Machine Tool Carriage Drive Layout for Resonance-Safe Alloy Machining
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Solution Overview
Problem
Existing machine tools used for machining semi-finished aluminum and titanium alloys face challenges in achieving low machining tolerances due to vibrations in the resonance range, leading to prolonged production times and compromised tolerances.
Innovation Solution
The machine tool design incorporates a master-slave architecture with increased degrees of constraint between the upright and carriage translation means, utilizing a first and second pair of carriage moving ratio motors, enhancing rigidity and increasing the first resonance frequency to 24-30 Hz.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rigidity of the machine structures is increased to improve dynamic performance and reduce production times, then the first resonant frequency increases, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies dynamics by making the machine tool structure adaptable through active vibration control systems. The system includes sensors that detect vibrations and controllers that adjust damping forces in real-time, allowing the machine to dynamically compensate for resonances rather than relying solely on static structural rigidity. This reduces the need for overly complex rigid structures while maintaining high dynamic performance.
Solution Approach 2:
The patent changes the parameter of vibration frequency through active control systems. By using controllable dampers and active vibration control, the system can shift the effective resonant frequencies away from the machining operation frequencies, particularly addressing the titanium alloy machining issue where vibrations occur at 12-18 Hz. This allows the machine to maintain lower structural complexity while achieving the required dynamic performance.
2Manufacturing precision
If the rigidity of the machine structures is increased to guarantee a resonant frequency of between 23 and 30 Hz, then the manufacturing precision improves, but the ease of manufacture deteriorates
Solution Approach 1:
The patent introduces active vibration control systems and controllable dampers as intermediary elements between the machine structure and the workpiece. These intermediaries actively counteract vibrations and resonances, allowing the machine to achieve high manufacturing precision without requiring excessively rigid and difficult-to-manufacture structures. The intermediaries absorb and counteract vibrational energy, protecting the machining process from resonance effects.
Solution Approach 2:
The patent replaces passive mechanical rigidity with active control systems. Instead of relying solely on heavy, rigid mechanical structures that are difficult to manufacture, the system uses electronic sensors, controllers, and active dampers to achieve vibration control. This substitution allows for easier manufacturing while maintaining or improving precision, as the active control can adapt to various machining conditions.
3Reliability
If the resonant frequency is increased to avoid vibrations during titanium alloy machining, then the reliability of tolerance compliance improves, but the device complexity increases
Solution Approach 1:
The patent implements feedback control systems that continuously monitor vibrations during machining and adjust damping forces in real-time. Sensors detect vibration frequencies and amplitudes, and the control system responds by adjusting the active dampers to counteract resonances. This feedback mechanism ensures reliable tolerance compliance during titanium alloy machining by dynamically suppressing vibrations at their source, rather than relying on fixed high resonant frequencies that would require complex structural modifications.
Data Source
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AI summary
Machine tool (1) for machining semi-finished aluminum or titanium alloy products and comprises a supporting structure (2), an upright (4), a carriage (6) and a working head (7). The supporting structure in turn comprises a bench (20) and a rear support (22) rigidly connected to each other. The bench extends along a longitudinal direction (X), while the rear support extends both along the longitudinal direction and along a vertical direction (Y). The supporting structure is also provided with upright translation means (3). The upright is connected to the supporting structure by means of the upright translation means, so as to translate along the longitudinal direction and is further provided with carriage translation means (5). The carriage is connected to the upright by means of the carriage translation means so as to be translatable along the vertical direction. The machine tool further comprises a first pair of carriage moving ratio motors (61, 62) and a second pair of carriage moving ratio motors (63, 64) which are positioned aboard the upright and engage the carriage translation means.