Machine Tool Vibration Cancellation for Real-Time Machining Accuracy
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Solution Overview
Problem
Existing machine tools face challenges in actively reducing vibrations that occur due to real-time changes in dynamic characteristics, particularly under normal finishing machining conditions, leading to reduced machining accuracy, increased defective products, and higher costs.
Innovation Solution
An active vibration reduction device and method that uses an excitation unit controlled by a sensing and control module to generate excitation opposite to the detected vibrations in real time, distinguishing between weak-structure and normal-machining modes, thereby improving dynamic stiffness and machining accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vibration reduction is not actively controlled in real-time, then the device complexity is low, but the manufacturing precision deteriorates due to vibration during machining
Solution Approach 1:
The patent implements a feedback control system where vibration sensors detect vibration in real-time, and the control module adjusts excitation unit parameters based on detected vibration levels to actively reduce vibration during machining, thereby improving manufacturing precision
Solution Approach 2:
The patent dynamically adjusts excitation unit parameters (such as frequency and amplitude) based on real-time vibration conditions detected during machining. The system transitions from static to dynamic control, allowing the vibration reduction mechanism to adapt to changing machining conditions and maintain high precision throughout the process
2Manufacturing precision
If real-time vibration control is implemented, then the manufacturing precision is improved, but the device complexity increases due to additional sensing and control components
Solution Approach 1:
The control module serves multiple functions: it processes vibration sensor data, determines optimal excitation parameters, controls excitation unit operation, and monitors machining conditions. By consolidating these functions into a single multi-functional control unit, the patent reduces overall system complexity while maintaining high machining precision
3Manufacturing precision
If vibration is not reduced during weak-structure mode, then the device complexity is low, but the manufacturing precision deteriorates due to increased vibration in weak-structure regions
Solution Approach 1:
The patent applies local quality control by detecting the specific location and characteristics of vibration (weak-structure mode vs. normal mode) and applying targeted excitation counter-vibrations only where needed. The control module adjusts excitation parameters based on the identified vibration mode, providing localized precision control without requiring complex system-wide modifications
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 effectively reduces vibrations, enhances machining accuracy, improves surface quality, and reduces production and maintenance costs by actively adapting to real-time changes in dynamic characteristics.
Implementation Method 1
causing an excitation unit to change and generate excitation opposite to vibration generated in the individual unit in any one of a weak-structure mode or a normal-machining mode depending on a type of vibration occurring in real time
Data Source
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AI summary
The present disclosure relates to an active vibration reduction device and method for a machine tool, which actively reduces vibration of an individual unit according to a workpiece machining condition by causing an excitation unit to change and generate excitation opposite to vibration generated in the individual unit in any one of a weak-structure mode or a normal-machining mode depending on a type of vibration occurring in real time during driving of the individual unit for workpiece machining.