Analysis system for vibration processing equipment
The analysis system for vibration processing apparatuses optimizes mechanical specifications with high precision and reduces analysis time by using static displacement analysis to balance rigidity, accuracy, and mass, addressing the trade-offs in existing designs.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- JTEKT CORP
- Filing Date
- 2025-01-17
- Publication Date
- 2026-07-30
AI Technical Summary
Existing vibration processing apparatuses face a trade-off between mechanical rigidity, machining accuracy, and mass reduction, leading to increased costs and potential accuracy deterioration.
An analysis system that includes a model storage unit, operating range storage unit, first and second analysis units to obtain maximum acceleration and displacement data, and a third analysis unit for optimization, allowing for high-precision optimization without reducing machining accuracy by performing static displacement analysis.
The system reduces analysis time by 80% and optimizes mechanical specifications with high precision, minimizing mass and inertia while maintaining machining accuracy.
Smart Images
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Abstract
Description
Technical Field
[0001] The present invention relates to an analysis system for a vibration processing apparatus.
Background Art
[0002] Generally, in a processing apparatus for machining a workpiece, the machining becomes more stable and the machining accuracy improves as the mechanical rigidity increases. However, if the rigidity of the mechanical structure is simply increased, thick-walled parts and members will be used, resulting in an increase in the mechanical weight and inertia, an increase in the mechanical manufacturing cost and operation cost, and it may become unsuitable for the use environment. However, if mass reduction is performed by inappropriate thinning or the like, there is a risk of adverse effects such as deterioration of machining accuracy due to a decrease in rigidity. Therefore, mechanical design that balances mechanical specifications such as machining accuracy and mass is required. Therefore, simulation technology is used to determine mechanical behavior and machining accuracy, and based on this, mechanical design is optimized. For example, Patent Document 1 discloses a design technique for adjusting the thermal displacement amount and mass of a structure using machine learning technology. This invention has been made in view of the above problems, and aims to provide an analysis system for a vibration processing device that can achieve both reduced analysis time and high-precision optimization. [Means for solving the problem]
[0006] One aspect of the present invention is, An analysis system for a vibration machining apparatus that processes a workpiece using a tool attached to a vibrating part, A model storage unit that stores the model data of the vibration processing apparatus, which is the vibration processing apparatus model, An operating range storage unit that stores the operating range of the vibrating part, A first analysis unit obtains maximum acceleration data of the tool's machining point within the operating range by performing a dynamic analysis of the vibration processing device model when the vibration part is vibrated, A second analysis unit obtains the maximum displacement data of the processing point by performing a static displacement analysis in the vibration processing device model based on the maximum acceleration data, The analysis system for a vibration processing device includes a third analysis unit that performs an optimization analysis of the mechanical specifications of the vibration processing device based on the aforementioned maximum displacement data. [Effects of the Invention]
[0007] In the above-described analysis system for vibration machining equipment, maximum displacement data of the machining point is obtained by static displacement analysis based on maximum acceleration data of the machining point in the tool within the operating range, which is obtained by dynamic analysis. Then, based on the maximum displacement data, an optimization analysis of the machine specifications of the vibration machining equipment is performed. This eliminates the need to perform dynamic analysis when obtaining the maximum displacement data of the machining point, thus shortening the analysis time. Furthermore, the machining accuracy of the vibration machining equipment depends on the maximum displacement of the machining point. In this configuration, since the optimization analysis of the machine specifications of the vibration machining equipment is performed using maximum displacement data based on the maximum acceleration data of the machining point, the machine specifications of the vibration machining equipment can be optimized with high precision without reducing machining accuracy.
[0008] As described above, according to the above embodiment, it is possible to provide an analysis system for a vibration processing device that can achieve both a reduction in analysis time and high-precision optimization. [Brief explanation of the drawing]
[0009] [Figure 1] A conceptual diagram showing the configuration of the analysis system for the vibration processing apparatus in Embodiment 1. [Figure 2] Conceptual diagram of the vibration processing apparatus model in Embodiment 1. [Figure 3] (a) First conceptual diagram, (b) Second conceptual diagram, and (c) Third conceptual diagram for explaining the vibration state of the vibrating part in Embodiment 1. [Figure 4] A diagram showing the analysis results of the first analysis unit in Embodiment 1. [Figure 5] (a) Cross-sectional view of the vibrating part before optimization, and (b) Cross-sectional view of the vibrating part after optimization, in Embodiment 1. [Figure 6] A flowchart for performing analysis using the analysis system for the vibration processing apparatus in Embodiment 1. [Modes for carrying out the invention]
[0010] (Embodiment 1) 1. Configuration of the Vibration Processing Equipment Analysis System 1 The analysis system 1 of the vibration processing apparatus according to Embodiment 1 will be described with reference to Figure 1. The analysis system 1 for the vibration processing apparatus includes, as shown in Figure 1, a model storage unit 2, an operating range storage unit 3, a first analysis unit 10, a second analysis unit 20, and a third analysis unit 30. The analysis system 1 is composed of a computing device and a storage device capable of executing predetermined programs to provide the functions of each component. The components of the analysis system 1 of Embodiment 1 will be described in detail below.
[0011] 1-1. Model Memory Unit 2 The model storage unit 2 shown in Figure 1 stores the model data of the vibration machining apparatus, which is the vibration machining apparatus model 4. The vibration machining apparatus is not particularly limited as long as it processes a workpiece by vibrating a tool. The type of workpiece is not limited, and in this embodiment, it is a component of a hub unit that integrates a wheel bearing and surrounding parts for a vehicle. In this embodiment, as shown in Figure 2, the vibration machining apparatus model 4 has a vibration unit 40, a drive unit 45, and a control unit 46. The vibration unit 40 is configured to vibrate and a tool T can be attached to it. The drive unit 45 is configured to generate a driving force and, in this embodiment, is configured to reciprocate in the vertical direction P. The control unit 46 controls the drive of the drive unit 45. In Figure 2, the vertical direction, which is the direction of movement of the drive unit 45, is denoted as Y, and the direction perpendicular to the vertical direction is denoted as X.
[0012] 1-2. Vibration section 40 The vibrating section 40 shown in Figure 2 includes a connecting member 41, an arm member 42, and a tip member 43. The connecting member 41 is connected to the drive unit 45. It moves in conjunction with the reciprocating movement of the drive unit 45. The arm member 42 is connected to the connecting member 41 via a bolt 44. The arm member 42 is rod-shaped with a central axis O extending in the X direction, and as shown in Figure 3(a), it is pivotally mounted on the connecting member 41 by the bolt 44 at a position eccentric from the central axis O, so as to be rotatable about the central axis O. In Figure 3, the direction perpendicular to the X and Y directions is defined as Z.
[0013] As shown in Fig. 2, the tip member 43 is connected to the arm member 42 and the tool T is attached thereto. The tip member 43 is rotatable integrally with the arm member 42. In the present embodiment, the tip member 43 has a substantially J shape, one end is connected to the arm member 42, and the tool T is attached to the other end. Then, as shown in Figs. 3(a) to 3(c), as the drive unit 45 makes a reciprocating movement P in the upward direction P1 and the downward direction P2, the connecting member 41 drives, so that the arm member 42 makes a reciprocating rotation, and integrally therewith, the tip member 43 makes a reciprocating rotation. Since the reciprocating movement of the drive unit 45 is performed at high speed, the tip member 43 repeatedly goes through the states shown in Figs. 3(a) to 3(c) at high speed. As a result, the tip member 43 vibrates by performing a pendulum motion as shown in Figs. 3(a) to 3(c).
[0014] The operating range of the vibration unit 40 can be set as appropriate, and in the present embodiment, it is set as the range of the central angle θ with the central axis O of the arm member 42 in the tip member 43 as the rotation center. As shown in Figs. 3(a) to 3(c), the tool T attached to the tip member 43 vibrates together with the tip member 43. Then, as shown in Fig. 2, the tool tip T2 at the tip of the shaft portion T1 of the tool T can contact the workpiece W to perform surface machining.
[0015] 1-3. Operating Range Memory Unit 3 The operating range memory unit 3 shown in Fig. 1 stores the operating range of the vibration unit 40. In the present embodiment, the operating range memory unit 3 stores the range of the central angle θ, which is the operating range of the tip member 43 shown in Fig. 3(a).
[0016] 1-4. First Analysis Unit 10 The first analysis unit 10 shown in FIG. 1 obtains the maximum acceleration data of the machining point of the tool T within the operating range of the vibration unit 40 by performing dynamic analysis on the vibration machining apparatus model 4 when the vibration unit 40 is vibrated. In the present embodiment, the machining point is the tool tip T2 shown in FIG. 2, and as shown in FIG. 4, the angular velocity of the tool tip T2 in the pendulum-moving tool T is analyzed. Then, the maximum angular velocity data of the tool tip T2 in the pendulum-moving tool T is obtained as the maximum acceleration data. The maximum angular velocity data can be the angular velocity at the maximum point A in the positive direction in FIG. 4. Note that, as the maximum angular velocity data in the reverse direction, the angular velocity at the minimum point B in FIG. 4 may be obtained.
[0017] 1-5. Second analysis unit 20 The second analysis unit 20 shown in FIG. 1 obtains the maximum displacement data of the machining point by performing static displacement analysis on the vibration machining apparatus model 4 based on the maximum acceleration data. In the present embodiment, the maximum displacement data of the tool tip T2 is obtained by performing multi-load static displacement analysis using only the maximum acceleration data of the tool tip T2 which is the machining point.
[0018] 1-6. Third analysis unit 30 The third analysis unit 30 shown in FIG. 1 performs optimization analysis of the mechanical specifications of the vibration machining apparatus based on the maximum displacement data. Examples of the mechanical specifications include the mass, inertia, etc. of the vibration unit 40. In the present embodiment, optimization analysis of the mass and inertia of the vibration unit 40 is to be performed. Then, the optimization analysis by the third analysis unit 30 in the present embodiment uses the maximum displacement data obtained by the second analysis unit 20 as a constraint condition, the mass and inertia of the vibration unit 40 as an objective function, and performs optimization with the mass as a variable in order to minimize the mass and inertia of the vibration unit 40.
[0019] In this embodiment, the third analysis unit 30 includes a deflection amount calculation unit 31, a stress distribution calculation unit 32, and an optimization unit 33, as shown in Figure 1. The deflection amount calculation unit 31 calculates the maximum deflection amount at the machining point based on the maximum displacement data. In this embodiment, in addition to the maximum angular acceleration data at the machining point shown in Figure 3, minimum and intermediate angular acceleration data are extracted, and the deflection amount at the machining point is calculated by multi-load static displacement analysis, and the maximum deflection amount is extracted.
[0020] The stress distribution calculation unit 32 shown in Figure 1 calculates the stress distribution generated in the vibrating section 40 based on the calculation results of the maximum deflection calculation unit 31. The stress distribution can be shown, for example, as a contour plot. In this embodiment, the stress distribution calculation unit 32 calculates the stress distribution generated in the vibrating section 40 when the maximum deflection occurs and identifies the high stress concentration region H and the low stress concentration region L in the vibrating section 40 before optimization, as shown in Figure 5(a).
[0021] The optimization unit 33 shown in Figure 1 optimizes the shape of the vibrating unit 40 based on the calculation results of the stress distribution calculation unit 32. In this embodiment, the optimization unit 33 optimizes the shape of the vibrating unit 40 as shown in Figure 5(b) by adding material to the high stress concentration region H and removing material from the low stress concentration region L. The optimization is performed while leaving areas necessary for mounting the vibrating unit 40 and maintaining its shape.
[0022] 2. Analysis method using the analysis system 1 for vibration processing equipment Next, the analysis method using the analysis system 1 of the vibration processing apparatus of Embodiment 1 will be explained with reference to the flowchart in Figure 6. First, in step S1 of Figure 6, the first analysis unit 10 performs a dynamic analysis of the vibration processing apparatus model 4 when the vibration unit 40 is vibrated, thereby obtaining the maximum acceleration data of the machining point of the tool T within the operating range of the vibration unit 40.
[0023] Next, in step S2 of Figure 6, the second analysis unit 20 obtains the maximum displacement data of the tool tip T2 by performing a multi-load static displacement analysis using only the maximum acceleration data of the tool tip T2, which is the machining point. Then, in step S3 of Figure 6, the deflection amount calculation unit 31 extracts the maximum, minimum, and intermediate angular acceleration data of the machining point, calculates the deflection amount of the machining point by multi-load static displacement analysis, and extracts the maximum deflection amount.
[0024] Subsequently, in step S4 of Figure 6, the stress distribution calculation unit 32 calculates the stress distribution generated in the vibrating section 40 based on the calculation results of the maximum deflection calculation unit 31. Then, in step S5 of Figure 6, the stress distribution calculation unit 32 identifies the high stress concentration region H and the low stress concentration region L in the vibrating section 40 before optimization.
[0025] Next, in step S6 of Figure 6, the optimization unit 33 optimizes the shape of the vibrating section 40 by adding material to the high-stress concentration region H and removing material from the low-stress concentration region L. Then, this flow is completed.
[0026] 3. Confirmation Test When comparing the maximum displacement data of the tool tip T2 obtained by multi-load static displacement analysis in the second analysis unit 20 with the angular velocity data of the tool tip T2 obtained by multi-body dynamic displacement analysis, both showed similar trends. This confirmed that dynamic displacement analysis can be reproduced by static displacement analysis. Furthermore, the analysis time for static displacement analysis was reduced by 80% compared to the analysis time for dynamic displacement analysis, confirming that a significant reduction in analysis time is possible.
[0027] Furthermore, comparing the state of the vibrating section 40 before and after optimization by the optimization unit 33, it was confirmed that in the optimized vibrating section 40 shown in Figure 5(b), the inertia verified by dynamic analysis was reduced by 52%, the deflection at the machining point was reduced by 2%, the stress generated in the bolt 44 was reduced by 23%, and the tensile stress of the optimized vibrating section 40 remained within the allowable tensile stress limit.
[0028] 4. Effects The following describes the effects of the analysis system 1 for the vibration machining apparatus of this embodiment 1. In the analysis system 1 for the vibration machining apparatus, the maximum displacement data of the machining point T2 is obtained by static displacement analysis based on the maximum acceleration data of the tool T at the machining point T2 within the operating range obtained by dynamic analysis. Then, based on the maximum displacement data, an optimization analysis of the machine specifications of the vibration machining apparatus is performed. As a result, it is not necessary to perform dynamic analysis when obtaining the maximum displacement data of the machining point T2, so the analysis time can be shortened. Furthermore, the machining accuracy of the vibration machining apparatus depends on the maximum displacement of the machining point T2. With this configuration, since the optimization analysis of the machine specifications of the vibration machining apparatus is performed using the maximum displacement data based on the maximum acceleration data of the machining point T2, the machine specifications of the vibration machining apparatus can be optimized with high precision without reducing the machining accuracy.
[0029] Furthermore, in this embodiment, the vibrating unit 40 is configured to vibrate by a pendulum motion in a part of the vibrating unit 40, and the maximum acceleration data is the maximum angular acceleration data during the pendulum motion. This makes it possible to obtain the maximum acceleration data of the vibrating unit 40 for obtaining the maximum displacement of the machining point T2.
[0030] Furthermore, in this embodiment, the above-mentioned mechanical specifications are the mass and inertia of the vibrating part 40. This allows for optimization to prevent damage to the vibrating part 40 due to vibration.
[0031] Furthermore, in this embodiment, the vibrating section 40 includes a connecting member 41 connected to a drive unit 45 that generates a driving force, an arm member 42 connected to the connecting member 41 via a bolt 44, and a tip member 43 connected to the arm member 42 and to which a tool T is attached, and is configured such that the tip member 43 vibrates due to the driving force. This makes it possible to optimize the shape of the vibrating section 40 in which the tip member 43 vibrates.
[0032] Furthermore, in this embodiment, the third analysis unit includes a deflection calculation unit 31 that calculates the maximum deflection amount of the tool tip T2, which is the machining point, based on the maximum displacement data; a stress distribution calculation unit 32 that calculates the stress distribution generated in the vibrating unit 40 based on the calculation result of the maximum deflection calculation unit 31; and an optimization unit 33 that optimizes the shape of the vibrating unit 40 based on the calculation result of the stress distribution calculation unit 32. This makes it possible to optimize the shape of the vibrating unit 40 with high precision.
[0033] Furthermore, in this embodiment, the stress distribution calculation unit 32 calculates the stress distribution generated in the vibrating section 40 when the maximum deflection occurs, identifies the high-stress concentration region H and the low-stress concentration region L in the vibrating section 40, and the optimization unit 33 optimizes the shape of the vibrating section 40 by adding material to the high-stress concentration region H and removing material from the low-stress concentration region L. This makes it possible to minimize the mass and inertia of the vibrating section 40.
[0034] As described above, according to the above embodiment, it is possible to provide an analysis system 1 for a vibration processing apparatus that can achieve both a reduction in analysis time and high-precision optimization.
[0035] The present invention is not limited to the embodiments described above, and can be applied to various embodiments without departing from its spirit. [Explanation of symbols]
[0036] 1. Analysis system for vibration processing equipment 2 Model Memory Unit 3. Operating range storage unit 4. Vibration Processing Equipment Model 10 1st analysis section 20 2nd Analysis Department 30 3rd Analysis Department 31 Quantity calculation part 32. Stress Distribution Calculation Unit 33 Optimization Unit 40 Vibration section 41 Connecting member 42 Arm member 43 Tip member 44 volts 45. Driving Department 46 Ministry of Control H High-efficiency concentration area L Low-efficiency concentration area O Central axis T tools W workpiece
Claims
1. An analysis system for a vibration machining apparatus that processes a workpiece using a tool attached to a vibrating part, A model storage unit that stores the model data of the vibration processing apparatus, which is the vibration processing apparatus model, An operating range storage unit that stores the operating range of the vibrating part, A first analysis unit obtains maximum acceleration data of the tool's machining point within the operating range by performing a dynamic analysis of the vibration processing device model when the vibration part is vibrated, A second analysis unit obtains the maximum displacement data of the processing point by performing a static displacement analysis in the vibration processing device model based on the maximum acceleration data, An analysis system for a vibration processing apparatus, comprising: a third analysis unit that performs an optimization analysis of the mechanical specifications of the vibration processing apparatus based on the aforementioned maximum displacement data.
2. The vibrating part is configured to vibrate by a part of the vibrating part performing pendulum motion. The analysis system for a vibration processing apparatus according to claim 1, wherein the maximum acceleration data is the maximum angular acceleration data in the pendulum motion.
3. The analysis system for a vibration processing apparatus according to claim 1 or 2, wherein the machine specifications are the mass and inertia of the vibrating part.
4. The analysis system for a vibration processing apparatus according to claim 1 or 2, wherein the vibrating section includes a connecting member connected to a drive unit that generates a driving force, an arm member connected to the connecting member via a bolt, and a tip member connected to the arm member and to which the tool is attached, and the tip member is configured to vibrate due to the driving force.
5. The third analysis unit is, A deflection amount calculation unit calculates the maximum deflection amount at the machining point based on the maximum displacement data, A stress distribution calculation unit calculates the stress distribution generated in the vibrating part based on the calculation results of the maximum deflection calculation unit, An analysis system for a vibration processing apparatus according to claim 1 or 2, comprising: an optimization unit that optimizes the shape of the vibration unit based on the calculation results of the stress distribution calculation unit.
6. The stress distribution calculation unit calculates the stress distribution generated in the vibrating section when the maximum deflection occurs, and identifies high-stress concentration regions and low-stress concentration regions in the vibrating section. The analysis system for a vibration processing apparatus according to claim 5, wherein the optimization unit optimizes the shape of the vibration unit by adding material to the high-stress concentration region and removing material from the low-stress concentration region.