Self-Powered Tool Holder for Stable High-Speed Micro-Machining
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Solution Overview
Problem
Existing tool holders for processing machines are limited by high costs and speed capabilities, as they require external energy sources and are not easily adaptable for high-speed micro-machining applications.
Innovation Solution
A tool holder with an integrated electric drive and energy storage unit, allowing for high-speed operation without a permanent external energy connection, featuring a control unit and actuating element for manual speed adjustment, and a sealing mechanism for secure operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a fluid-driven high-speed spindle is used as an attachment, then high speeds can be achieved, but the speed becomes load-dependent and operating costs are comparatively high
Solution Approach 1:
The patent replaces the fluid-driven mechanical system with an electric drive system. The electric motor directly drives the rotor and shaft element, eliminating the fluid coupling that caused load-dependent speed variations. This substitution provides more stable and controllable speeds while reducing operating costs associated with fluid systems.
2Speed
If tools are rotated by a spindle of a processing machine, then material removal can be performed, but the bearings must absorb considerable forces which limits suitability for high speeds
Solution Approach 1:
The patent segments the drive system by placing a compact electric motor directly in the tool holder, separating the high-speed rotation function from the main machine spindle. This allows the tool to rotate at high speeds independent of the main spindle, which only needs to provide positioning and support, thereby reducing bearing force requirements.
Solution Approach 2:
The patent moves the drive mechanism from the machine spindle level to the tool holder level, adding a new dimensional layer to the system architecture. This enables high-speed rotation at the tool level while the machine spindle operates at lower speeds, effectively decoupling the speed and force requirements.
3Adaptability or versatility
If an electric drive with integrated energy storage is used, then high speeds can be achieved without permanent external energy connection, but the device complexity increases
Solution Approach 1:
The patent merges the energy storage unit with the electric drive system in a single integrated assembly. The energy storage unit, electric motor, and control electronics are combined within the tool holder housing, creating a self-contained portable unit that eliminates the need for external energy connections while managing complexity through integration.
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 cost-effective high-speed machining with reduced operational changes between machines, achieving speeds up to 200,000 rpm or more, and provides efficient tool monitoring and maintenance through direct voltage power measurement.
Implementation Method 1
The electric drive has a stator (26) connected to the housing unit (12) and a rotor (28) which is motion-coupled to the shaft element (18)
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a tool holder as a spindle insert for insertion into a clamping element of a motor spindle, wherein the tool holder has: a housing unit; a spindle unit arranged in the housing unit, which spindle unit comprises a drive element and a rotatably mounted shaft element which is movement-coupled to the drive element and has a holding element for holding a tool; an energy storage unit arranged on or in the housing unit for supplying energy to the drive element; and a control unit arranged on or in the housing unit for controlling the drive element.