Linear Drive with Counterweight for Optical Machining
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Solution Overview
Problem
Existing linear drives for machining optical surfaces face challenges with high forces and vibrations during rapid movements, leading to inaccuracies and a lack of compactness, as seen in prior technologies like leaf spring-mounted rotors and air-cushioned systems.
Innovation Solution
A linear drive with a linearly movable compensating body and an electrical compensating drive, where the rotor and compensating body move oppositely to reduce reaction forces, combined with a direct drive system using two separate linear motors for precise and rapid motion, and a bearing arrangement that prevents torsion forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a linear drive with leaf spring-mounted rotor is used, then the structure is simple, but high forces and vibrations occur during rapid movements leading to inaccuracies
Solution Approach 1:
The patent introduces a compensating body with mass that moves in the opposite direction to the rotor through a separate linear drive. This counterbalances the reaction forces and mass forces generated during rapid rotor acceleration, eliminating vibrations and positioning errors while maintaining structural simplicity.
Solution Approach 2:
The patent replaces traditional mechanical coupling between the rotor and compensation mechanism with two independent linear drives. The first linear drive controls the rotor position, while the second linear drive controls the compensating body position, using electrical control instead of mechanical linkages to achieve momentum decoupling.
2Device complexity
If a momentum-decoupled direct drive with spring element is used, then the structure is more compact, but optimum compensation or momentum decoupling cannot be achieved
Solution Approach 1:
The patent eliminates the spring element mechanical coupling in favor of two independent linear drives with electronic control. This substitution provides precise, programmable momentum decoupling that adapts to varying acceleration conditions, achieving optimal compensation that mechanical springs cannot provide.
Solution Approach 2:
The patent uses dynamically controllable linear drives that can adjust their operation in real-time based on the machining requirements. The second linear drive controlling the compensating body can be programmed to provide exact counter-acceleration, making the system adaptable rather than fixed like spring-based mechanisms.
3Force
If a linear drive with mechanical coupling of slide to compensating masses is used, then mass forces are compensated, but the structure is unsuited for rapid movement of optical surfaces
Solution Approach 1:
The patent replaces mechanical gear and rack couplings with direct-drive linear motors. This eliminates the mechanical transmission chain that limited speed, allowing rapid acceleration and deceleration of both the rotor and compensating body without the inertia and friction associated with mechanical gear systems.
Solution Approach 2:
The patent extracts the compensating masses from the traditional mechanical transmission system and makes them independently controllable through a separate linear drive. This allows the compensating body to be accelerated and decelerated independently and simultaneously with the rotor, enabling much higher speeds than mechanical coupling permits.
4Force
If structurally large linear drives are used, then mass compensation is achieved, but the drives are relatively inert and not optimized for rapid movement
Solution Approach 1:
The patent segments the mass compensation function into two independent subsystems: the rotor drive and the compensating body drive. Each has its own linear motor and control system, allowing optimized mass ratios and independent acceleration profiles that reduce overall system inertia and enable rapid movement.
Solution Approach 2:
The patent changes the operational parameters by using electrically controlled linear drives instead of mechanical transmission systems. This allows continuous adjustment of acceleration, velocity, and position parameters, optimizing performance for rapid movement while maintaining mass compensation capability.
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
Enables very accurate and rapid machining of optical workpieces with a compact structure, reducing vibrations and inaccuracies by decoupling mass forces and allowing for high-speed movements with minimal reaction forces.
Implementation Method 1
an electrical rotor drive, which is made as a linear motor
Implementation Method 2
an electrical compensating drive, which is made as a linear motor
Data Source
AI summary
A linear drive and its use for machining an optical workpiece are proposed, the linear drive having a linear movable rotor, a linearly movable compensating body and an electrical compensating drive for movement of the compensating body opposite to the rotor and the rotor extending into the compensating drive and/or a first bearing arrangement mounting the rotor in a torsionally stiff manner and a second bearing arrangement pivotally mounting the rotor.