Active Boring Bar Damper With Electromagnetic Vibration Feedback
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Solution Overview
Problem
Existing solutions for reducing self-excited vibrations in machining processes, such as passive and active dampers, face limitations in flexibility and effectiveness due to specific tuning requirements and geometric constraints.
Innovation Solution
An active damper that uses acceleration sensors to measure vibrations and adjust electromagnetic forces based on optimal amplitude, phase, and frequency, allowing for dynamic control of vibrations and improved damping effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the weight of the moving mass of the passive damper is increased to improve vibration damping efficiency, then the damping effectiveness is improved, but the volume of the cutting tool increases and geometric limitations are imposed
Solution Approach 1:
The patent replaces the passive mechanical damper system with an active electromagnetic control system. Electromagnets generate controllable electromagnetic forces to counteract vibrations without requiring large moving masses. This substitution allows effective vibration damping while maintaining compact tool geometry, directly resolving the contradiction between damping efficiency and tool volume.
Solution Approach 2:
The patent changes the fundamental parameter from mechanical mass to electromagnetic force generation. By using electromagnets with controllable current, the system achieves variable damping forces without being constrained by physical mass limitations. This parameter change enables effective vibration control in compact tool designs where passive dampers would be too bulky.
2Reliability
If passive dampers are tuned specifically for each tool to match critical bending mode frequency, then damping effectiveness is improved, but the device complexity increases and flexibility is reduced
Solution Approach 1:
The patent implements a dynamic control system where electromagnetic forces are continuously adjusted based on real-time vibration measurements from accelerometers. The control system modifies force magnitude and frequency dynamically to match varying operating conditions, eliminating the need for static pre-tuning of each tool. This dynamic adaptation reduces complexity while maintaining effectiveness across different tool configurations.
Solution Approach 2:
The patent incorporates accelerometer sensors that provide real-time feedback on tool vibrations to the control system. This feedback loop enables automatic adjustment of electromagnetic damping forces without requiring manual tuning or knowledge of the tool's critical frequencies. The system self-adjusts based on measured vibrations, significantly reducing device complexity and improving flexibility across different tool types.
3Adaptability or versatility
If active dampers use electromagnetic forces to suppress vibrations, then adaptability to varying vibration conditions is improved, but the force density is limited and actuator volume increases
Solution Approach 1:
The patent merges multiple electromagnets into a compact array integrated directly into the tool structure. By combining the functions of sensing (accelerometers) and actuation (electromagnets) into a unified compact system, the patent achieves high force density. The merged design allows electromagnetic forces to be applied at the exact location where vibrations occur, maximizing effectiveness while minimizing actuator volume.
Solution Approach 2:
The patent distributes electromagnets in a three-dimensional arrangement around the tool's critical vibration zones rather than using a single large actuator. This spatial distribution in multiple dimensions enables the system to generate controllable forces in various directions, achieving high adaptability to different vibration modes while maintaining compact overall dimensions and high force density.
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
The active damper effectively attenuates and suppresses self-excited vibrations, increasing the dynamic rigidity of the cutting tool and improving machining stability and productivity.
Implementation Method 1
an acceleration sensor configured to measure accelerations of the actuator, attached to the fixed body of the actuator and the accelerations having directions perpendicular to the longitudinal direction
Implementation Method 2
electromagnets that are fixed with respect to the body (2) of the actuator, the electromagnets being configured to generate a magnetic field in the cavity
Implementation Method 3
an inertial mass in the cavity, the inertial mass being movable with respect to the body in directions perpendicular to the longitudinal direction; the electromagnets being around the inertial mass
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention relates to an active damper (1) for vibration attenuation in a boring bar (100) comprising an actuator (101) with electromagnets (4) attached to a body (2) thereof, and an inertial mass (3) in a cavity (12) of the actuator (101) movable in directions perpendicular to the longitudinal direction of the actuator (101); comprising an acceleration sensor (5) in the actuator (101) and control means (9) of currents of the electromagnets (4) depending on the measurements of the acceleration sensor (5).