Open-Loop Air-Bearing Platform for Stable Workpiece Support
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Solution Overview
Problem
High-performance non-contact support platforms using air-bearing technology face challenges in maintaining consistent pressure fields to support fragile workpieces, as the flowrate and pneumatic source control are affected by workpiece coverage, leading to slow response times and varying floating heights.
Innovation Solution
A non-contact support platform with open-loop control, utilizing a surface with fluid-bearing nozzles and a supply system controlled by a controller that adjusts fluid flow based on workpiece parameters such as position, dimension, and velocity, eliminating the need for real-time feedback sensors and allowing for faster adjustments in pressure and vacuum levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If pneumatic sources are used to supply air-bearing platform without active control, then the platform can support workpiece, but the response time is slow and floating height varies with workpiece coverage
Solution Approach 1:
The system pre-calculates and stores the relationship between workpiece coverage area and required flowrate in a lookup table before operation. When a workpiece is placed on the platform, the controller immediately queries the lookup table based on the covered nozzle count to determine the optimal flowrate, eliminating the need for slow real-time iterative adjustments and achieving instant response while maintaining consistent floating height.
Solution Approach 2:
The system dynamically adjusts the airflow rate based on the actual coverage area by mapping the number of covered nozzles to corresponding flowrate values from pre-stored lookup tables. This dynamic adjustment ensures the floating height remains consistent regardless of varying workpiece coverage, while the lookup table approach enables rapid response without complex real-time calculations.
2Reliability
If flowrate is increased to maintain pressure field when workpiece coverage changes, then floating height can be maintained, but pneumatic source adjustment time causes workpiece to move during transition
Solution Approach 1:
The system performs all necessary flowrate calculations and stores optimal values in lookup tables before actual operation. During workpiece processing, the controller simply retrieves the pre-calculated flowrate corresponding to the current coverage area, enabling instantaneous adjustment without the 0.25-second delay that would cause workpiece displacement during transition.
3Reliability
If vacuum source is used to evacuate air, then air-bearing can be maintained, but vacuum level varies with workpiece coverage area
Solution Approach 1:
The system pre-calculates and stores the relationship between workpiece coverage area and required vacuum flowrate in lookup tables. The controller uses these pre-stored values to immediately adjust vacuum flowrate based on covered nozzle count, maintaining stable vacuum level across different coverage areas without requiring complex real-time sensing and adjustment.
4Measurement precision
If traditional closed-loop control with sensors is used, then precise pressure control can be achieved, but system complexity and cost increase
Solution Approach 1:
The system uses the naturally occurring relationship between workpiece coverage area and required flowrate, storing this relationship in lookup tables. The controller simply queries the lookup table based on easily measurable coverage parameters (number of covered nozzles) to determine the optimal flowrate, achieving precise pressure control without requiring complex pressure sensors or iterative feedback control algorithms.
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
Enables consistent support of workpieces across varying coverage areas with reduced response time, maintaining optimal floating height and processing performance without the need for dedicated nozzle sensors, enhancing the efficiency and speed of non-contact support processes.
Implementation Method 1
Pneumatic sources are typically used to produce pressure for forcing air through the pressure nozzles
Implementation Method 2
The remaining nozzles are air evacuation nozzles through which air may be freely evacuated to ambient space, or sucked away by a vacuum source
Implementation Method 3
High-performance, non-contact support platforms using air-bearing technology supplied by pneumatic sources
Data Source
AI summary
A non-contact support platform with open-loop control, including: a surface, to support a workpiece by fluid-bearing of fluid flowing through a plurality of nozzles, a supply system, connected to the surface and configured to maintain the fluid-bearing by applying pressure to cause flow of the fluid out of a subset of the plurality of nozzles, and a controller, to control fluid flow in the supply system with an open-loop circuit to support the workpiece while it moves over the non-contact support platform, wherein the fluid flow is controlled based on at least parameter of a group of workpiece parameters consisting of a position of the workpiece, dimensions of the workpiece and a velocity of the workpiece while supported by the surface.