Modular Inductive Coil Assembly for Vibration Machining Spindles
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Solution Overview
Problem
Conventional non-contact vibration processing devices face issues with energy loss, complex ferrite core manufacturing, brittleness leading to high costs and instability, and cumbersome coil assembly due to large and complex ferrite core designs.
Innovation Solution
A machining device with a modular, compact ferrite core and coil assembly design that reduces manufacturing costs and improves assembly efficiency, featuring a primary and secondary coil system with detachable ferrite cores and coil assemblies, allowing for easy assembly and reduced energy loss, and enhancing processing precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional ferrite core with flanges and annular groove is designed, then electromagnetic induction performance is achieved, but manufacturing complexity increases and ceramic materials are likely to break
Solution Approach 1:
The ferrite core is divided into multiple modular segments that can be assembled together. Each segment has a simpler structure that can be manufactured separately without requiring complex additional processing, reducing the risk of ceramic breakage while maintaining the overall electromagnetic induction performance through proper segmentation and assembly.
2Reliability
If a conventional large ferrite core is installed on high-speed spindle, then electromagnetic induction is achieved, but spindle oscillation increases and stability decreases
Solution Approach 1:
The large ferrite core is segmented into smaller modular units that can be distributed along the spindle. This segmentation reduces the moment of inertia of each individual component, minimizing spindle oscillation during high-speed rotation while maintaining the overall electromagnetic induction function through the distributed arrangement of segments.
Solution Approach 2:
The ferrite core structure transitions from a single large component to multiple smaller components arranged in a distributed pattern along the spindle axis. This dimensional redistribution reduces the concentrated mass and moment of inertia, improving spindle stability while preserving the electromagnetic induction capability through the extended arrangement.
3Reliability
If coil is wound around conventional ferrite core with flanges, then electromagnetic induction is achieved, but assembly convenience decreases
Solution Approach 1:
The ferrite core is segmented into modular units with simplified geometries that facilitate easier coil winding and assembly. Each segment can be independently assembled with its corresponding coil portion, and the segments are then connected to form the complete electromagnetic induction system, significantly improving assembly convenience.
Solution Approach 2:
Instead of winding the coil around the complete ferrite core structure, the approach is inverted by first assembling simpler ferrite segments and then integrating the coil around these modular units. This reversal of the assembly sequence simplifies the coil winding process and makes the overall assembly more convenient.
4Shape
If additional processing such as grinding and machining is applied to ferrite core, then complex geometrical structures are formed, but manufacturing cost increases and yield decreases
Solution Approach 1:
The complex geometrical structure is achieved through segmentation into multiple modular ferrite units, each with simpler shapes that can be manufactured directly without additional grinding or machining. The complex overall structure emerges from the assembly of these simple segments, maintaining high manufacturing yield and low cost.
Solution Approach 2:
The ferrite core system uses composite construction with multiple modular segments that can be manufactured using standard powder metallurgy processes. This composite approach allows complex overall geometries to be achieved through assembly of simple components, avoiding the need for additional costly and yield-reducing processing steps.
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 results in lower manufacturing costs, improved processing precision, and increased yield by simplifying ferrite core production and assembly, reducing energy loss, and stabilizing the spindle and tool rotation during high-speed operation.
Implementation Method 1
a piezoelectric actuator, and at least one secondary coil... The piezoelectric actuator is electrically connected to the primary coil and is engaged with the toolholder to be controlled to drive the tool to vibrate
Implementation Method 2
The non-contact way of energy transmission has become a trend for vibration processing devices nowadays... an inductive structure for transmitting energy in the vibration processing device... The primary coil includes a first ferrite core and a first coil assembly... The at least one secondary coil is adjacent to the primary coil, and includes a second ferrite core and a second coil assembly
Data Source
AI summary
A machining device is adapted to be provided on a mount provided with a toolholder. The toolholder is controllable to rotate and is adapted to be engaged with a tool. A primary coil engaged with the toolholder includes a first ferrite core and a first coil assembly detachably engaged with the first ferrite core. The first coil assembly is modular molded, and is adhered to be an annular body having a first hollow portion. A piezoelectric actuator is electrically connected to the primary coil to drive the tool to vibrate. The secondary coil includes a second ferrite core and a second coil assembly detachably engaged with the second ferrite core. The second coil assembly is modular molded to be an annular body having a second hollow portion.