Motor Controller Vibration Suppression for Machine Tools
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Solution Overview
Problem
The vibration of fan motors in machine tools can transmit to the spindle, reducing machine accuracy and the quality of machining surfaces, especially during precise finishing operations.
Innovation Solution
A motor controller that integrates a motor driver, fan motor, and control unit to selectively adjust the rotation speed of the fan motor to minimize vibration transmission to the machine support, using machining mode selection and load detection to optimize fan motor operation, either by reducing or stopping the fan motor's rotation to avoid resonance with the natural vibration frequency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the fan motor rotates at high speed to cool the motor driver, then cooling efficiency is improved, but vibration transmitted to the machine support increases
Solution Approach 1:
The fan motor rotation speed is made dynamically adjustable based on machining mode. During finishing operations, the rotation speed is reduced to minimize vibration transmission to the machine support, while during roughing operations, higher rotation speeds are permitted for effective cooling
Solution Approach 2:
The rotation speed parameter of the fan motor is changed according to the machining mode. By adjusting this parameter, the system optimizes the balance between cooling efficiency and vibration control, preventing resonance during precision finishing operations
2Manufacturing precision
If the fan motor rotation speed is reduced to minimize vibration, then machine accuracy is improved, but cooling efficiency decreases
Solution Approach 1:
The fan motor operates at different rotation speeds according to periodic machining stages. During roughing operations, high speed cooling is applied; during finishing operations, low speed operation is used to maintain accuracy. This periodic adjustment of operation parameters optimizes both cooling efficiency and machine accuracy
Solution Approach 2:
The system dynamically adjusts fan motor rotation speed based on the machining stage. The control unit changes the rotation speed parameter in real-time according to whether the machine is performing roughing or finishing operations, optimizing the trade-off between cooling efficiency and vibration control
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 solution effectively suppresses the transmission of fan motor vibrations to the machine support, enhancing machine accuracy and surface quality during machining operations by adjusting fan motor speed based on machining modes and load conditions.
Implementation Method 1
the rotation of a fan of the fan motor may cause the vibration of the fan motor, and this vibration may be transmitted to the spindle through a support supporting the spindle
Implementation Method 2
changing the rotation number of the fan motor so as to reduce vibration to be transmitted from the housing to the machine support
Data Source
AI summary
A motor controller comprises: a motor driver arranged at a housing attached to a machine support; fan motors and arranged in or outside the housing; and a control unit. The motor driver drives motors. The fan motors blow cooling air for cooling the interior of the housing. The CPU includes a machining mode selection unit allowing selection of at least either a first machining mode of machining a machining target finely or a second machining mode of machining the machining target more roughly than in the first machining mode. If the first machining mode is selected, the machining mode selection unit exerts control to change the rotation numbers of the fan motors and so as to reduce vibration to be transmitted from the housing to the support column.