Coolant-Driven Generator Assembly for Non-Rotating Machining Tools
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Solution Overview
Problem
Existing machining tools face challenges in efficiently harvesting electric energy for wireless monitoring electronics, particularly in non-rotating tools, and experience abrupt energy variations due to tool body movements, which can stress the electric system.
Innovation Solution
The machining tool incorporates a generator assembly that utilizes a medium flow, such as coolant, to create relative movement between components, including a magnet and piezoelectric cantilever, allowing for efficient electric energy generation without requiring tool body movement, using a circular ring with an uneven internal profile and strategically placed magnets to optimize energy production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the generator assembly relies on tool body movement (acceleration and retardation) to generate electric energy, then energy can be harvested in rotating tools, but non-rotating tools cannot harvest energy and the system experiences abrupt energy variations causing stress
Solution Approach 1:
The system uses the coolant medium already flowing through the tool body to drive the generator assembly, eliminating the need for external energy sources or tool body movement. The coolant serves dual purposes: cooling the cutting zone and driving the energy harvesting mechanism
Solution Approach 2:
The invention employs hydraulic principles by using pressurized coolant flow through channels to rotate the turbine wheel, converting fluid kinetic energy into mechanical rotation for electricity generation without requiring tool body motion
2Use of energy by moving object
If the generator assembly uses tool body acceleration and retardation for energy generation, then energy can be harvested, but the abrupt variations cause stress on electric system members
Solution Approach 1:
The coolant flow provides continuous, steady rotational motion to the turbine wheel throughout the machining process, eliminating the abrupt starts and stops that occur with acceleration-based generation. This continuous action produces stable electrical output without stress variations
3Ease of operation
If a turbine is used to convert coolant flow into rotational movement for energy generation, then energy can be harvested without tool body movement, but the turbine structure adds complexity to the tool design
Solution Approach 1:
The turbine wheel and generator assembly are nested within the existing tool body structure, with the turbine housed in a dedicated chamber and the generator positioned to receive direct mechanical drive. This nested arrangement minimizes external complexity while integrating multiple functions
Solution Approach 2:
The coolant flow channels serve dual functions: delivering cooling fluid to the cutting zone and providing the driving force for the turbine. This multi-functionality reduces the need for separate energy harvesting components, simplifying the overall tool structure
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 enables efficient electric energy harvesting for wireless sensor provision in non-rotating tools, reduces energy variation stress, and allows for controlled energy generation, enhancing the reliability of monitoring electronics.
Implementation Method 1
an arrangement configured to conduct a medium flow to hit and act upon the second component (10) for moving it with respect to the first component (5)
Implementation Method 2
the first component comprises a second member of piezoelectric material secured to the cantilever and to flex and oscillate therewith for generating electric energy
Implementation Method 3
the first member is magnetic and arranged on the cantilever to make the cantilever flex and oscillate by interaction with the at least one magnet of the second component
Implementation Method 4
WO 86/04535 A1, on which the preamble of appended claim 1 is based, discloses a tool with an electricity generator connected to a turbine driven by pressurized fluid supplied from the machine
Data Source
Figure 1~1a
Figure 2
Figure 3
AI summary
A machining tool for chip-removing machining comprises a tool body (2) and a generator assembly for harvesting electric energy to be used in the tool and having at least one first component (5) secured to the tool body and a second component (10) movably connected to the tool body so as to by moving with respect to the first component through interaction therewith generate electric energy in the first component. The generator assembly comprises an arrangement for conducting a medium flow to hit and act upon the second component for moving it with respect to the first component.