Pulse Spindle Drill Assembly for Chip Breaking and Vibration Damping
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Solution Overview
Problem
Conventional drilling devices struggle with producing small, sharp chip breaking points and high material removal efficiency when drilling composite materials, and they often cause vibrations that robots and CNC machines find difficult to handle, limiting productivity in industries like aircraft and vehicle manufacturing.
Innovation Solution
A drill device with a precharged elastic element and a milled surface area on a pulse spindle unit, combined with a damping unit, generates distinct and sharp pulses with a plateau, allowing for efficient drilling and minimizing vibrations by using a counterweight that oscillates in phase and amplitude with the drill spindle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a sinus shaped oscillation is used in conventional drilling devices, then the drill spindle can provide chips at regular distances, but it is not possible to provide sharp predetermined breaking points on the spiral chips
Solution Approach 1:
The patent applies periodic pulsed oscillation instead of continuous sinusoidal oscillation. The drill spindle executes periodic pulses with specific timing and amplitude to create sharp breaking points in chips while maintaining efficient material removal. The pulsed nature allows for controlled chip formation and breaking at predetermined locations.
Solution Approach 2:
The patent changes the oscillation parameters dynamically - using high acceleration pulses rather than smooth sinusoidal waves. By modifying the temporal characteristics of the oscillation (sharp peaks with plateaus instead of smooth curves), the system achieves both sharp chip breaking points and high productivity through optimized pulse duration and frequency.
2Manufacturing precision
If high axial acceleration is provided to produce sharp chip breaking points, then small cuttings can be produced, but the electronic, mechanic and hydraulic systems cannot provide the required acceleration
Solution Approach 1:
The patent utilizes mechanical vibration through a specially designed oscillating mechanism that generates high acceleration pulses. The mechanical system incorporates a pulse generator that creates rapid oscillations with sharp peaks, enabling the drill spindle to achieve the necessary acceleration for uniform chip breaking without requiring complex electronic or hydraulic systems.
3Productivity
If a drill device produces small chips with sharp breaking points, then chip removal is efficient, but the axial pulse force creates vibrations that robots and CNC machines struggle to absorb
Solution Approach 1:
The patent employs a counterweight mechanism balanced against the drill spindle assembly. The counterweight offsets the axial pulse forces generated during drilling, significantly reducing vibrations transmitted to the robot or CNC machine. This allows the system to maintain high productivity through effective chip removal while minimizing harmful vibrations that would otherwise limit the use of robotic drilling.
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 drill device produces sharp, predetermined breaking points in chips, enhances material removal rate, and reduces vibrations, making it suitable for use with robots and CNC machines, thereby improving drilling efficiency and productivity in composite materials.
Implementation Method 1
at least a first elastic element that is abutting the housing with one end and the drill assembly with the other end, whereby said first elastic element is at least partially compressed when it is mounted in the drill device
Implementation Method 2
a damping unit having a counterweight, which damping unit is also capable of storing potential energy via an elastic element, said counterweight oscillating in phase and amplitude with the drill spindle unit to cancel out vibrations resulting from the longitudinal pulses of the drill spindle
Data Source
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AI summary
Disclosed herein is a drill device comprising: - a housing (2); - a drill spindle unit (12) arranged at least partially in the housing (2), the drill spindle unit (12) comprising a drill assembly (32), the drill assembly (32) comprising bearings (40), a first coupling portion (30), a drill axle (44) configured to receive a drill, the drill axle (44) being embedded in the bearings (40) and being configured to rotate about a longitudinal axis (a), the drill spindle unit (12) further comprising at least a first elastic element (26) that is at least partially compressed when it is mounted in the drill device. The drill device further comprises a pulse spindle unit (14) having a cylinder-shaped pulse spindle (34) that can be rotated about its longitudinal axis (b), the cylinder-shaped pulse spindle (34) being at least partially arranged within the housing (2), the cylinder-shaped pulse spindle (34) comprising a milled surface area (50) on the lateral surface. The longitudinal axis (b) of the cylinder-shaped pulse spindle (34) is arranged perpendicular to the longitudinal axis (a) of the drill axle (44), the drill spindle unit (12) being arranged so that the first coupling portion (30) is pushed towards the cylinder-shaped pulse spindle (34) so that along the longitudinal axis (a) of the drill axle (44) pulses can be generated when the cylinder-shaped pulse spindle (34) is rotating due to the lateral surface of the cylinder-shaped pulse spindle (34), which lateral surface is interrupted by the milled surface area (50) and due to the pre-compression of the elastic force of the at least partially compressed first elastic element (26).