Integrated MR and Magnetostrictive Actuator for Chatter Compensation
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Solution Overview
Problem
Industrial machines and structures experience chatter vibrations due to design errors or disturbances, leading to reduced durability, precision, and stability in manufacturing, and thermal deformations cause processing position displacement, especially in high-temperature environments, which existing methods fail to adequately address.
Innovation Solution
An active integrated heat and chatter compensation device using an MR actuator and a magnetostrictive actuator, with sensors to detect chatter and displacement, and a controller to adjust damping forces and magnetic fields to compensate for aftershocks, torsions, and thermal deformations, thereby changing resonance frequencies and rigidity to reduce vibrations and maintain processing precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an MR actuator is used to reduce chatter vibration, then chatter is reduced, but aftershock and torsion occur which deteriorate processing precision
Solution Approach 1:
The patent combines an MR actuator and a magnetostrictive actuator into a single integrated device. The MR actuator reduces chatter vibration through variable damping, while the magnetostrictive actuator compensates for the resulting aftershock and torsion, thereby maintaining processing precision without sacrificing chatter reduction effectiveness.
Solution Approach 2:
The system uses sensors to detect chatter vibration and processes the signal to control both the MR actuator for chatter reduction and the magnetostrictive actuator for compensating aftershock and torsion. This feedback mechanism ensures that processing precision is maintained by actively correcting the side effects of chatter reduction.
2Object-affected harmful factors
If a manual chatter reducing method using elastic material is used, then chatter is reduced, but the system cannot compensate for thermal deformation
Solution Approach 1:
The integrated compensation device performs multiple functions: the MR actuator reduces chatter vibration, the magnetostrictive actuator compensates for aftershock and torsion, and the same magnetostrictive actuator also compensates for thermal deformation. This multi-functional design eliminates the need for separate systems for each type of compensation.
Solution Approach 2:
The system changes the damping characteristics of the MR actuator and the magnetic field strength of the magnetostrictive actuator based on real-time sensor feedback. This allows the system to adapt to varying conditions including chatter, aftershock, and thermal deformation, maintaining processing precision across different operating conditions.
3Object-affected harmful factors
If an active chatter reducing method using smart actuators is used, then chatter is reduced, but the system complexity increases
Solution Approach 1:
The patent merges the MR actuator and magnetostrictive actuator into a single integrated device with shared components such as the bobbin structure, coil windings, and sensor system. This integration reduces the overall system complexity compared to using separate independent systems for chatter reduction and precision compensation.
Solution Approach 2:
The integrated device performs multiple functions including chatter reduction, aftershock compensation, torsion compensation, and thermal deformation compensation. By consolidating these functions into one device, the system complexity is managed more efficiently than using multiple separate systems.
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 chatter and aftershocks, compensates for thermal deformation-induced displacements, and enhances processing precision by actively controlling resonance frequencies and rigidity, improving the stability and accuracy of industrial processes.
Implementation Method 1
an MR actuator... which includes a first bobbin portion, an MR fluid receiving portion formed in the first bobbin portion, a first coil wound around an outer side of the first bobbin portion, and an MR shaft
Implementation Method 2
a magnetostrictive actuator... one end of the magnetostrictive element may be connected to the upper cover to compensate displacement of the processing product
Data Source
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AI summary
The active compensation device (1000) is disclosed. An active compensation device (1000) according to an exemplary embodiment of the present invention is provided between a processing product mounting portion (3000) and a stage (4000), and includes: a body (100) in which a receiving space is formed; an MR actuator (200) provided in an inner side of the receiving space and of which a damping force is changed according to change in viscosity of an MR fluid; and a magnetostrictive actuator (300) provided in an outer side of the receiving space and including a magnetostrictive element (310) of which length displacement occurs due to a magnetic force.