Machine Tool Driven Shaft Vibration Optimization

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Solution Overview

Problem

Machine tools experience imprecise processing and deteriorated surface qualities due to unbalanced driven shafts, leading to unwanted vibrations during high-speed operations, which existing methods fail to adequately suppress or balance.

Innovation Solution

A method that involves selecting a speed range around the target speed, sensing vibrations, and adjusting the speed to find an optimal range where vibrations are minimized, allowing for continuous or stepwise speed changes to optimize vibration dampening and processing quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the driven shaft is balanced as optimal as possible, then vibrations are reduced and processing precision is improved, but this is not always possible to the desired extent due to minor remaining unbalances from clamping or tool contribution

Engineering Contradiction:

Improveprocessing precisionVSAvoidbalancing complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent changes the operating parameter (rotational speed) to optimize vibration characteristics. Instead of attempting perfect mechanical balancing, the system varies the speed parameter to find optimal ranges where vibrations are minimized, thereby achieving high processing precision without requiring complex balancing procedures

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces mechanical balancing methods with a sensor-based vibration measurement and evaluation system. The control unit automatically detects vibration levels at different speeds and determines optimal operating parameters, substituting complex mechanical adjustment procedures with automated electronic control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If high speeds of 40000 rpm or more are used, then productivity is increased, but vibrations are generated resulting in imprecise processing and deteriorated surface qualities

Engineering Contradiction:

Improveprocessing speedVSAvoidsurface quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent introduces dynamic speed adjustment to find optimal operating points. The system continuously or stepwise varies the rotational speed within a range and uses vibration sensors to identify speeds that minimize vibrations while maintaining high productivity, allowing the machine to adaptively operate at optimal speeds rather than fixed high speeds

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent implements a feedback control system where vibration sensors continuously monitor vibration levels during operation. The control unit receives this feedback and automatically determines optimal speed ranges, enabling the system to maintain high productivity while automatically compensating for vibration-induced quality degradation

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If a speed range is passed through to find optimal vibration dampening, then processing quality is enhanced, but time is consumed for speed variation and measurement

Engineering Contradiction:

Improveprocessing qualityVSAvoidoptimization time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent performs preliminary vibration measurements and speed optimization before actual workpiece processing begins. The control unit pre-determines optimal speed ranges by sweeping through a speed range and measuring vibrations, storing this information for use during subsequent processing operations to avoid repeated optimization cycles

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent performs a complete speed range sweep with vibration measurements to ensure optimal parameters are found. This excessive action (measuring across the entire speed range rather than just testing a few points) guarantees that the true optimal speed is identified, preventing re-optimization during production and minimizing total time loss

Inventive Principle:

Principle #16Partial or excessive action

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 method significantly enhances processing quality by automatically minimizing vibrations and achieving optimal vibration characteristics, reducing noise emissions, and adapting to various workpieces and processing parameters, while utilizing existing sensors to reduce costs.

Implementation Method 1

The vibrations occurring in the speed range are sensed

Methodology Applied

Scientific EffectVibration sensing: Vibration

Data Source

PatentUS8317440B2Method for vibration-optimizing a machine tool

Publication Date: 2012.11.27 P&L GMBH & CO KG

AI summary

The invention relates to a method for optimizing vibration of a machine tool, in which a driven shaft is rotated, in which a speed range is subsequently passed through, wherein the vibrations occurring in said speed range are sensed and wherein an optimum speed having a minimized vibration is determined and adjusted.