Abstract: Automated Part Loader (APL) systems and methods for loading and unloading product parts within a machine, e.g., a vertical mill, are provided. The APL system is compact and has a smaller footprint compared with current automated loading systems. The APL system may include a spring-based rotatable loader arm that may be actuated to rotate, e.g., via low voltage motors, relative to a loading table, e.g., 90 degrees, and extend linearly through a side door of the machine for loading and unloading product parts. The loader arm may include a pair of pneumatic grippers configured for picking up and releasing product parts.

Abstract: A mist extraction system is provided that includes a plenum box having an inlet configured to be coupled in fluid communication with a machine tool enclosure. A blower is coupled in fluid communication with the plenum box and is configured to draw air into the plenum box from the machine tool enclosure via the inlet of the plenum box and exhaust the air back into the machine tool enclosure via an outlet of the blower. A baffle plate is arranged in the plenum box to redirect the air drawn into the plenum box through the inlet of the plenum box and a filter panel is arranged in the plenum box to filter the air redirected by the baffle plate prior to the air entering the blower. A collector arranged to collect mist from the air condensed on the baffle plate and the filter panel.

Abstract: A mist extraction system is provided that includes a plenum box having an inlet configured to be coupled in fluid communication with a machine tool enclosure. A blower is coupled in fluid communication with the plenum box and is configured to draw air into the plenum box from the machine tool enclosure via the inlet of the plenum box and exhaust the air back into the machine tool enclosure via an outlet of the blower. A baffle plate is arranged in the plenum box to redirect the air drawn into the plenum box through the inlet of the plenum box and a filter panel is arranged in the plenum box to filter the air redirected by the baffle plate prior to the air entering the blower. A collector arranged to collect mist from the air condensed on the baffle plate and the filter panel.

Abstract: A conveyor in a machine tool system is dynamically controlled. A volume of material to be conveyed by the conveyor is iteratively determined. During each iteration, a current position of a tool is determined. An intersection of a tool model representing the tool at the current position and a workpiece model representing a workpiece is determined and a nominal volume of material removed from the workpiece by the tool based on the intersection of the tool model and the workpiece model is determined. The volume of material to be conveyed is updated based on the nominal volume of material removed from the workpiece and an operating state of the conveyor. The operating state of the conveyor is controlled based on the updated volume of material to be conveyed.

Abstract: A machine tool control system may include a processing module and subsystem circuitry coupled to the processing module by a bus. The processing module may include memory circuitry and a multi-core processor. The multi-core processor may include a first set of processor cores assigned exclusively to perform real-time tasks for controlling motion relative to one or more axes by executing first instructions stored in the memory circuitry, a second set of processor cores assigned exclusively to perform non-real-time tasks by executing second instructions stored in the memory circuitry, and a timer circuit configured to generate a cycle signal at periodic intervals. The subsystem circuitry may be configured to obtain axis feedback data from one or more feedback encoders and axis control data from the first set of processor cores during each of the periodic intervals.

Abstract: A leveling pad for stabilizing a device is provided. The leveling pad comprises a metal base having a socket configured to receive a portion of the device and a liner coupled to the metal base and being configured to cold flow into a profile of a floor surface when a weight of the device is applied to the leveling pad. The liner may be of a polymer, such as vinyl. The liner is further configured to plastically deform into the profile of the floor surface. The plastic deformation is designed to increase a magnitude of a shear force or a tensile force required to separate the liner from a portion of the floor surface into which it is configured to plastically deform.

Abstract: A machine tool coolant supply system includes a chassis configured to mount the coolant supply system to a coolant storage tank of a machine tool. The coolant supply system further includes a concentrate tank arranged within the chassis, a first flow control valve coupled to the concentrate tank, a second flow control valve coupled to a water supply line, and a mixer configured to mix a concentrate with water. The mixer includes a first inlet coupled to the first flow control valve and configured to receive the concentrate from the concentrate tank via the first flow control valve, a second inlet coupled to the second flow control valve and configured to receive the water from the water supply line via the second flow control valve, and an outlet configured to dispense a mixture of the concentrate and the water into the coolant storage tank of the machine tool.

Abstract: A leveling pad for stabilizing a device is provided. The leveling pad comprises a metal base having a socket configured to receive a portion of the device and a liner coupled to the metal base and being configured to cold flow into a profile of a floor surface when a weight of the device is applied to the leveling pad. The liner may be of a polymer, such as vinyl. The liner is further configured to plastically deform into the profile of the floor surface. The plastic deformation is designed to increase a magnitude of a shear force or a tensile force required to separate the liner from a portion of the floor surface into which it is configured to plastically deform.

Abstract: A method of detecting machine tool vibration is provided. The method includes receiving, from a sensor arranged in a machine tool, motion data measured along an axis. The method also includes comparing the motion data against a first threshold. The method also includes adjusting a counter if the motion data has a magnitude greater than the first threshold. The method also includes generating an alarm if the counter is greater than a second threshold.

Abstract: A rotary union including a housing, a piston, and a shaft is provided. The piston has a first fluid passage therethrough and is configured to slide axially between a first position and a second position. The shaft has a second fluid passage therethrough and is configured to rotate. A first port is arranged in the housing and is in fluid communication with a cavity formed between the housing and the piston. The first port is configured to deliver a pressurized fluid into the cavity to actuate the piston from the first position to the second position. A chamber is formed in the housing and surrounds an interface between the first and second fluid passages. A second port arranged in the housing is in fluid communication with the chamber. The second port is configured to apply a vacuum to the chamber to evacuate fluid leaked into the chamber from the interface.

Abstract: A rotary position encoder is described that includes a hub configured to mount on an end of a rotatable shaft of a machine tool and rotate concurrently with the rotatable shaft. The hub includes a cup formed in a first end to receive the rotatable shaft, the cup having equally spaced axial grooves formed on an inner surface. A collar clamps the hub to the rotatable shaft by collapsing the cup around the rotatable shaft. The rotary position encoder further includes a sensor configured to detect a rotational position of the hub and a housing, wherein the sensor is mounted to the housing in a position opposite a second end of the hub. The hub is rotatably coupled to the housing via a bearing and a bracket is attached to the housing for mounting the rotary position encoder to the machine tool and preloading the bearing.

Abstract: A cut optimization system controls chatter in a machine tool during a cutting operation. A microphone is configured to capture acoustic noise emitted by the machine tool during the cutting operation and to generate an AC signal corresponding to the captured acoustic noise. A filter is configured to attenuate frequencies of the AC signal outside of a frequency band and a rectifier is configured to rectify the filtered AC signal into a DC component. A controller is configured to compare the DC component with a threshold value and, if the DC component is greater than the threshold, cyclically vary the rotational speed of a spindle in the machine tool from a commanded speed.

Abstract: A dampened spindle cartridge and a dampened spindle adaptor are provided for damping tool vibrations during operation of a machine tool. Damping media is arranged inside a cavity formed within the spindle adaptor or the spindle cartridge. The damping media may be a solid aggregate, such as steel shot or sand, or a viscous fluid, such as oil. The damping media attenuates and/or converts tool vibrations into friction and heat, thereby dissipating vibration energy generated during cutting operations performed by the machine tool and prevents reinforcement of the forced vibration.

Abstract: A method of detecting machine tool vibration is provided. The method includes receiving, from a sensor arranged in a machine tool, motion data measured along an axis. The method also includes comparing the motion data against a first threshold. The method also includes adjusting a counter if the motion data has a magnitude greater than the first threshold. The method also includes generating an alarm if the counter is greater than a second threshold.

Abstract: A leveling pad for stabilizing a device is provided. The leveling pad comprises a metal base having a socket configured to receive a portion of the device and a liner coupled to the metal base and being configured to cold flow into a profile of a floor surface when a weight of the device is applied to the leveling pad. The liner may be of a polymer, such as vinyl. The liner is further configured to plastically deform into the profile of the floor surface. The plastic deformation is designed to increase a magnitude of a shear force or a tensile force required to separate the liner from a portion of the floor surface into which it is configured to plastically deform.

Abstract: A method of controlling the motion of a moveable door includes determining the direction that the door is moving with respect to its anticipated closed position, and based on the direction, regulating an amount of force that is available to the door for its motion. The method may further include monitoring the position of the door as it is moving, and adjusting the motion of the door and regulating the amount of force available to the door for its motion, based on the calculated difference between the door's position as detected during monitoring and its expected position.

Abstract: A smart machine tool lubrication system monitors the distance traveled by a motion component in a machine tool. A predetermined amount of lubricant is dispensed at a lubrication point of the motion component when the monitored distance exceeds a first threshold value. The smart machine tool lubrication system may further monitor the duration of time the motion component is in motion and dispense the predetermined amount of lubricant with the monitored duration of time exceeds a second threshold value.

Abstract: Systems and methods for interfacing a portable control system (PCS) with a machine tool are provided. In some aspects, a computer numerical controlled (CNC) machine tool includes a machine tool having a motor, a machine control system (MCS), and a motor controller. The MCS is configured to generate program status data associated with a machining program run by the MCS. The motor controller is configured to generate feedback data associated with the motor. The CNC machine tool also includes a port system configured to couple a PCS to the machine tool. The port system is configured to detect when the PCS is coupled to the machine tool and to provide at least one of the program status data and the feedback data to the PCS in response to the detection of the PCS being coupled to the machine tool.

Abstract: A rotary union including a housing, a piston, and a shaft is provided. The piston has a first fluid passage therethrough and is configured to slide axially between a first position and a second position. The shaft has a second fluid passage therethrough and is configured to rotate. A first port is arranged in the housing and is in fluid communication with a cavity formed between the housing and the piston. The first port is configured to deliver a pressurized fluid into the cavity to actuate the piston from the first position to the second position. A chamber is formed in the housing and surrounds an interface between the first and second fluid passages. A second port arranged in the housing is in fluid communication with the chamber. The second port is configured to apply a vacuum to the chamber to evacuate fluid leaked into the chamber from the interface.

Abstract: A method for decelerating a motor in a computer numerical controlled machine tool is provided. The method includes calculating a present rate of deceleration DP, for a motor of a motor drive system, based on a present speed SP of the motor, a reference speed SR of the motor, and a reference rate of deceleration DR of the motor. The method also includes decelerating the motor from SP according to DP. The motor drive system comprises a maximum power rating that defines a maximum power, generated by the motor while decelerating, that can be dissipated without overloading the motor drive system. DR is a rate of deceleration such that power, generated by the motor while decelerating from SR according to DR, is equal to the maximum power rating. Power, generated while decelerating the motor from SP according to DP, is equal to or less than the maximum power rating.