge is retracted from the substrate. 
     
     
       4. The tool of  claim 1 , wherein the tool body further comprises an end effector connector that is detachably connected to the cutting tool. 
     
     
       5. The tool of  claim 1 , wherein a pivot motion of the arm is initiated by contact between the cutting tool and the substrate. 
     
     
       6. A method of removing material from a substrate using a rotary machine having a rotary head and a rotation restraint member, the method comprising:
 coupling a machine connector of a tool body to the rotary head, the tool body including an arm extending substantially perpendicularly to a rotational axis of the rotary head, wherein the arm includes (i) an elongated aperture, and (ii) a cutting tool detachably coupled to the tool body that is arranged to pivot along with the arm about the rotational axis; 
 coupling the arm of the tool body to the rotation restraint member such that a protrusion of the rotation restraint member is positioned between a first end of the elongated aperture and an opposing second end of the elongated aperture; and 
 removing the material from the substrate by pivoting the cutting tool along with the arm about the rotational axis during a material removal operation, wherein during the material removal operation, the arm pivots about the rotational axis according to (i) a first angular limit that corresponds to a position where the protrusion contacts the first end of the elongated aperture, and (ii) a second angular limit that corresponds to a position where the protrusion contacts the second end of the elongated aperture. 
 
     
     
       7. The method of  claim 6 , wherein a longitudinal axis of the arm extends substantially perpendicular to a longitudinal axis of the machine connector. 
     
     
       8. The method of  claim 6 , further comprising:
 coupling the cutting tool to an end effector connector of the tool body. 
 
     
     
       9. The method of  claim 6 , further comprising:
 decoupling a rotary tool from the rotary head prior to coupling the machine connector of the tool body to the rotary head. 
 
     
     
       10. A method of removing material from a substrate by using a rotary machine having a rotary head and a rotation restraint member, the method comprising:
 coupling a tool body to the rotary head via a machine connector of the tool body, the machine connector configured to engage the rotary head, wherein the tool body includes an arm extending substantially perpendicular to a rotational axis of the rotary head, and the arm includes an elongated aperture and a cutting tool detachably coupled to the tool body, wherein the cutting tool is arranged to pivot along with the arm about the rotational axis and is detachably connected to the tool body; 
 coupling the arm to the rotation restraint member such that a protrusion of the rotation restraint member is positioned between a first end of the elongated aperture and an opposing second end of the elongated aperture; and 
 translating the cutting tool with respect to the substrate to remove the material from the substrate during a material removal operation, wherein during the material removal operation, the arm pivots about the rotational axis according to (i) a first angular limit that corresponds to a position where the protrusion contacts the first end of the elongated aperture, and (ii) a second angular limit that corresponds to a position where the protrusion contacts the second end of the elongated aperture. 
 
     
     
       11. The method of  claim 10 , wherein translating the cutting tool with respect to the substrate comprises engaging a first cutting edge of the cutting tool with the substrate and retracting a second cutting edge of the cutting tool from the substrate. 
     
     
       12. The method of  claim 11 , wherein translating the cutting tool with respect to the substrate comprises engaging the second cutting edge of the cutting tool with the substrate and retracting the first cutting edge of the cutting tool from the substrate. 
     
     
       13. The method of  claim 10 , wherein the pivot motion of the arm provides clearance for chips of material to be removed from the substrate. 
     
     
       14. The method of  claim 10 , further comprising coupling the cutting tool with an end effector of the tool body. 
     
     
       15. A tool configured to be coupled to a rotary machine for removing material from a substrate, the rotary machine including a rotary head and a rotation restraint member, the tool comprising:
 a tool body including (i) a machine connector configured to engage the rotary head, and (ii) an arm extending substantially perpendicular to a rotational axis of the rotary head, wherein the arm includes an elongated aperture capable of receiving a protrusion of the rotation restraint member; and 
 a cutting tool detachably connected to the tool body and the cutting tool is capable of rotating along with the arm during a material removal operation, wherein during the material removal operation, the arm is capable of pivoting with respect to the rotary head in a direction perpendicular to the rotational axis, and the cutting tool includes (i) a first cutting edge, and (ii) a second cutting edge opposite the first cutting edge, and during the material removal operation, the arm pivots about the rotational axis such that the first cutting edge is arranged to remove the material from the substrate in accordance with the arm pivoting according to a first angular limit that corresponds to a position where the protrusion contacts a first end of the elongated aperture, and the second cutting edge is arranged to remove the material from the substrate in accordance with the arm pivoting according to a second angular limit that corresponds to a position where the protrusion contacts a second end of the elongated aperture that is opposite to the first end. 
 
     
     
       16. The tool of  claim 15 , wherein the first and second cutting edges are laterally displaced from the rotational axis. 
     
     
       17. The tool of  claim 15 , wherein the rotation restraint member is parallel to the rotational axis. 
     
     
       18. The tool of  claim 15 , wherein the cutting tool is characterized as having a triangular shape and the first and second cutting edges correspond to sides of the triangular shape. 
     
     
       19. The tool of  claim 15 , wherein a rotational motion of the cutting tool is initiated by contact between the cutting tool and the substrate. 
     
     
       20. The tool of  claim 15 , wherein during the material removal operation, when the arm pivots according to the first angular limit, the second cutting edge is arranged to retract from the substrate.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of priority from U.S. Provisional Patent Application No. 61/899,816, filed on Nov. 4, 2013, which is hereby incorporated herein by reference in its entity. 
     FIELD 
     The present disclosure relates generally to cutting tools, and more particularly to an apparatus configured to convert a rotary machine to a non-rotary machine and a related non-rotary tool. 
     BACKGROUND 
     Components employed to form various devices such as computing devices often undergo numerous manufacturing operations during the production thereof. Additive manufacturing processes add material to form a component. By way of example, injection molding may be employed to form a component. Conversely, subtractive manufacturing processes remove material from a workpiece or substrate to form a component. For example, material may be machined from a substrate to form the component. In some embodiments additive and subtractive processes may both be employed to form a component, depending on the particular desired final configuration of the component. 
     Computer numerical control (CNC) machining is one example of a type of subtractive manufacturing process commonly employed to form components. CNC machining typically employs a robotic assembly and a controller. The robotic assembly typically may include a rotating spindle to which a milling cutter is coupled. The milling cutter includes cutting edges that remove material from a substrate to form a component defining a desired shape and dimensions. In this regard, the controller directs the robotic assembly to move the milling cutter along a machining path that forms the component. 
     However, CNC machining may not be configured to or capable of forming certain desired shapes of components. Accordingly, improved methods for machining may be desirable. 
     SUMMARY 
     Embodiments of the present disclosure relate to an apparatus configured to convert a rotary machine to a non-rotary machine. Thus, for example, a CNC mill may be employed to scrape or otherwise remove material from a substrate without employing a rotary tool. The apparatus may include a tool body that engages a rotary head of the CNC mill. The apparatus may additionally include a rotation restraint member. The rotation restraint member may engage a stationary member, such as a body of the CNC mill, and thereby the rotation restraint member may be positioned at a fixed distance from the rotary head. The tool body may include an arm that engages the rotation restraint member and thereby a cutting tool coupled to the tool body may be prevented from rotating. 
     More particularly a protrusion defined by the rotation restraint member may engage an aperture in the arm of the tool body, or vice versa. The aperture may be elongated in one embodiment such that the protrusion may move slightly within the aperture. Thereby, the cutting tool may pivot slightly. This pivoting movement may allow a rear cutting edge of the cutting tool to retract from a substrate being cut with a front cutting edge to allow a clearance for removal of chips and other removed material. 
     Other apparatuses, methods, features and advantages of the disclosure will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the disclosure, and be protected by the accompanying claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The included drawings are for illustrative purposes and serve only to provide examples of possible structures and arrangements for the disclosed apparatuses, assemblies, methods, and systems. These drawings in no way limit any changes in form and detail that may be made to the disclosure by one skilled in the art without departing from the spirit and scope of the disclosure. 
         FIG. 1  illustrates a front facing perspective view of an embodiment of the portable computing device in a closed configuration according to an example embodiment of the present disclosure; 
         FIG. 2  illustrates the portable computing device of  FIG. 1  in an open configuration according to an example embodiment of the present disclosure; 
         FIG. 3  illustrates a bottom perspective view of a top case of a base portion of the portable computing device of  FIG. 1  according to an example embodiment of the present disclosure; 
         FIG. 4  illustrates a bottom view of the portable computing device of  FIG. 1  according to an example embodiment of the present disclosure; 
         FIG. 5  schematically illustrates a computer numerical control (CNC) mill including a rotary cutter according to an embodiment of the present disclosure; 
         FIG. 6  illustrates the rotary cutter cutting a substrate according to an example embodiment of the present disclosure; 
         FIG. 7  schematically illustrates a material removal system comprising a non-rotary tool including a tool body and a cutting tool according to an example embodiment of the present disclosure; 
         FIG. 8  illustrates a side view of the tool body of  FIG. 7  according to an example embodiment of the present disclosure; 
         FIG. 9  illustrates a perspective view of the tool body of  FIG. 7  according to an example embodiment of the present disclosure; 
         FIG. 10  illustrates a side view of a carousel of the material removal system of  FIG. 7  with the tool body received in a slot therein according to an example embodiment of the present disclosure; 
         FIG. 11  illustrates a perspective view of a rotation restraint member of the material removal system of  FIG. 7  according to an example embodiment of the present disclosure; 
         FIG. 12  illustrates a partial side view of the material removal system with the tool body engaged with the rotation restraint member according to an example embodiment of the present disclosure; 
         FIG. 13  schematically illustrates a side view of the material removal system with the tool body engaged with the rotation restraint member according to an example embodiment of the present disclosure; 
         FIG. 14  illustrates a top view of the non-rotary tool of  FIG. 7  according to an example embodiment of the present disclosure; 
         FIG. 15  illustrates a top view of the non-rotary tool of  FIG. 7  moving in a first direction according to an example embodiment of the present disclosure; 
         FIG. 16  illustrates a top view of the non-rotary tool of  FIG. 7  moving in a second direction according to an example embodiment of the present disclosure; 
         FIG. 17  schematically illustrates a method for converting a rotary machine to non-rotary machine according to an example embodiment of the present disclosure; 
         FIG. 18  schematically illustrates a manufacturing method according to an example embodiment of the present disclosure; and 
         FIG. 19  schematically illustrates a block diagram of an electronic device according to an example embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Representative applications of systems, apparatuses, computer program products and methods according to the presently described embodiments are provided in this section. These examples are being provided solely to add context and aid in the understanding of the described embodiments. It will thus be apparent to one skilled in the art that the presently described embodiments can be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order to avoid unnecessarily obscuring the presently described embodiments. Other applications are possible, such that the following examples should not be taken as limiting. 
     As described in detail below, the following relates to manufacturing tools, assemblies, apparatuses, systems, devices, computer program products, and methods. Embodiments of the disclosure may be employed to form a variety of components including, for example, electronic devices. By way of more specific example, the manufacturing methods disclosed herein may be employed in manufacturing a computing device such as a desktop computer, a laptop computer, a net book computer, a tablet computer, a cellphone, a smartphone, etc., or any accessory therefor such as a keyboard and a monitor. Thus, purely for purposes of example, embodiments of a portable computing device that may be formed by these manufacturing methods are described and illustrated herein. However it should be understood that various other embodiments of devices may be formed using the tools, assemblies, apparatuses, systems, devices, computer program products, and methods of the present disclosure. 
     In one embodiment a portable computing device can include a multi-part housing having a top case and a bottom case joining at a reveal to form a base portion. The portable computing device can have an upper portion (or lid) that can house a display screen and other related components whereas the base portion can house various processors, drives, ports, battery, keyboard, touchpad and the like. The top case and the bottom case can each be joined in a particular manner at an interface region such that the gap and offset between top and bottom cases are not only reduced, but are also more consistent from device to device during the mass production of devices. 
     In a particular embodiment, the lid and base portion can be pivotally connected with each other by way of what can be referred to as a clutch assembly. The clutch assembly can include at least a cylindrical portion that in turn includes an annular outer region, and a central bore region surrounded by the annular outer region, the central bore suitably arranged to provide support for electrical conductors between the base portion and electrical components in the lid. The clutch assembly can also include a plurality of fastening regions that couple the clutch to the base portion and the lid of the portable computing device with at least one of the fastening regions being integrally formed with the cylindrical portion such that space, size and part count are minimized. 
     The top case can include a cavity, or lumen, into which a plurality of operational components can be inserted during an assembly operation. In the described embodiment, the operational components can be inserted into the lumen and attached to the top case in a “top-bottom” assembly operation in which top most components are inserted first followed by components in a top down arrangement. For example, the top case can be provided and shaped to accommodate a keyboard module. The keyboard module can include a keyboard assembly formed of a plurality of keycap assemblies and associated circuitry, such as a flexible membrane on which can be incorporated a switching matrix and protective feature plate. Therefore, following the top-bottom assembly approach, the keyboard assembly is first inserted into the top case followed by the flexible membrane and then the feature plate that is attached to the top case. Other internal components can then be inserted in a top to bottom manner (when viewed from the perspective of the finished product). 
     In one embodiment, the keyboard module can be configured in such a way that a keycap assembly can be used to replace a power switch. For example, in a conventional keyboard each of a top row of keycaps can be assigned at least one function. However, by re-deploying one of the keycaps as a power button, the number of operational components can be reduced by at least eliminating the switch mechanism associated with the conventional power button and replacing it with the already available keycap assembly and associated circuitry. 
     In addition to the keyboard, the portable computing device can include a touch sensitive device along the lines of a touch pad, touch screen, etc. In those embodiments where the portable computing device includes a touch pad the touch pad can be formed from a glass material. The glass material provides a cosmetic surface and is the primary source of structural rigidity for the touchpad. The use of the glass material in this way significantly reduces the overall thickness of the touchpad compared to previous designs. The touchpad can include circuitry for processing signals from a sensor associated with the touchpad. In one embodiment, the circuitry can be embodied as a printed circuit board (PCB). The PCB can be formed of material and placed in such a way that it provides structural support for the touchpad. Thus, a separate touchpad support is eliminated. 
     In one embodiment, the top case can be formed from a single billet of aluminum that is machined into a desired shape and size. The top case can include an integrated support system that adds to the structural integrity of the top case. The integrated support system can be continuous in nature in that there are no gaps or breaks. The integrated support system can be used to provide support for individual components (such as a keyboard). For example, the integrated support system can take the form of ribs that can be used as a reference datum for a keyboard. The ribs can also provide additional structural support due to the added thickness of the ribs. The ribs can also be used as part of a shield that helps to prevent light leaking from the keyboard as well as act as a Faraday cage that prevents leakage of extraneous electromagnetic radiation. 
     The continuous nature of the integrated support system can result in a more even distribution of an external load applied to the multi-part housing resulting in a reduced likelihood of warping, or bowing that reduces risk to internal components. The integrated support system can also provide mounting structures for those internal components mounted to the multi-part housing. Such internal components include a mass storage device (that can take the form of a hard disk drive, HDD, or solid state drive, SSD), audio components (audio jack, microphone, speakers, etc.) as well as input/output devices such as a keyboard and touch pad. 
     These and other embodiments are discussed below with reference to  FIGS. 1-4 . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes only. 
       FIG. 1  illustrates a portable computing device  100  in the form of a laptop computer in accordance with an example embodiment of the present disclosure. More particularly,  FIG. 1  shows a front facing perspective view of the portable computing device  100  in a closed configuration. As illustrated, the portable computing device  100  may include a housing  102  comprising a base portion  104  and a lid portion  106 . In the closed configuration, the lid portion  106  and the base portion  104  form what appears to be a uniform structure having a continuously varying and coherent shape that enhances both the look and feel of the portable computing device  100 . In some embodiments portable computing device  100  may include a logo  108  at a rear case  110  of the lid portion  106  of the housing  102 . In one embodiment, the logo  108  can be illuminated by light emitted from a display  112  (see, e.g.,  FIG. 2 ). 
     The base portion  104  can be pivotally connected to the lid portion  106  by way of a hinge that may include a clutch assembly in some embodiments. The base portion  104  may include an inset portion  114  suitable for assisting a user in lifting the lid portion  106  by, for example, a finger. Accordingly, the lid portion  106  of the housing  102  can be moved with respect to the base portion  104  of the housing with the aid of the clutch assembly from a closed position (see, e.g.,  FIG. 1 ) to an open position (see, e.g.,  FIG. 2 ). 
       FIG. 2  shows a front facing perspective view of the portable computing device  100  in the open configuration. The display  112  may be coupled to the rear case  110  of the lid portion  106  such that the display is provided with structural support. In this regard, the lid portion  106  can be formed to have uni-body construction provided by the rear case  110  that can provide additional strength and resiliency to the lid portion which is particularly important due to the stresses caused by repeated opening and closing. In addition to the increase in strength and resiliency, the uni-body construction of the lid portion  106  can reduce overall part count by eliminating separate support features, which may decrease manufacturing cost and/or complexity. 
     The lid portion  106  may include a mask (also referred to as display trim)  116  that surrounds the display  112 . The display trim  116  can be formed of an opaque material such as ink deposited on top of or within a protective layer of the display  112 . Thus, the display trim  116  can enhance the overall appearance of display  112  by hiding operational and structural components as well as focusing attention onto the active area of the display. 
     The display  112  can display visual content such as a graphical user interface, still images such as photos as well as video media items such as movies. The display  112  can display images using any appropriate technology such as a liquid crystal display (LCD), a light emitting diode (LED) display, an organic light emitting diode (OLED) display, etc. Further, the portable computing device  100  may include an image capture device  118 . In one embodiment the image capturing device  118  may be located on a transparent portion of the display trim  116 . The image capture device  118  can be configured to capture both still and video images in some embodiments. 
     The base portion  104  may comprise a top case  120  (see, e.g.,  FIG. 3 ) fastened to a bottom case  122  (see, e.g.,  FIG. 4 ). As illustrated in  FIG. 2 , the top case  120  can be configured to accommodate various user input devices such as a keyboard  124  and a touchpad  126 . The keyboard  124  can include a plurality of low profile keycap assemblies  128 . In one embodiment, an audio transducer (not shown) can use selected portions of keyboard  124  to control output audio signals such as music. One or more microphones  130  can be located on the lid portion  106 . The microphones  130  may be spaced apart to improve frequency response of an associated audio circuit. 
     Each of the plurality of keycap assemblies  128  can have a symbol imprinted thereon for identifying the key input associated with the particular key pad. The keyboard  124  can be arranged to receive a discrete input at each keycap assembly  128  using a finger motion referred to as a keystroke. In the described embodiment, the symbols on each keycap assembly  128  can be laser etched thereby creating an extremely clean and durable imprint that will not fade under the constant application of keystrokes over the life of portable computing device  100 . In order to reduce component count, one of the keycap assemblies  128  can be re-provisioned as a power button. In this way, the overall number of components in the portable computing device  100  can be commensurably reduced. 
     The touchpad  126  can be configured to receive finger gesturing. A finger gesture can include touch events from more than one finger applied in unison. The gesture can also include a single finger touch event such as a swipe or a tap. The gesture can be sensed by a sensing circuit in the touchpad  126  and converted to electrical signals that are passed to a processing unit for evaluation. In this way, portable computing device  100  can be at least partially controlled by touch. 
     One or more data ports  132 ,  134 ,  136  can be used to transfer data and/or power between an external circuit(s) and the portable computing device  100 . The data ports can include, for example, an input slot  132  that can be used to accept a memory card (such as a FLASH memory card), whereas the remaining data ports  134 ,  136  can be used to accommodate data connections such as USB, FireWire, Thunderbolt, and so on. Further, in some embodiments, one or more speaker grids  137  can be used to output audio from an associated audio component enclosed within base portion  104  of the housing  102 . 
       FIG. 3  illustrates a perspective bottom view of the top case  120  of the base portion  104  of the housing  102 . As illustrated, the top case  120  may comprise a major wall  138  and an outer rim  140  extending therefrom. A plurality of vents  142  may be defined in the top case  120 . For example, the vents  142  are defined in the outer rim  140  in the illustrated embodiment. The vents  142  may be configured to provide a flow of outside air that can be used to cool internal components by allowing air to enter or exit therethrough. For example, the vents  142  in the outer rim  140  may comprise intake vents and a plurality of vents  144  defined in a rear wall  146  may comprise exhaust vents. In another embodiment the vents  142  in the outer rim  140  can act as a secondary air intake subordinate to primary air intake vents or the vents in the outer rim may comprise exhaust vents. 
     The vents  142  in the outer rim  140  can also be used to output audio signals in the form of sound generated by an audio module. Accordingly, the vents  142  can be used to output sound at a selected frequency range in order to improve quality of an audio presentation by the portable computing device  100 . Additionally, the vents  142  in the outer rim  140  can be part of an integrated support system for the top case  120 . In this regard, internal ribs  148  may be positioned within the vents  142  and/or external ribs  150  may be positioned between the vents to provide additional structural support to the portable computing device  100 . In some embodiments the vents  142  may be machined from the material defining the top case  120  with the ribs  148 ,  150  comprising retained material. 
     The cadence and size of the vents  142  can be used to control air flow into portable computing device  100  as well as control emission of radio frequency (RF) energy in the form of electromagnetic interference (EMI) from the portable computing device. In this regard, the internal ribs  148  can separate an area within the vents  142  to produce an aperture sized to reduce passage of RF energy. The size of an aperture defined by each of the vents  142  may dictate the wavelength of RF energy that can be “trapped” by the aperture. In this case, the size of vents  142  is such that a substantial portion of RF energy emitted by internal components can be trapped within the portable computing device  100 . Furthermore, by placing vents  142  at a downward facing outer surface of the top case  120 , the aesthetics of portable computing device  100  can be enhanced since views of internal components from an external observer are eliminated during normal use. 
     As illustrated, the rear wall  146  may extend from the major wall  138 . The rear wall  146  may be configured to hide the clutch at the hinge between the base portion  104  and the lid portion  106  of the housing  102 . A plurality of inner sidewalls  152   a - d  may also extend from the major wall  138 . The inner sidewalls  152   a - d  may divide an interior space defined by the base portion  104  into a plurality of compartments  154   a - d.    
     As schematically illustrated in  FIG. 3 , the portable computing device  100  may include a plurality of electronic components  156 , which may be received in one or more of the compartments  154   a - d . As may be understood, by way of example, the electronic components  156  may include a mass storage device (e.g., a hard drive or a solid state storage device such as a flash memory device including non-transitory and tangible memory that may be, for example, volatile and/or non-volatile memory) configured to store information, data, files, applications, instructions or the like, a processor (e.g., a microprocessor or controller) configured to control the overall operation of the portable electronic device, a communication interface configured for transmitting and receiving data through, for example, a wired or wireless network such as a local area network (LAN), a metropolitan area network (MAN), and/or a wide area network (WAN), for example, the Internet, a fan, a heat pipe, and one or more batteries. However, various other electronic components may additionally or alternatively be received in the housing  102  of the portable electronic device as may be understood by one having skill in the art. 
       FIG. 4  shows an external view of the bottom of the bottom case  122  of the base portion  104  of the housing  102 . One or more fasteners  158  may be positioned at the bottom case  122  of the base portion  104  of the housing  102 . The fasteners  158  may be configured to secure the bottom case  122  to the top case  120  to enclose the above-described electronic components  156 . 
     Additionally, in some embodiments the portable computing device  100  may include one or more bumpers. Bumpers may serve a variety of purposes. In this regard, in the illustrated embodiment the portable computing device  100  includes bumpers in the form of feet  160  coupled to an outer surface  162  of the bottom case  122  of the base portion  104  of the housing  102 . 
     Devices such as the above-described portable computing device  100  may be produced by machining a substrate to define one or more components thereof. For example, computer numerical control (CNC) machining may be employed to form components of the portable computing device  100 . By way of more particular example, a CNC mill may be employed to form components of the portable computing device  100 . 
     In this regard,  FIG. 5  illustrates an example embodiment of a CNC mill  200  according to an example embodiment of the present disclosure. In one embodiment the CNC mill  200  may comprise a 3-axis vertical mill available from FANUC Corporation of Oshino-mura, Japan. However, various other embodiments of CNC mills may be employed in accordance with embodiments of the present disclosure. 
     As illustrated, the CNC mill  200  may include a machine body  202 , which may be stationary or configured to move in one or more directions (e.g., due to coupling to moveable arms). The CNC may further comprise a motor  204  configured to rotate a rotary head  206  coupled thereto via a spindle  208 . The rotary head  206  may couple to a rotary tool  210  such as any of various milling cutters. A machining table  212  may be configured to support a workpiece or substrate  214 . The machining table  212  may be stationary or configured to move in one or more directions. Further, the CNC mill  200  may include a controller  216 . 
     Accordingly, the controller  216  may direct the motor  204  to rotate, which may in turn rotate the spindle  208 , the rotary head  206 , and the rotary tool  210  coupled thereto. Further, the controller  216  may direct movement of the rotary tool  210  relative to the substrate  214 . For example, the machining table  212  may move the substrate  214  or the CNC mill  200  may move the body  202  and/or other portion of the CNC mill to move the rotary tool  210 . In the illustrated embodiment the CNC mill  200  further comprises a carousel  218  including various slots  220  configured to hold additional rotary tools. Thereby, the carousel  218  may rotate to swap the rotary tool  210  with another rotary tool to perform various differing operations on the substrate  214  and/or replace worn rotary tools. 
     Accordingly, the CNC mill  200  may remove material from the substrate  214  to form a component. For example, the substrate  214  may be machined to form the above-described top case  120  of the base portion  104  of the housing  102 . However, depending on the characteristics of the rotary tool  210  and the desired shape of the component, the rotary tool may be incapable of removing material from the substrate  214  to the desired extent. In this regard, as illustrated in  FIGS. 5 and 6 , after machining the substrate  214  with the rotary tool  210  of the CNC mill  200 , certain remaining material sections  222  may exist. As illustrated in  FIG. 6 , the remaining material sections  222  may result from the rotary tool  210  defining a round cross-section perpendicular to a rotational axis thereof. Accordingly, the rotary tool  210  may be incapable of forming square corners in the substrate  214 . Instead, the remaining material sections  222 , defining a rounded configuration, may be present at the desired corners. 
     In the production of some embodiments of components, formation of rounded corners may not be of concern. However, in other embodiments of components, rounded corners may detrimentally affect the product produced therefrom. For example, in the portable computing device  100  described above, rounded corners between the inner sidewalls  152   a - d  may result in a reduction in volume of the compartments  154   a - d  (see, e.g.,  FIG. 3 ). Thereby, the size of the electronic components  156  received in the compartments  154   a - d  may have to be reduced. Thus, the size of a battery or a hard drive received in one of the compartments  154   a - d  may have to be reduced, with a respective reduction in memory or battery capacity. Accordingly, it may be important to produce square corners or otherwise remove material to meet component specifications (e.g., in the context of a blind pocket). Further, it may be desirable to produce components defining configurations that may be difficult to produce using a rotary tool (e.g., a pocket defined in a substrate bound on either side by two integral walls). 
     Certain existing technologies may allow for removal of material from locations that may be difficult or impossible to remove using a rotary tool. For example, Electro Chemical Machining (ECM) is a process wherein material is removed by controlled dissolution. More particularly, metal particles are removed by the application of electrical power and a saline solution, which washes away the removed particles. Further, material removal may also be accomplished via Electric Discharge Machining (EDM), which is also known as spark erosion. EDM functions by inducing a spark between an electrode and the substrate that results in a very small crater on the surface thereof. By producing repetitive sparks, more material is removed, and the waste material may then be washed away. Like ECM the material closest to the electrode is affected first. 
     However, ECM, EDM, and other similar methods of removing material are relatively slow. Further, ECM and EDM typically require removal of the substrate from the CNC mill to perform these operations, resulting in additional manufacturing complexities and manufacturing time. Accordingly, improved material removal processes may be desirable. 
     In this regard,  FIG. 7  illustrates an example embodiment of a material removal system  300  according to an example embodiment of the present disclosure. As illustrated, in one embodiment the material removal system  300  may include some or all of the components of the CNC mill  200  described above. In this regard, one embodiment of the present disclosure is configured to retrofit existing CNC mills to include additional or alternative functionality. 
     One embodiment of the present disclosure is configured to convert a rotary machine (e.g., a CNC mill) to operate as a non-rotary machine, as described hereinafter. In this regard, the system  300  may further comprise a rotation restraint member  302  and a non-rotary tool  304  configured to remove material from a substrate (e.g., substrate  214 ). As illustrated, the non-rotary tool  304  may initially be received in one of the slots  220  in the carousel  218 . In this regard, the non-rotary tool  304  may comprise a cutting tool  306  and a tool body  308 , wherein the tool body is configured to engage one of the slots  220  in the carousel  218 . In some embodiments the cutting tool may be integral with the tool body. However, in other embodiments the cutting tool  306  may be detachable from the tool body  308 . 
     In this regard,  FIGS. 8 and 9  illustrate the tool body  308  separated from the cutting tool  306 . As illustrated, the tool body  308  may comprise a machine connector  310  configured to engage the rotary head  206  of the CNC mill  200 . In this regard, the machine connector  310  may include any feature associated with a typical tool connector configured to engage the rotary head  206 . The tool body  308  may further comprise an arm  312 . The arm  312  may be configured to extend substantially perpendicularly to a rotational axis of the rotary head  206 . In this regard, as illustrated, the arm  312  may extend substantially perpendicularly to the machine connector  310 . As used herein, substantially perpendicular extension of the arm  312  refers to a configuration in which the end of the arm is displaced from the rotational axis of the tool body  308  and the rotary head  206  to which the tool body is configured to connect. Thus, the arm  312  need not extend at a right angle with respect to the machine connector  310  in all embodiments. 
     Additionally, the tool body  308  may comprise an end effector connector  314 . The end effector connector  314  may be configured to engage the cutting tool  306 . In this regard, for example, the end effector connector  314  may comprise a so-called “chuck,” or any other embodiment of connector configured to engage a tool. 
       FIG. 10  illustrates the tool body  308  engaged with one of the slots  220  in the carousel  218 . As illustrated, in some embodiments the tool body  308  may be stored in the slot  220  separately from the cutting tool  306 . However, in another embodiment the cutting tool  306  may be coupled to the tool body  308  when the tool body is received in the slot  220  in the carousel  218  (see, e.g.,  FIG. 7 ). Thereby, when the carousel  218  is rotated and the tool body  308  is transferred from the carousel to the rotary head  206 , the non-rotary tool  304  may be ready for use. 
       FIG. 11  illustrates the rotation restraint member  302 . As illustrated, the rotation restraint member  302  may be coupled to the body  202  of the CNC mill. For example, the rotation restraint member  302  may be coupled thereto via one or more bolts extending through existing bolt holes. Accordingly, the CNC mill may be relatively easily retrofitted to include the rotation restraint member  302 . However, the rotation restraint member  302  may be coupled in any manner to a portion of the CNC mill that is positioned at a fixed distance from the rotational axis of the rotary head  206 . 
     The rotation restraint member  302  may comprise a protrusion  316  (see, e.g.,  FIG. 11 ). Further, the arm  312  of the tool body  308  may comprise an aperture  318  (see, e.g.,  FIG. 9 ). Note that in another embodiment the rotation restraint member may comprise the aperture and the arm may comprise the protrusion. Regardless, as illustrated in  FIG. 12 , the arm  312  of the tool body  308  may engage the rotation restraint member  302  when the machine connector  310  is coupled to the rotary head  206  of the CNC mill. For example, the arm  312  may engage the rotation restraint member  302  when the cutting tool  210  is removed from the rotary head  206  (e.g., received in one of the slots  220  in the carousel  218 ) and the tool body  308  is transferred from one of the slots in the carousel to the rotary head  206 . Further, as described above, the rotation restraint member  302  may be coupled to the body  202  of the CNC mill or other component or structure such that the rotation restraint member is positioned at a fixed location. Accordingly, the rotation restraint member  302  may restrain rotary motion of the tool body  308  when the tool body is coupled to the rotary head  206  and engaged with the rotation restraint member. 
     Further, the cutting tool  306  may couple to the end effector connector  314  such that the cutting tool is rotationally fixed with respect to the tool body  308 . Thereby, as illustrated in  FIG. 13 , the cutting tool  306  may be rotationally restrained and the system  300  may be ready for use in removing material from the substrate  214 . Accordingly, the cutting tool  306  may be moved (e.g., translated) with respect to the substrate  214  such that the cutting tool contacts the substrate and removes material therefrom. In this regard, the cutting tool  306  may be configured to scrape against the substrate  214  to remove material therefrom. For example, the cutting tool  306  may remove the remaining material sections  222  by scraping thereagainst. In one embodiment the machining table  212  may move the substrate  214  relative to the cutting tool  306  to remove the material. However, in an alternative embodiment the substrate  214  may be stationary and the CNC mill may move the non-rotary tool  304  with respect thereto, or both the non-rotary tool and the substrate  214  may move. 
     In some embodiments the non-rotary tool  304  may include certain features configured to facilitate removal of material from a substrate. In this regard,  FIG. 14  illustrates a top view of the non-rotary tool  304 . As illustrated, in one embodiment the aperture  318  in the arm  312  may be elongated. More particularly, the aperture  318  in the arm  312  may be elongated relative to the dimensions of the protrusion  316  of the rotation restraint member  302 . Accordingly, as illustrated, the tool body  308  and the cutting tool  306  may rotate slightly between first and second angular limits  320   a ,  320   b  defined by contact between first and second ends  322   a ,  322   b  of the aperture  318  and the protrusion  316  of the stationary member. Accordingly, the non-rotary tool  304  may be configured to pivot within a limited angular range  324  about the rotational axis of the rotary head  206 . Note, as described above, in an alternative embodiment the aperture may be defined in the rotation restraint member and the arm of the tool body may define the protrusion. In this embodiment, movement of the non-rotary tool within the limited angular range may be accomplished in a similar manner by employing an elongated aperture in the rotation restraint member. 
     As further illustrated in  FIG. 14 , in some embodiments the cutting tool  306  may include first and second cutting edges  326   a ,  326   b .  FIG. 15  illustrates cutting the substrate  214  with the first cutting edge  326   a . Conversely,  FIG. 16  illustrates cutting the substrate with the second cutting edge  326   b.    
     More particularly,  FIG. 15  illustrates movement of the non-rotary tool  304  relative to the substrate  214  in a first direction  328 , whereby the cutting tool  306  may remove one of the remaining material sections  222 . As illustrated, contact between the substrate  214  and a first cutting edge  326   a  of the cutting tool  306  may cause the non-rotary tool  304  to pivot such that the first end  322   a  of the aperture  318  comes into contact with the protrusion  316  of the rotation restraint member  302 . Further, as a result of engagement of the first cutting edge  326   a  of the cutting tool  306  with the substrate  214  and the above-described pivoting movement, the second cutting edge  326   b  of the cutting tool may retract from the substrate. Accordingly, a clearance between the second cutting edge  326   b  of the cutting tool  306  may allow for removal of chips, chunks, or other removed pieces of the material defining the substrate  214 . In this regard, without the pivoting movement, material removed from the substrate  214  may become lodged in the cutting tool  306  or otherwise detrimentally affect the cutting operation. 
     Further, in order to facilitate additional removal of chips cut from the substrate  214 , after the cutting tool  306  cuts the substrate to a desired extent (e.g., when the first cutting edge  326   a  reaches the end of the remaining material section  222 , the non-rotary tool  304  may be retracted from the substrate in an outward direction  330 . Thereafter, the non-rotary cutting tool  304  may be moved (e.g., translated) with respect to the substrate in a second direction  332  that at least partially opposes the first direction  326 . 
     Thus, the non-rotary tool  304  may pivot during transition from movement in the first direction  328  to movement in the second direction  332 . The pivoting may be passive in that pivoting of the non-rotary tool  304  is caused by contact with the substrate  214 . In this regard,  FIG. 16  illustrates movement of the non-rotary tool  304  in the second direction  332  after the contact between the substrate  214  and the second cutting edge  326   b  of the cutting tool  306  causes the non-rotary tool  304  to pivot such that the second end  322   b  of the aperture  318  comes into contact with the protrusion  316  of the rotation restraint member  302 . Further, as a result of engagement of the second cutting edge  326   b  of the cutting tool  306  with the substrate  214  and the above-described pivoting movement, the first cutting edge  326   a  of the cutting tool may retract from the substrate. Accordingly, a clearance between the first cutting edge  326   a  of the cutting tool  306  may allow for removal of chips, chunks, or other removed pieces of the material defining the substrate  214 . In this regard, without the pivoting movement, material removed from the substrate  214  may become lodged in the cutting tool  306  or otherwise detrimentally affect the cutting operation. Thereafter, the non-rotary tool  304  may be retracted from the substrate in the outward direction  330  and the non-rotary tool may once again be directed in the first direction  328 . Accordingly, repetitive movement of the cutting tool  306  in this manner may allow for removal of material from the substrate  214  (e.g., the remaining material sections  222 ), which may otherwise be difficult to remove, as described above. Note that, as a result of the pivoting movement of the non-rotary tool  304 , the total lateral movement of the tool body  308  relative to the substrate  214  may exceed the dimensions cut by the cutting tool  306 . 
     A related method for converting a rotary machine to non-rotary machine is also provided. As illustrated in  FIG. 17 , the method may include coupling a tool body to a rotary head, the tool body comprising an arm extending substantially perpendicularly to a rotational axis of the rotary head at operation  402 . Further, the method may include coupling the arm of the tool body to a rotation restraint member such that a rotary motion of the tool body is restrained at operation  404 . 
     In some embodiments of the method, coupling the tool body to the rotary head at operation  402  may comprise inserting a machine connector of the tool body into the rotary head. Further, coupling the arm of the tool body to the rotation restraint member at operation  404  may comprise inserting a protrusion of the rotation restraint member into an aperture defined in the arm. Additionally, the method may include coupling a cutting tool to an end effector connector of the tool body. The method may further comprise decoupling a rotary tool from the rotary head prior to coupling the tool body to the rotary head at operation  402 . 
     A manufacturing method is also provided. As illustrated in  FIG. 18 , the method may include providing a machine comprising a rotary head configured to rotate about a rotational axis, a tool body coupled to the rotary head via a machine connector, and a cutting tool rotationally fixed with respect to the tool body, the tool body comprising an arm coupled to a rotation restraint member such that a rotary motion of the tool body about the rotational axis is restrained within first and second angular limits at operation  502 . Further, the method may include translating the cutting tool with respect to a substrate in a first direction and a second direction to remove a material therefrom at operation  504 . The method may additionally include pivoting the cutting tool between the angular limits during a transition between movement in the first direction and the second direction at operation  506 . 
     In some embodiments translating the cutting tool with respect to the substrate in the first direction at operation at operation  504  may comprise engaging a first cutting edge of the cutting tool with the substrate and retracting a second cutting edge of the cutting tool from the substrate. Further, translating the cutting tool with respect to the substrate in the second direction may comprise engaging the second cutting edge of the cutting tool with the substrate and retracting the first cutting edge of the cutting tool from the substrate. Additionally, pivoting the cutting tool at operation  506  may comprise passively pivoting the cutting tool. Further, pivoting the cutting tool between the angular limits at operation  506  may comprise disengaging the rotation restraint member from a first end of an aperture defined in the arm and engaging the rotation restraint member with a second end of the aperture defined in the arm. 
       FIG. 19  is a block diagram of an electronic device  600  suitable for use with the described embodiments. In one example embodiment the electronic device  600  may be embodied in or as a controller configured for controlling manufacturing operations as disclosed herein. In this regard, the electronic device  600  may be configured to control or execute the above-described manufacturing operations performed by the CNC mill  200  of the system  300 . In this regard, the electronic device  600  may be embodied in or as the controller  216 . 
     The electronic device  600  illustrates circuitry of a representative computing device. The electronic device  600  may include a processor  602  that may be microprocessor or controller for controlling the overall operation of the electronic device  600 . In one embodiment the processor  602  may be particularly configured to perform the functions described herein relating to manufacturing. The electronic device  600  may also include a memory device  604 . The memory device  604  may include non-transitory and tangible memory that may be, for example, volatile and/or non-volatile memory. The memory device  604  may be configured to store information, data, files, applications, instructions or the like. For example, the memory device  604  could be configured to buffer input data for processing by the processor  602 . Additionally or alternatively, the memory device  604  may be configured to store instructions for execution by the processor  602 . 
     The electronic device  600  may also include a user interface  606  that allows a user of the electronic device  600  to interact with the electronic device. For example, the user interface  606  can take a variety of forms, such as a button, keypad, dial, touch screen, audio input interface, visual/image capture input interface, input in the form of sensor data, etc. Still further, the user interface  606  may be configured to output information to the user through a display, speaker, or other output device. A communication interface  608  may provide for transmitting and receiving data through, for example, a wired or wireless network such as a local area network (LAN), a metropolitan area network (MAN), and/or a wide area network (WAN), for example, the Internet. 
     The electronic device  600  may also include a manufacturing module  610 . The processor  602  may be embodied as, include or otherwise control the manufacturing module  610 . The manufacturing module  610  may be configured for controlling or executing the manufacturing operations as discussed herein. 
     In this regard, for example, in one embodiment a computer program product comprising at least one computer-readable storage medium having computer-executable program code portions stored therein is provided. The computer-executable program code portions, which may be stored in the memory device  604 , may include program code instructions for performing the manufacturing operations disclosed herein. 
     Although the foregoing disclosure has been described in detail by way of illustration and example for purposes of clarity and understanding, it will be recognized that the above described disclosure may be embodied in numerous other specific variations and embodiments without departing from the spirit or essential characteristics of the disclosure. Certain changes and modifications may be practiced, and it is understood that the disclosure is not to be limited by the foregoing details, but rather is to be defined by the scope of the appended claims.

Metadata:
Filing Date: 20131112
Publication Date: 20180807
Grant Date: 20180807
Priority Date: 20131104
Inventors: MULLER, PETER R.
THEOBALD, MATTHEW S.
TIAGA, VINCENT
Assignee: APPLE INC
CPC Classifications: [{"code": "Y10T409/309296", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49716", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23B2270/60", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T409/30448", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T483/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T409/30448", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23Q3/15566", "inventive": true, "first": true, "tree": "[]"}, {"code": "B23B2270/60", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T408/31", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23D11/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T483/1795", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23D11/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49716", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T409/309296", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T483/1795", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T483/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T408/31", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23B2270/60", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23D11/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "B23Q3/15566", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T483/1795", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49716", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23B31/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T409/30448", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T409/309296", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23D11/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T483/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T408/31", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23B2270/60", "inventive": false, "first": false, "tree": "[]"}, {"code": "B23B31/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "B23B31/02", "inventive": true, "first": true, "tree": "[]"}, {"code": "B23B31/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T408/03", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/53", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 53007167