Magneto-Pneumatic Percussion Control via Pressure Sensor
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Solution Overview
Problem
Existing machine tools for chiseling applications face inefficiencies in their magneto-pneumatic percussion mechanisms, particularly in the control of the air spring's compression and kinetic energy transfer, which affects the impact energy and overall efficiency of the chiseling process.
Innovation Solution
A control method that utilizes a pressure sensor to measure air spring pressure, initiating an acceleration phase when pressure drops, and strategically superimposing magnetic fields from multiple coils to optimize the kinetic energy transfer, including a destructive and constructive superposition of magnetic fields to enhance energy efficiency and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the primary drive continuously accelerates the hammer during the return phase, then the hammer reaches higher speeds, but the efficiency of the primary drive decreases due to increasing air spring compression
Solution Approach 1:
The control method divides the hammer operation into distinct periodic phases: an active return phase where the primary drive accelerates the hammer, followed by a rest phase where the drive is deactivated. This periodic switching allows the system to achieve high hammer speeds during the active phase while minimizing energy consumption during the rest phase when air spring compression would otherwise reduce drive efficiency.
Solution Approach 2:
The system uses a pressure sensor to detect when the air spring pressure drops to a predetermined level, initiating the active return phase before the hammer needs to return. This preliminary detection and timing ensure that the primary drive operates efficiently during the acceleration phase while the air spring is sufficiently decompressed, avoiding the efficiency loss that occurs at higher compression levels.
2Strength
If the air spring is highly compressed to store more potential energy, then the impact energy increases, but the primary drive efficiency decreases
Solution Approach 1:
The system alternates between active return phase and rest phase, allowing the air spring to be compressed during the rest phase (storing potential energy) while the primary drive operates efficiently during the active return phase when the spring is less compressed. This periodic operation resolves the contradiction between achieving high impact energy and maintaining drive efficiency.
Solution Approach 2:
The air spring continuously stores and releases energy throughout the hammer's reciprocating motion, providing a continuous source of potential energy that supplements the primary drive. This allows the system to maintain high impact energy output while the primary drive operates only during phases when it is most efficient.
3Productivity
If the hammer moves quickly against the direction of impact, then the cycle time decreases and productivity increases, but the air spring pressure drops rapidly requiring precise control
Solution Approach 1:
The pressure sensor provides continuous feedback on the air spring pressure, allowing the control system to precisely determine when to initiate the active return phase. This feedback mechanism enables accurate timing of the primary drive activation, ensuring optimal hammer acceleration while maintaining high productivity through rapid cycling.
Solution Approach 2:
The system replaces mechanical position sensing with pressure-based detection to determine hammer position and timing. By using air spring pressure as a proxy for hammer position, the system achieves precise control without complex mechanical sensors, enabling faster and more reliable detection suitable for high-speed operation.
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 the efficiency of the magneto-pneumatic percussion mechanism by optimizing the air spring compression and kinetic energy transfer, leading to improved impact energy and reduced energy losses, thereby increasing the overall efficiency of the chiseling process.
Implementation Method 1
a first magnetic field generated by the first magnetic coil within the first magnetic coil is destructively superimposed in the acceleration phase with the magnetic field of the ring magnet
Implementation Method 2
a second magnetic field generated by the second magnetic coil within the second magnetic coil is constructively superimposed in the acceleration phase with the magnetic field of the ring magnet
Implementation Method 3
an air spring that acts on the racquet in the direction of impact
Implementation Method 4
during a movement of the hammer against the direction of impact, a pressure sensor measures a current pressure in the air spring
Data Source
Figure 1
Figure 2
Figure 3~6
AI summary
A machine tool has a tool holder (6) which is arranged for moveable mounting of a chiselling tool (7) along an axis of movement (3). A magnetopneumatic percussion mechanism (2) contains a primary drive (22) which is disposed around the axis of movement (3) and has a first magnetic coil (46) and a second magnetic coil (47) one following the other in the percussion direction (5). The percussion mechanism (2) has a striker (4) and a die (13) one following the other on the axis of movement (3) within the magnetic coils (46, 47) and in the percussion direction (5). The percussion mechanism (2) also has an air spring (23) acting on the striker (4) in the percussion direction (5). The associated control method according to the invention provides that, during movement of the striker opposite to the percussion direction (5), a pressure sensor (74) measures a current pressure in the air spring (23). A controller (12) begins an acceleration phase (68) at the start of a drop in the pressure in the air spring (23). The primary drive (22) accelerates the striker (4) in the percussion direction (5) during the acceleration phase (68).