Pulse Spindle Drill Assembly for Sharp Chip Breaking
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Solution Overview
Problem
Conventional drilling devices struggle with producing small, sharp chip breaking points in composite materials, leading to surface damage and reduced productivity, especially when used with robots or CNC machines due to limitations in axial acceleration and vibration absorption.
Innovation Solution
A drill device with a pre-charged elastic element and a novel pulse spindle unit featuring a treated surface area on a center axle, generating distinct and sharp pulses with a plateau, combined with a damping unit that cancels out vibrations using a counterweight, allowing for efficient and versatile drilling in various materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a sinus shaped oscillation is used in conventional drilling devices, then the drill spindle can provide continuous motion, but it cannot produce sharp predetermined breaking points on spiral chips and the chip thickness remains non-homogenous
Solution Approach 1:
The patent applies periodic pulse-shaped oscillations instead of continuous sinusoidal motion. The drill spindle executes repeated pulse cycles with distinct acceleration phases, creating regular sharp breaking points on chips while maintaining high material removal rates through optimized pulse frequency and amplitude
Solution Approach 2:
The patent changes the motion parameter from sinusoidal continuous oscillation to pulse-shaped discontinuous oscillation. This parameter change enables sharp acceleration phases that create predetermined chip breaking points, while the pulse duration and frequency are optimized to maintain high productivity
2Manufacturing precision
If high axial acceleration is provided to produce sharp chip breaking points, then small uniform chips are obtained, but the electronic and hydraulic systems cannot provide the required acceleration speed
Solution Approach 1:
The patent applies preliminary action by pre-compressing elastic elements (springs) in the pulse generation mechanism before each drilling pulse. This stored elastic energy is rapidly released to generate the required high axial acceleration, overcoming the limitation of electronic and hydraulic systems that cannot respond fast enough
3Adaptability or versatility
If a drill device is mounted on a robot or robotic arm, then flexibility and automation are improved, but the robot cannot absorb the vibrations created by high accelerations due to low stiffness
Solution Approach 1:
The patent applies counterweight principle by incorporating a damping unit with counterweights that oscillate in opposition to the drill spindle's pulse motion. These counterweights generate equal and opposite forces to cancel out vibrations, enabling the drill device to be mounted on low-stiffness robotic arms without transmitting harmful vibrations
4Ease of operation
If conventional drilling is used with composite materials, then drilling can be performed, but long spiral chips destroy the surface of the drill hole in carbon material layers
Solution Approach 1:
The patent uses periodic pulse oscillations to create sharp breaking points on chips at regular intervals. This breaks long spiral chips into smaller uniform segments that can be efficiently evacuated from the hole without damaging the carbon material surface, while maintaining ease of drilling 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
The solution enables the production of small, sharp chip breaking points with higher material removal rates and reduced vibrations, enhancing drilling efficiency and adaptability to different materials and robotic systems.
Implementation Method 1
at least a first elastic element (26) that is abutting the housing (2) with one end and the drill assembly (32) with the other end, whereby said first elastic element (26) is at least partially compressed when it is mounted in the drill device (1)
Implementation Method 2
a damping unit (10) arranged at least partially in the housing (2), the damping unit (10) comprises a counterweight (24)... so that synchronized pulses along the longitudinal axis of the drill axle (44) in the damping unit (10) and the drill assembly (32) can be generated
Data Source
AI summary
A drill device for drilling holes in components includes: a housing having a first motion link, and a drill spindle unit arranged at least partially in the housing. The drill spindle unit includes a drill assembly which is guided in the first motion link. The drill assembly includes bearings, a first coupling portion, and a drill axle configured to receive a drill. The drill axle is embedded in the bearings and is configured to rotate about a longitudinal axis. The drill spindle unit further includes at least a first elastic element that is abutting the housing with one end and the drill assembly with the other end, whereby the first elastic element is at least partially compressed when it is mounted in the drill device.