Ultrasonic Spindle Power Transfer for Stable Vibration Machining
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Solution Overview
Problem
Existing ultrasonic vibration processing devices face inefficiencies in transmitting ultrasonic vibration energy to tools due to spindle length increases and unstable induced electromotive force caused by secondary transformer vibration.
Innovation Solution
The device incorporates a rotatable ultrasonic vibrator with a piezoelectric element and a non-contact power supply unit where the secondary transformer is connected to the ultrasonic vibrator, maintaining a clearance and rotating with it, and a connecting portion with a spline bearing to reduce vibration transmission to the motor, ensuring stable power supply and efficient energy transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a drive motor with stator on housing and rotor on spindle is used, then rotational driving is achieved, but the spindle length increases causing inefficient ultrasonic vibration energy transmission
Solution Approach 1:
The drive motor is extracted from the traditional spindle structure. The motor is divided into a stator fixed to the housing and a rotor that rotates independently on the spindle, allowing the spindle to be shortened while maintaining rotational driving capability.
Solution Approach 2:
The drive motor is segmented into separate stator and rotor components positioned at different locations. The stator remains stationary on the housing while the rotor rotates on the spindle, enabling independent optimization of each component's position and function.
2Reliability
If the secondary transformer is fixed relative to the primary transformer, then electromagnetic induction is stable, but the secondary transformer vibrates due to ultrasonic vibrator vibration causing unstable induced electromotive force
Solution Approach 1:
A flexible connection structure acts as an intermediary between the ultrasonic vibrator and the secondary transformer. This flexible connection allows the secondary transformer to move with the ultrasonic vibrator while maintaining electrical connection, preventing direct vibration transmission that would cause instability.
Solution Approach 2:
The connection between the secondary transformer and the ultrasonic vibrator is made dynamic rather than rigid. The flexible connection structure adapts to the vibration movements, allowing the secondary transformer to maintain its position relative to the primary transformer while accommodating the dynamic motion of the ultrasonic vibrator.
3Ease of operation
If the spindle length is increased to accommodate the drive motor, then rotational driving is achieved, but ultrasonic vibration energy cannot be efficiently transmitted to the tool side
Solution Approach 1:
The rotational driving function is extracted from the spindle and placed in a separate drive motor assembly. This allows the spindle to be shortened to optimal length for ultrasonic vibration transmission while the motor provides rotational driving independently.
Solution Approach 2:
The traditional mechanical spindle-driven motor system is replaced with a separate electromagnetic motor system. The motor uses electromagnetic fields to drive the rotor, eliminating the need for a long mechanical spindle and reducing mechanical energy losses.
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
This configuration suppresses vibration of components, stabilizes induced electromotive force, and effectively transmits ultrasonic vibration energy to tools, enhancing processing efficiency and extending equipment lifespan.
Implementation Method 1
an ultrasonic vibrator including a horn portion having a distal end portion to which a tool holder is detachably attached and a piezoelectric element held at an intermediate portion in a direction of a rotation axis
Implementation Method 2
the primary transformer has a primary coil which receives high frequency power from an external power supply. The secondary transformer has a secondary coil which generates induced electromotive force between itself and the primary coil by electromagnetic induction
Data Source
AI summary
Provided is an ultrasonic vibration processing device which can suppress vibration of components due to an ultrasonic vibrator and can perform processing using ultrasonic vibration in a preferable manner; the ultrasonic vibration processing device includes: a housing (10); an ultrasonic vibrator (20) including a horn portion (21A) to which a tool holder (70) is detachably attached and a piezoelectric element (23), the ultrasonic vibrator having a rear end located at a node of ultrasonic vibration and being supported inside the housing (10) so as to be rotatable; a connecting portion (30) stored in the housing (10) so as to be rotatable together with the ultrasonic vibrator (20); a motor (40) connected to the connecting portion (30); and a non-contact power supply unit (50) including a primary transformer (51) and a secondary transformer (52), the primary transformer (51) being fixed to the housing (10) and including a primary coil (51B) that receives high frequency power from an external power supply, the secondary transformer (52) being connected to the rear end of the ultrasonic vibrator (20) with a clearance maintained between the secondary transformer (52) and the primary transformer (51) and including a secondary coil (52B) that supplies an induced electromotive force to the piezoelectric element (23).