Probe Tip Electrochemical Shaping With Angle Adjustment
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Solution Overview
Problem
The existing methods for manufacturing probes are time-consuming, prone to damage, and costly due to rapid consumption of grinding wheels and sandpapers, and require expensive equipment for electrochemical machining (ECM), which is limited to conductive materials.
Innovation Solution
An ECM process is used to adjust the angle of the probe tip, with the workpiece connected as a positive electrode and the grinding module as a negative electrode, employing an electrolyte to form the desired shape, reducing material consumption and processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual grinding method is used to manufacture probes, then the manufacturing process is simple and equipment cost is low, but the processing time is long and the probability of damages is high
Solution Approach 1:
The patent replaces the traditional mechanical grinding system with an electrochemical machining (ECM) system. Instead of using grinding wheels or sandpaper to mechanically remove material, the invention uses electrochemical dissolution where the probe tip is formed by controlled anodic dissolution in an electrolyte solution. This substitution eliminates mechanical contact, reducing processing time and damage probability while maintaining manufacturing capability.
Solution Approach 2:
The patent changes the fundamental processing parameter from mechanical force (grinding pressure, speed) to electrochemical parameters (voltage, current density, electrolyte composition). By controlling the electrochemical reaction parameters, the probe tip shape and dimensions are precisely controlled, achieving both high productivity and low damage rate while keeping the process relatively simple.
2Productivity
If ECM method is used to manufacture probes, then the processing speed is rapid and manufacturing precision is high, but expensive instruments and equipment are required
Solution Approach 1:
The patent makes the ECM equipment multi-functional by using the same electrochemical machining setup to perform both the formation of the probe tip and the angle adjustment of the tip. Instead of requiring separate equipment for tip formation and angle adjustment, the invention accomplishes both operations in one integrated ECM process, thereby reducing equipment cost while maintaining high processing speed and precision.
Solution Approach 2:
The invention uses the workpiece itself (the probe body) as one of the electrodes in the ECM process. The probe body serves as the cathode, and a separate anode tool is used to dissolve the tip material. This self-service approach eliminates the need for complex external positioning and holding mechanisms, reducing equipment complexity and cost while maintaining high productivity and precision.
3Ease of manufacture
If traditional grinding method is used, then no special equipment is needed, but the consumption of grinding wheels and sandpapers is extremely rapid
Solution Approach 1:
The patent replaces the mechanical grinding system with an electrochemical machining system. Instead of consuming grinding wheels and sandpapers, the invention uses an electrolyte solution and electrical energy to remove material through controlled dissolution. The anode tool in ECM does not wear down like grinding wheels, eliminating the rapid consumption of abrasive materials while keeping equipment requirements relatively simple.
4Manufacturing precision
If repeated grinding and confirmation are performed to ensure probe shape, then the manufacturing precision is improved, but the processing time is extended
Solution Approach 1:
The patent implements a feedback control system in the ECM process where the probe tip formation and angle adjustment are monitored in real-time. By using electrical measurement techniques to detect the probe geometry during machining, the system provides continuous feedback to adjust the electrochemical dissolution process, ensuring high manufacturing precision in a single pass without requiring repeated grinding and confirmation cycles.
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 method significantly reduces processing time, increases production efficiency, and lowers manufacturing costs by eliminating the need for expensive equipment, while enabling rapid production of probes with precise specifications.
Implementation Method 1
The ECM method is to perform machining by electrochemical dissolution using a metal workpiece as the anode... Under low-voltage and high-current condition, the electrolyte can circulate rapidly through the electrodes and the object under machining under pressure for electrolysis
Data Source
AI summary
The present application discloses a method for processing probe. Firstly, a clamping member of a rotation shaft is clamped with a workpiece, and then the workpiece is moved to a processed area by the rotation shaft. The workpiece is rotated by the rotation shaft, and an electrochemical process of the workpiece is performed under the rotation of the shaft and an electrolyte sprayed between the workpiece and the polished module. During the performing of the electrochemical process, it can be that the rotation shaft is moved a processing distance or the included angle of the polish module is changed, for a probe being accomplished from the workpiece. Thereby, the abrasion of the polish module is lower and the performance for processing the probe under the electrochemical process.