Rotary Spindle Head with Coaxial Gear Reducer
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Solution Overview
Problem
Conventional rotary spindle heads for multi-axis machine tools face challenges in achieving high-speed and high-torque capabilities due to mechanical efficiency losses, reduced rotation speed, and compromised design flexibility in existing designs, particularly with high reduction ratio servo motor systems and torque motor configurations.
Innovation Solution
A rotary spindle head with a coaxially arranged torque motor and gear reducer, featuring a lower speed reduction ratio, which enhances torque output while maintaining high rotation speed, and a compact, symmetric configuration for improved dynamic balance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a high reduction ratio speed reduction mechanism is coupled to a servo motor to enlarge output torque, then the output torque is sufficiently enlarged for the rotary spindle head to operate, but the mechanical transmission causes considerable loss in mechanical efficiency and greatly reduces the rotation speed of the spindle head
Solution Approach 1:
The patent replaces the traditional mechanical speed reduction mechanism with a magnetic coupling system. The servo motor couples to a magnetic coupling device that directly drives the spindle head without mechanical transmission components. This substitution eliminates mechanical friction and transmission losses while maintaining the torque multiplication effect, thereby resolving the contradiction between enlarging output torque and preserving mechanical efficiency.
2Force
If a high reduction ratio speed reduction mechanism is used to enlarge output torque, then the rotary spindle head can operate with sufficient torque, but the rotation speed of the spindle head is greatly reduced so that it cannot be used for high speed machining
Solution Approach 1:
The patent substitutes the mechanical speed reduction mechanism with a magnetic coupling device that enables direct coupling between the servo motor and the spindle head. This eliminates the speed reduction effect of mechanical transmissions while maintaining torque multiplication through magnetic field interaction, allowing the spindle head to achieve both high torque and high rotation speed for high-speed machining applications.
3Force
If a high reduction ratio mechanical transmission is designed, then the output torque is sufficiently enlarged, but the volume of the transmission mechanism is larger which adversely affects the design degree of freedom of the rotary spindle head
Solution Approach 1:
The patent replaces the bulky mechanical speed reduction mechanism with a compact magnetic coupling device. The magnetic coupling system achieves torque multiplication without requiring large mechanical transmission components, significantly reducing the volume of the transmission mechanism and preserving the design degree of freedom of the rotary spindle head for various machining applications.
4Loss of energy
If torque motors are used to directly drive the spindle head, then the design can achieve low power loss and high rotation speed, but the cost increases and larger torque motors with larger torque outputs increase overall volume and compromise design flexibility
Solution Approach 1:
The patent merges the advantages of servo motors (precise control, compact size) with the benefits of torque motors (high torque output, low power loss) by using a magnetic coupling device. The servo motor provides precise rotational control while the magnetic coupling transmits torque efficiently to the spindle head, achieving low power loss and high rotation speed without requiring oversized torque motors, thereby controlling cost and volume while maintaining design flexibility.
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 high-speed light-machining and high-torque heavy-machining capabilities with increased torque density and dynamic balance, suitable for demanding applications like aerospace and energy industries.
Implementation Method 1
a gear reducer, having a driving gear, at least one idle gear, a ring gear and an axle seat... the at least one idle gear is mesh respectively with the driving gear and the ring gear
Data Source
AI summary
A rotary spindle head with gear reducer is provided, which comprises a rotary spindle unit, a fork-shaped type spindle base and a driving unit. The fork-shaped spindle base is for linking up the rotary spindle unit with a machine tool, and the driving unit comprises a torque motor and a gear reducer which are sited coaxially on the fork-shaped spindle base. The gear reducer is connected to the rotary spindle unit to drive and rotate the rotary spindle unit in the fork-shaped spindle base. The gear reducer is designed to lower decelerating rate. Besides, the input and output of the gear reducer are coaxial design, the torque of torque motor could be magnified to several times and maintain higher rotational speed to do the high speed light cutting and high torque heavy cutting work.