Ultrasonic Machining Calibration Using Component ID Data
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Solution Overview
Problem
Ultrasonic machining apparatuses face calibration challenges due to production tolerances in components, requiring complex measurements and slowing down the process, and existing methods need an initial weld assessment or indirect allowance for component tolerances.
Innovation Solution
The ultrasonic machining apparatus uses identifiers, such as RFID chips, smart codes, or USB sticks, to characterize individual component parameters, allowing for direct digital processing and calibration without on-site measurements, enabling quick setup and allowance for production tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex measurements are performed during calibration to account for production tolerances, then manufacturing precision is improved, but productivity deteriorates due to time-consuming measurement processes
Solution Approach 1:
The patent applies preliminary action by pre-measuring individual component parameters (mass, length, stiffness) during component manufacturing and storing them in a database before assembly. This eliminates the need for time-consuming measurements during calibration, as the pre-acquired data is directly used to calculate system parameters and determine optimal operating conditions.
Solution Approach 2:
The patent uses copying by creating a digital model of the ultrasonic system that replicates the physical system's characteristics. The digital model incorporates pre-measured component parameters and allows virtual calibration calculations to be performed, replacing the need for physical measurements and iterative adjustments during actual calibration.
2Measurement precision
If on-site measurements are performed during calibration, then measurement precision is improved, but loss of time increases due to the measurement process
Solution Approach 1:
The patent applies preliminary action by pre-measuring individual component parameters (mass, length, stiffness) during component manufacturing and storing them in a database before assembly. This eliminates the need for time-consuming measurements during calibration, as the pre-acquired data is directly used to calculate system parameters and determine optimal operating conditions.
Solution Approach 2:
The patent replaces mechanical measurement systems with computational methods. Instead of performing physical measurements during calibration, the system uses pre-measured data combined with finite element models and calculations to determine system parameters, substituting computational processing for physical measurement activities.
3Manufacturing precision
If manual assessment of initial weld quality is required, then manufacturing precision is improved, but device complexity increases due to additional assessment procedures
Solution Approach 1:
The patent applies feedback by using the results of initial tests (such as welding tests or machining tests) to automatically adjust and optimize system parameters. The system measures performance metrics from these tests and uses the feedback to refine the digital model and determine optimal operating conditions, eliminating the need for manual quality assessment.
Solution Approach 2:
The patent applies self-service by enabling the system to automatically perform its own calibration and optimization without requiring manual intervention. The system autonomously processes test results, adjusts parameters, and determines optimal operating conditions based on pre-measured component data and performance feedback, making the calibration process self-contained.
Data Source
AI summary
An ultrasonic machining device (1) for machining a workpiece. At least one component, selected from the group including a generator (11), a converter (12), a booster (13), a sonotrode (14), a HV cable (15), a machine frame (16) and a receiving device for the workpiece (17), is/are assigned an identifier (18). The identifier (18) characterizes at least one individual parameter of the component. The device (1) is assigned an input interface (19) which reads in the identifier (18) or generated data from the identifier. The device (1) is assigned a data processing arrangement (20). By way of the data processing arrangement (20), based on the read-in identifier (18) or the data generated from the identifier (18), at least one parameter of the device (1) is determined in such a way that the device (1) is operated in a target operating state, e.g., a resonant vibrating state.