Ultrasonic Machining Module Vibration Isolation Bridge

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Solution Overview

Problem

Existing machining systems are not designed to accommodate ultrasonic energy, posing challenges in incorporating ultrasonic machining modules without damaging or negatively impacting system performance.

Innovation Solution

A closed-loop machining system with an ultrasonic machining module that includes a vibration-isolating housing and a safety and compatibility bridge, allowing for the integration of ultrasonic energy into existing machining systems while preventing unwanted vibrations and ensuring safe operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If ultrasonic machining module is integrated into existing machining systems, then machining performance is enhanced, but system compatibility and safety are compromised

Engineering Contradiction:

Improvemachining performanceVSAvoidsystem compatibility

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A safety and compatibility bridge is introduced as an intermediary component between the ultrasonic machining module and the existing machining system processor. This bridge includes electrical connectivity and microprocessor-based communication that verifies system compatibility, checks for proper module installation, and prevents damage to the existing machining system while enabling ultrasonic machining functionality.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The safety and compatibility bridge implements feedback mechanisms by monitoring electrical connections, verifying microprocessor communication, and detecting proper module installation. The system provides real-time feedback to ensure the ultrasonic machining module is correctly integrated and operates safely within the existing machining system parameters.

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If ultrasonic vibrations are transmitted to machining system, then machining accuracy is improved, but unwanted vibrations damage the system

Engineering Contradiction:

Improvemachining accuracyVSAvoidunwanted vibrations

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The harmful vibrational effects are extracted and isolated from the main machining system through a vibration-isolating housing. This housing contains the ultrasonic transducer and acoustic vibrations, allowing only the beneficial axial vibrations to be transmitted to the machining tool while preventing unwanted vibrations from traveling backward into the machining system.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The ultrasonic vibrations, which could potentially harm the machining system, are converted into a beneficial tool by using a vibration-isolating housing that directs only the necessary axial vibrations to the tool while containing harmful lateral and backward vibrations within the housing structure.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Duration of action of moving object

If high power ultrasonic vibrations are applied to improve tool life, then productivity increases, but system complexity increases

Engineering Contradiction:

Improvetool lifeVSAvoidsystem complexity

Core Design Contradiction:

Duration of action of moving objectVSDevice complexity

Solution Approach 1:

The safety and compatibility bridge is designed to work with various existing machining systems (milling machines, lathes, drill presses) through universal communication protocols and electrical connections. The vibration-isolating housing provides multi-functional protection by isolating vibrations, containing acoustic energy, and supporting the ultrasonic transducer assembly, thereby reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 the effective incorporation of ultrasonic energy into machining systems, enhancing machining performance by isolating vibrations and ensuring compatibility, thereby improving tool life and accuracy without damaging the existing systems.

Implementation Method 1

an ultrasonic transducer connected to the collet for generating acoustical vibrations

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

at least one vibration-isolating structure that isolates substantially all acoustical vibrations generated by the ultrasonic transducer

Methodology Applied

Scientific EffectVibration isolation: Damping

Data Source

PatentUS9764390B2Closed-loop metalworking system

Publication Date: 2017.09.19 EDISON IND INNOVATION LLC

AI summary

A closed-loop machining system that includes a rotating spindle assembly having a body, a tool holder connected to the body, an ultrasonic machining module connected to the tool holder, and a power supply for powering the module; a processor for controlling the operation of the closed-loop machining system; a safety and compatibility bridge linking the ultrasonic machining module to the processor, wherein the safety and compatibility bridge further includes an electrical connection between the ultrasonic machining module and the processor; and at least one microprocessor located in or associated with the ultrasonic machining module for enabling and processing communication between the ultrasonic machining module and the processor.