Active Damping System Inside Machine Tool Ram
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Solution Overview
Problem
Machine tools with cantilevered moving elements, such as milling machines and vertical lathes, face challenges in effectively damping self-regenerative vibrations due to variable dynamic responses, leading to inefficient passive dampers and space constraints for active dampers near the cutting point, which affects surface quality and tool integrity.
Innovation Solution
An active damping system is integrated inside the ram, utilizing a hollow prismatic structure with a damper housed in a longitudinal wall opening and within the ram's hollow structure, minimizing space usage and proximity to the cutting point, protected from machining elements and allowing space for wiring and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If passive dampers are used to damp vibrations, then the damping effect is achieved, but the dampers become less effective when dynamic parameters vary and require excessive space
Solution Approach 1:
The patent applies active damping technology where the damping force is dynamically adjusted based on real-time vibration measurements. Sensors detect vibrations and controllers adjust the damping force accordingly, allowing the system to adapt to varying dynamic parameters during machining operations, thereby maintaining effectiveness without requiring excessive space
Solution Approach 2:
The patent replaces traditional passive mechanical dampers with an active damping system using sensors, controllers, and actuators. This substitution allows for intelligent control of damping forces, enabling the system to respond to changing vibration conditions while occupying less space compared to bulky passive dampers
2Reliability
If active dampers are placed close to the cutting point, then damping efficiency is improved, but space constraints and complexity of integration increase
Solution Approach 1:
The active damping system is segmented into distinct functional modules: vibration sensors mounted on the ram, control units, and actuators. This segmentation allows each component to be optimized independently and integrated into the limited space near the cutting point without excessive complexity
Solution Approach 2:
The patent utilizes the vertical dimension by mounting sensors and dampers on the upper surface of the ram, perpendicular to the cutting direction. This dimensional arrangement allows the damping system to be integrated close to the cutting point without interfering with the horizontal machining space
3Reliability
If the ram dimensions are increased to accommodate damping system, then damping capacity is improved, but interference with part to be machined increases
Solution Approach 1:
The damping system is extracted from the traditional location outside the ram and integrated inside the ram structure. By placing sensors and actuators within the ram's existing geometry, the system achieves effective damping capacity without increasing the external dimensions of the ram that would interfere with machining operations
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides efficient damping of self-regenerative vibrations close to the cutting point, reducing tool wear and improving surface quality while minimizing the ram's dimensions and interference risks, offering a compact and effective damping solution.
Implementation Method 1
this force is obtained by accelerating a moving mass that is suspended in the structure to be damped, such that when the moving mass is accelerated in the required direction, an inertial force reducing the vibration amplitude in the machine tool is generated
Implementation Method 2
The natural frequency of the passive damper is fine-tuned so that it coincides with the natural frequency of the structure to be damped
Data Source
Figure 1
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AI summary
The invention relates to a machine tool with an active damping system, comprising a ram (4) with a hollow prismatic structure with longitudinal walls (41), a volumetric body (13) which is housed at a free end of the ram (4) inside the hollow prismatic structure of the ram (4), and at least one damper (8, 18, 28, 38) which is arranged at the free end of the ram (4). The damper (8, 18, 28, 38) comprises a first portion (81, 181, 281, 381) which is housed in an opening (9) of a longitudinal wall (41) of the ram (4), and a second portion (82, 182, 282, 382) which is housed inside the hollow prismatic structure of the ram (4) in a gap (G) defined between the volumetric body (13) and the longitudinal wall (41) of the ram (4) in which the first portion (81, 181, 281, 381) of the damper (8, 18, 28, 38) is housed.