Active Vibration Damping for Flexible Workpieces
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Solution Overview
Problem
Current machining processes face challenges in eliminating vibrations, leading to surface defects and increased manufacturing costs due to the need for additional machining steps, tooling design complexities, and potential deformation of parts, especially those with reduced thicknesses.
Innovation Solution
A method involving a system with displacement, actuation, and fixing means to actively dampen vibrations in situ using inertial actuators and accelerometers, which can be magnetically, pneumatically, or hydraulically coupled to the part, allowing for flexible arrangement and adjustment based on vibration analysis and frequency bandwidths between 20-500 Hz.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additional machining steps are used to correct surface defects, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The patent applies preliminary action by implementing vibration control measures during the machining process itself, rather than correcting surface defects after machining. The active damping system prevents vibrations from occurring in the first place, eliminating the need for subsequent corrective machining steps and maintaining high productivity.
Solution Approach 2:
The patent converts the harmful vibrations into a controllable parameter by using sensors to detect vibrations and active damping systems to counteract them. This transforms the harmful effect into a measurable and manageable phenomenon, allowing real-time correction without stopping the machining process.
2Manufacturing precision
If tooling is designed to stiffen flexible portions of parts, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent applies universality by designing a vibration control system that can be applied to various part geometries and machining scenarios. The active damping system with sensors and actuators provides a universal solution that adapts to different parts through control algorithms, rather than requiring custom-designed tooling for each specific part geometry.
Solution Approach 2:
The patent replaces complex mechanical stiffening tooling with an active control system using sensors and actuators. Instead of designing elaborate mechanical fixtures to prevent vibrations, the system uses electronic sensing and active damping to achieve vibration control, reducing mechanical complexity.
3Manufacturing precision
If tooling is arranged close to the machining point, then manufacturing precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the vibration control function into separate modular components: sensors for detection, actuators for active damping, and control electronics. This modular approach allows each component to be optimized independently and facilitates easier manufacturing and implementation compared to integrated custom tooling.
4Manufacturing precision
If stiffening tooling is applied to parts with reduced thicknesses, then manufacturing precision is improved, but object-generated harmful factors increase
Solution Approach 1:
The patent replaces mechanical stiffening tooling that physically contacts and deforms thin parts with an active damping system using sensors and actuators. This substitution eliminates the need for physical contact that causes deformation, using instead electronic sensing and controlled counter-vibrations to achieve precision.
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 approach effectively reduces vibrations during machining, maintains part geometry, increases productivity, and extends tool life by actively damping vibrations without displacing the parts, thereby minimizing surface defects and residual stress.
Implementation Method 1
The actuation means act depending on the vibrations of the part discerned through the accelerometers. Alternatively, the actuation means act according to a bandwidth between 20-500 Hz in order to actively dampen vibrations when machining the part.
Implementation Method 2
The method comprises using at least one accelerometer arranged to discern the vibrations of the part.
Implementation Method 3
The fixing means fix the actuation means to the part by magnetism, pneumatic coupling or hydraulic coupling, Therefore, the part is kept intact in the fixing of the actuation means.
Implementation Method 4
The fixing means fix the actuation means to the part by magnetism, pneumatic coupling or hydraulic coupling
Implementation Method 5
The fixing means fix the actuation means to the part by magnetism, pneumatic coupling or hydraulic coupling
Data Source
Figure 1
AI summary
The invention relates to a method for controlling vibrations in parts (1), the parts (1) being susceptible to bending deformation when machined. The method comprises the steps of selecting a system (2) comprising displacement means (3), actuation means (4) and fixing means (6); displacing the system (2) to the part (1) using the displacement means (3); fixing the actuation means (4) firmly to the part (1) using the fixing means (6); and applying a force against the part (1) using the actuation means (4) in order to actively dampen vibrations when machining the part (1).