Elliptical Ultrasonic Spindle Powered by Non-Contact Induction
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Solution Overview
Problem
Conventional elliptical ultrasonic machining devices face limitations in high-speed rotation, stable power supply, and automatic tool change due to mechanical contact power supply methods, which lead to spark generation and restricted rotation speed.
Innovation Solution
An elliptical ultrasonic machining device powered by non-contact induction, featuring two independent loosely coupled transformers with primary and secondary units arranged along the axis, utilizing a primary magnetic core seat and secondary magnetic core seat with a small gap, allowing for high-speed rotation and automatic tool change without mechanical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If mechanical contact power supply is used, then power can be supplied to the rotating ultrasonic transducer, but the rotation speed is limited and sparks are generated
Solution Approach 1:
The patent replaces the mechanical contact power supply system with an electromagnetic induction power supply system. The stationary primary coil generates a magnetic field that induces current in the rotating secondary coil, eliminating mechanical contact between power supply components. This substitution resolves the contradiction by enabling high-speed rotation without mechanical contact sparks while maintaining reliable power supply through electromagnetic coupling.
2Extent of automation
If mechanical contact power supply is used, then power supply can be maintained, but automatic tool change cannot be realized
Solution Approach 1:
By replacing mechanical contact power supply with non-contact electromagnetic induction, the patent enables automatic tool change capability. The stationary primary coil can continuously power different rotating tools through the air gap, eliminating the need for mechanical power transmission connections during tool changes. This reduces device complexity by removing mechanical power coupling components while enabling full automation.
3Speed
If non-contact induction power supply is used, then high-speed rotation and automatic tool change are enabled, but two independent induction power supply signals are required
Solution Approach 1:
The patent divides the power supply system into two independent induction power supply channels, each with its own primary and secondary coils. This segmentation allows each channel to independently control one of the two perpendicular vibration directions, enabling elliptical motion. While this increases system complexity, it achieves the goal of high-speed rotation and automatic tool change by eliminating mechanical constraints.
Solution Approach 2:
The patent designs the induction power supply system to simultaneously achieve multiple functions: high-speed rotation, automatic tool change, and elliptical ultrasonic vibration generation. By making the power supply system universal and adaptable to different operational requirements, the system can maintain reliable power delivery across varying speeds and tool configurations without mechanical intervention.
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 solution enables stable and reliable high-speed rotation, automatic tool change, and increased rotation stability, reducing mechanical interference and enhancing cutting efficiency with the elliptical ultrasonic transducer.
Implementation Method 1
induction power supply primary units (91) of the induction power supply device (9) are arranged at a primary magnetic core seat (911) outside the elliptical ultrasonic spindle shank (2)... induction power supply secondary units (92) encircle the spindle shank shell (6) and rotate with the machine tool spindle (4)... a relatively small gap exists between the primary magnetic core seat (911) and the elliptical ultrasonic spindle shank (2)
Data Source
AI summary
An elliptical ultrasonic machining device powered by non-contact induction mainly includes an induction power supply device and an elliptical ultrasonic spindle shank, wherein: induction power supply secondary units of the induction power supply device encircle a spindle shank shell of the elliptical ultrasonic spindle shank; induction power supply primary units are arranged at a primary magnetic core seat outside the elliptical ultrasonic spindle shank; the primary magnetic core seat and the elliptical ultrasonic spindle shank have a same circle center, and a small gap exists between the primary magnetic core seat and the elliptical ultrasonic spindle shank; the primary magnetic core seat is fastened on a machine tool spindle seat of a machine tool through a support and keeps still; the elliptical ultrasonic spindle shank is mounted on a machine tool spindle through a taper shank and rotates with the spindle in a high speed.