Electrolytic Probe Forming for Fast, Precise Tip Shaping
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Solution Overview
Problem
Existing probe manufacturing methods, such as grinding with wheels or sandpaper, are time-consuming and prone to damage, while electrochemical machining (ECM) is costly due to the need for expensive equipment, and both methods require repeated processes for achieving precise probe shapes.
Innovation Solution
A probe forming device utilizing a spinning shaft, angle adjusting structures, an electrolyte conveying member, and a power supply with positive and negative terminals to perform electrolysis, allowing for precise shaping of probes without the need for costly equipment, by adjusting the angles of the grinding members and using electrolysis to form the desired probe shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual grinding with grinding wheels or sandpaper is used, then the probe shape can be formed, but the processing time is long and the probability of damages is high
Solution Approach 1:
The patent replaces the mechanical grinding system with an electrolysis-based electrochemical system. Instead of using grinding wheels or sandpaper to mechanically remove material, the invention uses electrolytic dissolution to shape the probe, eliminating the need for repeated mechanical grinding and damage checks while reducing processing time
Solution Approach 2:
The patent changes the fundamental processing parameter from mechanical force (grinding pressure, speed) to electrochemical parameters (current, voltage, electrolyte concentration). This parameter transformation enables continuous material removal without the intermittent stopping required for damage inspection in mechanical grinding
2Productivity
If electrochemical machining (ECM) method is used, then the processing speed is fast and manufacturing precision is high, but the equipment cost is expensive
Solution Approach 1:
The patent uses simple, inexpensive components such as a power supply, electrolyte solution, and basic forming members instead of expensive ECM equipment. The electrolyte and forming members can be easily replaced or adjusted, providing a cost-effective alternative to high-cost ECM machinery while achieving similar processing speeds and precision
Solution Approach 2:
The patent extracts the core electrochemical dissolution principle from the complex ECM system and implements it with minimal equipment. By separating the essential electrochemical function from the expensive supporting infrastructure, the invention achieves fast processing with simple, low-cost equipment
3Ease of manufacture
If manual grinding is used, then the probe can be formed, but repeated grinding and confirmation are required which increases processing time
Solution Approach 1:
The patent enables continuous electrolytic dissolution without interruption for inspection, unlike mechanical grinding which requires stopping to check for damages. The electrochemical process can proceed continuously until the desired shape is achieved, significantly improving production efficiency while maintaining ease of manufacture through simple process control
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 significantly reduces processing time, increases production efficiency, lowers the consumption of grinding materials, and enables rapid production of probes with precise specifications, eliminating the need for repeated grinding and costly machinery.
Implementation Method 1
negative charges are provided to the workpiece and positive charges are provided to the angle adjusting member. By using the electrolyte, the workpiece and the angle adjusting member connected electrically to form the required shape of probes
Data Source
AI summary
The present invention is a probe forming device, the probe forming device comprises a spinning shaft, a first adjusting structure, a second adjusting structure, an electrolyte conveying member and a power supply. One of the holding member of the spinning shaft holds a workpiece, and a driving member drives the workpiece to move and abut the first adjusting structure and the second modulating structure. The electrolyte conveying member conveys an electrolyte to the workpiece, the first adjusting structure and the second adjusting structure, and is electrically connected. At least one positive end of the power supply is connected to the workpiece or the spinning shaft, and at least one negative end is connected to the first adjusting structure and the second modulating structure.