Workpiece Machining Vibration Analysis for Resonance-Free Tool Speeds
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Solution Overview
Problem
Existing workpiece processing systems face challenges in achieving high process reliability and cutting quality for plate-shaped workpieces due to vibrations caused by rotating components, which affect accuracy and edge quality, and result in increased wear and maintenance costs.
Innovation Solution
A method and system that utilize sensors to detect and analyze vibrations during different tool speeds, allowing for optimized operation by avoiding speed ranges with high amplitudes and determining target speeds that minimize vibrations, thereby improving machining accuracy and reducing wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the tool is rotated at higher speeds to increase productivity, then the cutting speed and productivity improve, but vibrations and resonance occur which deteriorate cutting quality and accuracy
Solution Approach 1:
The patent applies vibration analysis to detect and identify resonance frequencies of the tool during rotation. By measuring vibrations at different rotational speeds and frequencies, the system identifies dangerous resonance conditions and adjusts operating parameters to avoid them, thereby maintaining cutting quality while preserving productivity benefits of high-speed operation.
Solution Approach 2:
The system dynamically changes operating parameters (rotational speed, feed rate) based on detected vibration characteristics. When resonance is detected at a particular speed, the system adjusts the parameters to operate at non-resonant speeds, thus maintaining high productivity while avoiding quality deterioration caused by vibrations.
2Productivity
If the tool is operated at speeds that maximize productivity, then output increases, but wear on the tool and system components increases due to vibrations
Solution Approach 1:
The patent implements a feedback mechanism where vibration sensors continuously monitor tool vibrations during operation. The measured vibration data is processed to identify resonance conditions, and this information feeds back to adjust operational parameters. This closed-loop control allows the system to maintain high productivity while automatically avoiding operating conditions that cause excessive wear, thereby extending tool life.
3Manufacturing precision
If vibration analysis is performed to identify optimal speeds, then cutting quality and accuracy improve, but the complexity of the operating system increases
Solution Approach 1:
The patent replaces complex mechanical vibration control mechanisms with a sensor-based measurement and analysis system. Instead of using complex mechanical dampers or active vibration control mechanisms, the system uses sensors to detect vibrations and processes the data to identify optimal operating speeds, thereby achieving high cutting accuracy with relatively simple added complexity.
4Manufacturing precision
If the tool is driven at different speeds to analyze vibrations, then optimal operating speeds can be determined, but the time required for setup and analysis increases
Solution Approach 1:
The patent performs vibration analysis and identifies optimal operating speeds in advance, before actual production machining begins. By conducting the analysis during setup or idle periods and storing the results, the system eliminates the need for time-consuming analysis during production runs, thereby maintaining high process reliability without significant time loss during actual manufacturing.
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 approach enhances cutting quality, reduces operating noise, prolongs tool life, and enables preventative maintenance by identifying optimal operating speeds that minimize vibrations and resonance, leading to improved process reliability and reduced maintenance costs.
Implementation Method 1
at least one sensor device (68) detects at least one variable which characterizes a vibration ('operating vibration') in at least one area of the workpiece processing system during rotation of the tool
Implementation Method 2
The determined speed or the determined speed range is compared with a standard target speed of the tool in the second operating mode, and that an action takes place depending on the result of the comparison
Implementation Method 3
evaluating the detected variable (assigned to the speed) by means of a vibration analysis, in particular a frequency analysis, and further in particular a Fourier analysis
Data Source
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AI summary
The invention relates to a method for operating a workpiece machining system (10), in which: at least one tool is set in rotation; at least one variable is sensed by a sensor device, said variable characterising a vibration at least in one region of the workpiece machining system (10) during rotation of the tool; and the at least one sensed variable is evaluated. According to the invention, the method comprises the following steps: in a first operating mode: (a) driving a tool of the workpiece machining system (10) at different speeds of rotation; (b) during step a: sensing the variable at the different speeds of rotation of the tool; (c) evaluating the sensed variable by means of a vibration analysis; and (d) in a second operating mode: driving the tool to machine a workpiece depending on the result of the evaluation in step (c).