Claims:We Claim:
1. A trimming assembly comprising:
a spindle rotatively housed on the robotic arm wrist of a robot;
a plurality of cutting apparatus mounted on the spindle adapted to trim the work piece smoothly in any angle;
a fixed trim station for trimming the work piece,
wherein said trimming assembly is characterised in performing the trimming by covering any small angles without moving the trim station.

2. The trimming assembly as claimed in claim 1, wherein the robot is mounted on floor using a sliding rail adapted to cover larger jobs.

3. The trimming assembly as claimed in claim 2, wherein the sliding rail is linear sliding or circular sliding rail.

4. The trimming assembly as claimed in claim 1, wherein the spindle is mounted to rotate any angle while performing the operation.

5. The trimming assembly as claimed in claim 1, wherein the spindle used is high speed water cooled spindle.

6. The trimming assembly as claimed in claim 5, wherein the spindle is having built in water cooling circuit around the same.

7. The trimming assembly as claimed in claim 1, wherein the spindle runs at 24000 rpm or higher rpm.

8. The trimming assembly as claimed in claim 1, wherein the trimming station is fixed and devoid of motion guidelines, slides, ball screws to perform the operation.

9. The trimming assembly as claimed in claim 1, wherein the trimming station is having a scrap removal assembly.

10. The trimming assembly as claimed in claim 9, wherein the scrap removal assembly collects scrap rings and blows them away to a scrap collector.

11. The trimming assembly as claimed in claim 9, wherein scrap removal assembly is having a vacuum source draws a vacuum to enable the movement of the trimmed off blow away from the spindle.

12. The trimming assembly as claimed in claim 1, wherein said assembly uses real time tool path program generated with teach-in mode available in robot which enable nullifying the necessity of using additional programming software.

13. A method of trimming Thermo formed parts, comprising the steps of:
placing parts vacuum formed part which needs trimming on the trimming table employing fixtures to secure tight in position;
trimming said vacuum formed part with on job call part program by controller; and,
decamping and removing the part once operation is done,
wherein said trimming assembly is characterised in performing the trimming by covering any small angles without moving the trim station.

14. The method as claimed in claim 13, wherein the trimming is performed by a robot having a spindle and wherein said spindle is operably mounted on robot which enable rotation of the spindle in any axis.

15. The method as claimed in claim 14, wherein the robot is mounted on floor using a sliding rail adapted to cover larger jobs and wherein the sliding rail is linear sliding or circular sliding rail.

16. The method as claimed in claim 14, wherein the spindle is having built in water cooling circuit around the same.

17. The method as claimed in claim 14, wherein the spindle is capable of runs at 24000 rpm or more.

18. The method as claimed in claim 13, wherein the trimming station is having a scrap removal assembly.

19. The method as claimed in claim 18, wherein the scrap removal assembly collects scrap rings and blows them away to a scrap collector.

20. The method as claimed in claim 18, wherein scrap removal assembly is having a vacuum source draws a vacuum to enable the movement of the trimmed off blow away from the spindle.

21. The method as claimed in claim 13, wherein said method uses real time tool path program generated with teach-in mode available in robot which enable nullifying the necessity of using additional programming software. , Description:A TRIMMING ASSEMBLY AND METHOD THEREOF

Field of the Invention
In general, this invention, relates to a trimming operation for thermo formed parts. More particularly, the present invention provides an improved cost-effective trimming assembly and method of performing trimming operation in highly flexible and precision way.

Background of the Invention
For trimming of Thermo formed parts conventionally 5 Axis CNC Routers are used universally. Due to the constructional of machine and servo drive motors, ball screws, guide ways etc., on one hand the machine becomes sturdy but on other hand the cost goes up.

To perform trimming operations generally sophisticated tilting heads are used on such routers to use electrically driven spindle motors for cutting the material with conventional cutters. There are various designs of tilting heads developed depending on the applications. The cost of the machine varies as per the sophistications of design.

Some advance development has already taken place to replace electrically driven spindle motor by Laser Head. This has given freedom from conventional milling cutters and the swarf generated in cutting, the cost of the equipment has also gone up considerably.

Various approaches have been disclosed in the prior arts in relation to develop trimming assembly by using different kind of robotic system, spindle, various arrangement of spindle, focusing on the spindle speed etc.

FR2649630B1, titled, apparatus to bypass blocking for a burr catalysts protection discloses, a pneumatic spindle equipped with a tachometer which controls the reversal of feed of a pneumatic jack connecting the spindle to the wrist of the robot as soon as the rotational speed of the cutter falls below a threshold value.

ES2668530T3, titled, rotary tool removal of matter of a piece of plastic material, discloses system for removing material from a plastic part, comprising a rotating spindle provided with abrasive means. The rotating spindle includes a non-abrasive section, which can form a radial stop for the system on a guide edge. The system includes driving means for rotating the abrasive means connected to the rotating spindle and a mechanical means for linking to a robot, the mechanical linkage being of type ball joint with pin.

US5765975A, titled, compliant end effector for an industrial robot, discloses a compliant end effector particularly suited for use with a robotic arm for accurately cutting and trimming the edges of a hot molded sheet of flexible plastic. The compliant end effector includes a mount secured to the robotic arm, an adjustment assembly pivotally attached to the mount, a guide that engages the plastic sheet near the area to be cut and trimmed, a tool for cutting and trimming the flexible sheet, and a pneumatic cylinder that biases the guide into engagement with the flexible sheet and presses the sheet against a rigid surface. The pneumatic cylinder moves the guide and tool through a range of positions as the robotic arm moves along a single path of travel down the length of the flexible sheet. The guide remains in contact with the flexible sheet despite warping or other imperfections in the stabilizing surface. The tool is fixed a predetermined distance from the guide to ensure that the plastic sheet is cut and trimmed within specific tolerances. By rotating the end effector, tabs and recesses can be formed in the edge of the flexible sheet while the robot moves along its single path of travel.

DE102011054885B4, titled, trimming device and articulated arm therefor, discloses the device has a machining head rotatably mounted in a spindle. The spindle is firmly held in a work piece holder, which comprises a movable component bearing the spindle. The component is moved in a direction relative to a remaining part holder. The component is firmly guided into remaining space axes, which run vertically to a movement direction. A spring element i.e. pneumatic spring, is arranged between the movable component and the remaining part holder such that the spindle together with the movable component is moved near to the remaining part holder against the spring action. The machining head is designed as a milling cutter.

US6763752, titled, apparatus for trimming a flange on a cylindrical opening of a plastic container, discloses the present invention includes a trim station for trimming the flange of a container, an apparatus for trimming the flange of a container and a method of trimming the flange of a container. The trim station includes a rotating primary knife and a secondary knife mounted on a movable member, wherein the secondary knife is moved into a cutting position by advancing the movable member in a direction parallel to the axial direction of the container. The present invention also includes a spindle assembly and a container by process of trimming the flange of the container.

However, currently available solutions as disclosed above have their own restrictions in developing different types of system and method for trimming operation such as, cost effectiveness, friction while performing the operation, accuracy and precision in the performance, effective trimming in all peripheral direction etc.

It would be desirable, therefore, there is need to develop an improved assembly to perform the trimming operation effectively with cost efficient manner.

Summary of the Invention
The various objectives and embodiments of the present invention as presented herein are understood to be illustrative of the present invention and not restrictive thereof and are non-limiting with respect to the scope of the invention.

It is one objective of the present invention to offer a cost-effective improved trimming assembly to allow to select best suitable size of the product and the processing requirements.

It is another objective is to provide an improved trimming assembly having minimal floor space and reduces the unnecessary cost.

It is another objective of the present invention to provide an improved trimming assembly which is capable of rotate and perform trimming operation in all axis.

It is another objective of the present invention to provide an improved trimming assembly which has sufficient strength and light weight and also very minimal outside dimensions to avoid interference with part under trimming.

The above and other objectives of the present invention are achieved according to the following embodiments of the present invention. However, the disclosed embodiments are exemplary based on the preferred and best mode of the invention and not limit the scope of the present invention.

In one embodiment, the present invention relates to a trimming assembly comprisinga spindle/trimmer head rotatively housed /mounted on the robotic arm wrist, a plurality of cutting apparatus mounted on the spindle/trimmer head adapted to trim the work piece smoothly in any angle, a fixed trim station for trimming the work piece.

In one embodiment, the present invention relates to a trimming assembly comprisinga spindle/trimmer head rotatively housed /mounted on the robotic arm wrist, a plurality of cutting apparatus mounted on the spindle/trimmer head adapted to trim the work piece smoothly in any angle, a fixed trim station for trimming the work piece, wherein said trimming assembly is characterised in performing the trimming by covering any small angles without moving the trim station.

In one embodiment, the present invention relates to a trimming assembly comprisinga spindle/trimmer head rotatively housed /mounted on the robotic arm wrist, a plurality of cutting apparatus mounted on the spindle/trimmer head adapted to trim the work piece smoothly in any angle, a fixed trim station for trimming the work piece, wherein the robot is mounted on floor using a sliding rail adapted to cover larger jobs.

According to the embodiments as described above, the sliding rail disclosed herein is linear sliding or circular sliding rail.

According to the embodiments disclosed herein, the spindle used is high speed water cooled spindle and wherein the spindle is having built in water cooling circuit around the same.

According to the embodiments disclosed herein, the spindle used is high speed water cooled spindle, wherein the spindle is capable of runs at 24000 rpm or more.

In one embodiment, the present invention relates to a trimming assembly comprisinga spindle/trimmer head rotatively housed /mounted on the robotic arm wrist, a plurality of cutting apparatus mounted on the spindle/trimmer head adapted to trim the work piece smoothly in any angle, a fixed trim station for trimming the work piece, wherein the trimming station is devoid of motion guidelines, slides, ball screws to perform the operation.

According to the embodiments disclosed herein above comprises the trimming station adaptable to accommodate the swarf which enable to connect to a scrap removal assembly which is capable of collecting scrap rings and blows them away to a scrap collector, wherein scrap removal assembly is having a vacuum source draws a vacuum to enable the movement of the trimmed off blow away from the spindle/trimmer head.

In one embodiment, the present invention relates to a trimming assembly comprisesa spindle/trimmer head rotatively housed /mounted on the robotic arm wrist, a plurality of cutting apparatus mounted on the spindle/trimmer head adapted to trim the work piece smoothly in any angle, a fixed trim station for trimming the work piece, wherein the assembly uses real time tool path program generated with built-in teach-in module enabling nullifying the necessity of using additional programming software.

In accordance with another embodiment of the present invention, there is provided a method of trimming Thermo formed parts, comprising the steps of a method of trimming Thermo formed parts, comprising placing parts vacuum formed part which needs trimming on the trimming table employing fixtures to secure tight in position, trimming said vacuum formed part with on job call part program by controller and decamping and removing the part once operation is done, wherein said trimming assembly is characterised in performing the trimming by covering any small angles without moving the trim station.

In accordance with another embodiment of the present invention, there is provided a method of trimming Thermo formed parts, comprising the steps of a method of trimming Thermo formed parts, comprising placing parts vacuum formed part which needs trimming on the trimming table employing fixtures to secure tight in position, trimming said vacuum formed part with on job call part program by controller and decamping and removing the part once operation is done, wherein the trimming is performed by a robot having spindle and wherein said spindle is operably mounted on robot which enable rotation of the spindle in any axis and wherein the spindle runs at variables rpm, preferably at 24000 rpm or more.

According to another embodiment of the present invention, the method further comprising removing the scrap using the scrap removal assembly which collects scrap rings and blows them away to a scrap collector, wherein scrap removal assembly is performed employing a vacuum source which draws a vacuum to enable the movement of the trimmed off blow away from the spindle/trimmer head.

According to embodiments disclosed herein, said method uses real time tool path program generated with teach-in mode available in robot which enable nullifying the necessity of using additional programming software.

These and other embodiments, processes and features of the invention will become more fully apparent when the following detailed description is read with the accompanying drawing figures. However, both the foregoing summary of the invention and the following detailed description of it represent one potential embodimentand are not restrictive of the invention or other alternate embodiments of the invention.

Brief Description of Drawings
To illustrate the solutions according to the embodiments of the present disclosure more clearly, the accompanying drawings needed for describing the embodiments are introduced below briefly. Apparently, the accompanying drawings in the following descriptions merely show some of the embodiments of the present disclosure, and persons skilled in the art may obtain other drawings according to the accompanying drawings without creative efforts.

Figure1 illustrates a schematic diagram of the complete assembly, according to an embodiment of the invention.

Figure2 illustrates a schematic diagram of the trimming operation using the trimming assembly, according to an embodiment of the invention.

Detailed Description of the Invention
The solutions of the present disclosure are to be clearly described in the following with reference to the accompanying drawings. It is obvious that the embodiments to be described are only a part rather than all the embodiments of the present disclosure. All other embodiments obtained by persons skilled in the art based on the embodiments of the present disclosure without creative efforts shall fall within the protection scope of the present disclosure.

According to one non-limiting embodiment of the present invention, a trimming assembly for thermo form parts and method thereof consist of a robot having a spindle operably housed on the robotic arms wherein the spindle is adapted to move in any axial direction.

Advantage of the present invention is to obviate the drawback associated with the existing arts and provide perfect path control, high flexibility for trimming applications to replace the conventional expensive CNC Routers.

The assembly is constructed with a unique design concept to achieve optimum performance for the user, wherein the construction principle of this machine uses a robotic arm with a high speed water cooled spindle and a fixed table with multiple tap holes to accommodate different size of fixtures and wherein linear motors, ball screws, linear motion guides and the complete corresponding structural element required for housing above parts are eliminated and hence reduced the cost of the assembly.

According to the present invention, the disclosed trimming assembly requires 50% of space as compare to conventional Routers engaged in doing same operation.

According to the present invention, the disclosed trimming assembly provide highly dynamic fast feed rates and guarantees shortest cycle time along with highest productivity and low cost per product.

The design of tables as per the current invention is capable of accommodating a swarf which can be further attached with extraction system minimising the requirement of cleaning implications for the user and environment.

The assembly can be equipped with motorised front doors for safety or with an economical option of photo electric sensors, when photoelectric beam is obstructed by human movement the robotic operations stops immediately as a safety feature.

The assembly for use is designed for accommodating part of 1000X1500X400 size. Large size parts can be accommodated by using two robotic arms in synchronised movement of each other.

The basic assembly is suitably equipped for trimming of vacuum formed parts. The spindle can take up 1-13 mm size of cutters in suitable collet. The spindle has 2.2 Kw of power and it runs at variables rpm, preferably at 24000 rpm or more. For continual use heat generated at 24000 rpm is exchanged by built-in water-cooling circuit around the spindle, wherein the spindle has freedom of rotation in all axis.

Assembly is equipped with opened assembly table of preferably about 1000X1520 size with precision of tapped holes at 250mm square pitch for ease off mounting different fixtures.

Assembly has vacuum system assisted with buffer tank to assist fixture for clamping the vacuum formed parts.

Trimming head according to the present invention is a simple specifically designed suitable for trimming of various type of formed parts and prototype applications. It was initially tried using assembly plates for proving the concept which eventually is converted to aluminium housing casting.

The placement of all peripherals like servo-controlled stabilizers, Power conditioners for controller, chilled/Cooled water tanks, vacuum pump and buffer tanks etc. are done on the mezzanine deck over the assembly for minimizing the requirement of floor space.

According to the present invention, the spindle is used herein is water cooled spindle, the bearing of the spindle is surrounded by a channel, wherein water is circulating through the channel to cool the bearing by carried away the heat generated during the trimming operation via returned water to the tank to cool the water and again circulate to repeat the process. In this way the bearing life of the spindle is increased.

Further, the used spindle of said invention is light weight spindle and capable of holding plurality of cutting operation, wherein said cutting apparatus is operably connected with controller via all the points which capable of instructing real time on job instruction of trimming performance, thus avoiding generation of offline programing.

The present disclosure is about a trimming assembly using robotics for trimming of Thermo formed parts of a vehicle. The foregoing and other objects, features and advantages of the invention as well as the presently preferred embodiment thereof, will become more apparent from the accompanying drawings in which Figure 1 & 2 illustrates a schematic diagram of an assembly, according to an embodiment of the present invention. In an embodiment, the assembly uses a robotic arm (100)with a high speed water cooled spindle (102) (incoming chilled water and outgoing hot water) by built in water cooling circuit (103) around the spindle and a fixed table (104) with multiple tap holes to accommodate different size of fixtures, wherein the assembly is eliminated linear motors, ball screws, linear motion guides and the complete corresponding structural element required for housing above parts. Robotic arm controller is protected from electrical surges by introducing power conditioner (108)in electric supply circuit.The vaccum formed part is held on the fixture having suitable profile to hold the part. The fixture is reinforced with built-in structure (101) for stability. The complete fixture is mounted on fixed table (104).

The assembly offers highly dynamic fast feed rates and guarantees shortest cycle time. Highest productivity and low cost per product. It has built in Teach-In tool path program facility to trim a 3D part and it has freedom of rotation in all axis.

The design of tables (105)is capable to accommodate a swarf which can be further attached with extraction system minimising the requirement of cleaning implications to user and environment.

The assembly is equipped with motorised front doors for safety or with an economical option of photo electric sensors.

The basic assembly is suitably equipped for trimming of vacuum formed parts. The spindle can take up 1-13 mm size of cutters in suitable collet. The spindle (106) has 2.2 Kw of power and it runs at 24000 rpm or more. For continual use heat generated at 24000 rpm is exchanged by chiller (109) connected to built-in water-cooling circuit around the spindle (102).

Assembly is equipped with opened assembly table of 1000X1520 size (104) with precision of tapped holes at 250mm square pitch for ease off mounting different fixtures.

Provision for accommodating larger parts a bigger size table can be used along with two independent robotic arms programmed to work in coordination with each other by making fool proof program to avoid any accidental collision.

Said assembly according to present invention has vacuum system assisted with buffer tank (107)to assist fixture for clamping the vacuum formed parts.

Trimming head (108) is a simple specifically designed suitable for trimming of various type of formed parts and prototype applications. It was initially tried using machined plates for proving the concept which eventually is converted to aluminium housing casting.

The embodiments in the specification are described in a progressive manner and focus of description in each embodiment is the difference from other embodiments. For same or similar parts of each embodiment, reference may be made to each other. Because the method disclosed in the embodiment is corresponding to the apparatus disclosed in the embodiment, the description of the method is simple. For related parts, reference may be made to the description of the apparatus.

It will be appreciated by those skilled in the art that the foregoing description was in respect of preferred embodiments and that various alterations and modifications are possible within the broad scope of the appended claims without departing from the spirit of the invention with the necessary modifications.

Based on the description of disclosed embodiments, persons skilled in the art can implement or apply the present disclosure. Various modifications of the embodiments are apparent to persons skilled in the art, and general principles defined in the specification can be implemented in other embodiments without departing from the spirit or scope of the present disclosure. Therefore, the present disclosure is not limited to the embodiments in the specification but intends to cover the most extensive scope consistent with the principle and the novel features disclosed in the specification.