Electromagnetic Linear Drive for Groove Broaching
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Solution Overview
Problem
Existing groove and profile machining devices face inefficiencies due to complex drive systems with mechanical belt couplings, leading to suboptimal vertical movement and wear issues, which affect precision and longevity.
Innovation Solution
The implementation of a vertically operating electromagnetic linear drive system outside the device housing, directly coupling the tool unit to linear guides for precise and low-wear movement, allowing for high-precision control and reduced contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a toothed belt drive with transmission gear is used to couple the servo motor to the lifting carriage, then the vertical movement can be achieved, but the drive system becomes complex and subject to wear and movement irregularities
Solution Approach 1:
The patent replaces the mechanical toothed belt drive and transmission gear system with an electromagnetic linear motor that directly drives the lifting carriage. This substitution eliminates mechanical wear, backlash, and complexity while providing direct coupling between the drive and the moving component, thereby improving reliability and reducing device complexity.
Solution Approach 2:
The patent extracts and removes the intermediate transmission components (toothed belt, transmission gear) from the drive system, leaving only the essential electromagnetic linear motor and lifting carriage. This extraction simplifies the overall system by eliminating unnecessary mechanical elements that cause wear and complexity.
2Volume of moving object
If the linear drive is arranged inside the device housing, then the structure is compact, but the linear drive is subject to contamination from machining operations
Solution Approach 1:
The patent extracts the electromagnetic linear drive from the device housing and positions it externally. This separation removes the sensitive linear drive components from the contaminated machining environment while maintaining the compact overall structure through optimized external mounting arrangements.
Solution Approach 2:
The patent introduces a carrier as an intermediary component that connects the externally positioned linear drive to the tool assembly. This carrier acts as a mediator, allowing the linear drive to remain outside the housing (avoiding contamination) while still providing the necessary mechanical connection and force transmission to the tool unit.
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 high-precision, low-wear, and contamination-free vertical movement of the tool unit, enhancing the machining process with the ability to handle both hard and soft materials and supporting dry or wet processing methods with high drive torques.
Implementation Method 1
the drive device that moves the tool unit, which is guided via at least one vertical linear guide, is a vertically operating electromagnetic linear drive
Data Source
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Figure 3
AI summary
The device (1) is designed as a frame (2) with two lateral vertically positioned support elements (7) and a tool aggregate (4) vertically moved on carriages within the frame (2). The drive unit (3) is assembled of two parallel positioned and simultaneously working electromagnetic linear drives attached with rails to the inner surfaces of the support elements (7). The tool aggregate (4) is directly driven without the use of a mechanically moved belt.