Inductive Power Transfer for High-Frequency Vibration Spindles
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Solution Overview
Problem
Current high frequency vibration spindle systems face deterioration and limited rotation speed due to contact-type power transmission methods, leading to reduced tool life and processing efficiency.
Innovation Solution
A non-contact induction method using concentric coils with ferrite cores for electric power transmission, allowing for higher spindle rotation speeds and minimizing tool deterioration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact-type power transmission method (conductive slip ring or conductive brush) is used, then electric power can be transmitted to the rotating spindle, but the contact components deteriorate or damage due to long time contact and friction
Solution Approach 1:
The patent replaces the mechanical contact-type power transmission system (conductive slip ring and brush) with an electromagnetic induction system. The stator coil generates a magnetic field that induces current in the rotor coil, transmitting power without physical contact. This eliminates wear and deterioration of contact components, directly resolving the reliability issue.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary to transmit power from the stator to the rotor. The stator coil creates a magnetic field that couples with the rotor coil, enabling energy transfer without direct contact. This intermediary field-based transmission avoids the harmful frictional contact between conductive components.
2Reliability
If contact-type power transmission method is used, then power can be transmitted, but electric sparks are generated by high-speed frictional contact
Solution Approach 1:
The patent replaces the mechanical contact system with an electromagnetic induction system. Power is transmitted through magnetic coupling between stator and rotor coils without physical contact, eliminating the frictional sparks that occur in contact-type systems. This ensures stable processing without interference from electric sparks.
3Speed
If contact-type power transmission method is used, then power transmission is achieved, but spindle rotation speed must be limited to mitigate deterioration
Solution Approach 1:
The patent replaces the contact-based mechanical power transmission with electromagnetic induction. The stator coil generates a rotating magnetic field that induces current in the rotor coil, driving the spindle at high speeds without mechanical contact. This eliminates the need to limit rotation speed to protect contact components, enabling high-speed vibration assisted processing.
4Speed
If non-contact induction method is used, then spindle rotation speed can be increased and tool life extended, but the system complexity increases with coils and ferrite cores
Solution Approach 1:
The electromagnetic induction system serves multiple functions: the stator coil generates the magnetic field, the ferrite core concentrates and directs the magnetic flux, and the rotor coil receives induced current to drive the spindle. This multi-functional integration achieves high-speed rotation while managing system complexity through coordinated component design.
Solution Approach 2:
The patent uses ferrite core material, which combines magnetic properties with structural stability. The ferrite core efficiently channels the magnetic field from the stator coil to the rotor coil while maintaining mechanical integrity at high rotation speeds. This composite approach (coils + ferrite core) achieves the desired performance with manageable complexity.
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 non-contact induction method enhances tool life and processing efficiency by preventing wear and allowing higher spindle speeds, improving the overall performance of the high frequency vibration spindle system.
Implementation Method 1
a non-contact induction method using concentric coils with ferrite cores for electric power transmission
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A high frequency vibration spindle system (100, 200, 300) which includes a spindle (10, 210, 310) having a spindle housing (12) and a spindle shaft (14, 214, 314) disposed in the spindle housing (12); a tool holder (20, 220, 320), engaged with the spindle (10, 210, 310) and adapted to be engaged with a tool (21); an electric power transmission device (40, 240, 340) disposed at the front end or a rear end of the spindle (10, 210, 310), including a first coil (41, 241, 341) and a second coil (42, 242, 342); the first coil (41, 241, 341) is disposed on the spindle housing (12), and the second coil (42, 242, 342) is disposed on the spindle shaft (14, 214, 314) to be rotated with the spindle shaft (14, 214, 314) coaxially; the first coil (41, 241, 341) and the second coil (42, 242, 342) are spaced with a gap; the second coil (42, 242, 342) is adapted to receive an electric power from the first coil (41, 241, 341) with a non-contact induction method; and a transducer (30, 230, 330), adapted to be controlled to vibrate the tool (21) and disposed in the toolholder (20, 220, 320) and electrically connected with the second coil (42, 242, 342) to receive the electric power.