Ultrasonic Workpiece Processing with Dual-Stroke Tool Positioning
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Solution Overview
Problem
Existing devices struggle to adjust the distance between the processing tool and the workpiece effectively when dealing with thickness variations or temperature fluctuations, leading to inefficiencies in machining workpieces with varying dimensions.
Innovation Solution
A device comprising a base frame with a carriage that is linearly displaceable, a tool holder movable relative to the carriage via parallel leaf springs, and a single lifting device that adjusts the tool distance by a large adjustment stroke while allowing precise working strokes through stiff leaf springs, enabling accurate and repeatable adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single lifting device is used to move both the carriage and the tool holder, then the device complexity is reduced, but the manufacturing precision deteriorates due to the inability to achieve both large adjustment stroke and precise working stroke
Solution Approach 1:
The lifting device is divided into two functional stages: a first lifting stage for large-displacement carriage adjustment and a second lifting stage for precise tool holder positioning. This segmentation allows each stage to be optimized for its specific function, resolving the contradiction between device simplicity and positioning precision.
Solution Approach 2:
The lifting device transitions between two operational modes: a coarse adjustment mode for large displacements and a fine adjustment mode for precise positioning. The system dynamically switches between these modes based on the required adjustment magnitude, enabling both large adjustment stroke and high precision with a single device.
2Ease of operation
If the carriage is allowed to move continuously during tool adjustment, then the ease of operation is improved, but the reliability deteriorates due to increased wear on the carriage moving parts
Solution Approach 1:
The carriage is pre-positioned to a fixed location before the actual tool holder adjustment begins. This preliminary positioning eliminates unnecessary carriage movement during the precision adjustment phase, reducing wear on carriage components while maintaining operational convenience.
Solution Approach 2:
The adjustment function is extracted from the carriage and assigned to the tool holder's second lifting stage. This separation allows the carriage to remain stationary during precision adjustments, minimizing wear on carriage moving parts while preserving ease of operation.
3Manufacturing precision
If stiff leaf springs are used to enable precise working stroke, then the manufacturing precision is improved, but the ease of manufacture deteriorates due to higher manufacturing requirements for the leaf springs
Solution Approach 1:
The leaf spring system is segmented into two functional zones: a first region that accommodates large displacements during carriage movement and a second region that provides stiffness for precise tool holder positioning. This segmentation allows the leaf springs to achieve high precision without requiring uniformly high manufacturing standards across their entire length.
Solution Approach 2:
The leaf springs exhibit spatially varying stiffness characteristics: they are more flexible in regions subjected to large displacements and stiffer in regions responsible for precision positioning. This local quality variation enables precise working strokes while maintaining manufacturability through targeted rather than universal high-precision requirements.
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 machining of workpieces with varying thicknesses by allowing a large adjustment stroke with high precision and minimal wear, facilitating efficient tool positioning and adaptation to material changes.
Implementation Method 1
a lifting device (20) is provided for moving the tool holder (14) relative to the carriage (12), which is arranged between the base frame (10) and the tool holder (14)
Implementation Method 2
connected to the carriage (12) via two parallel leaf springs (16, 18)
Data Source
Figure 1
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AI summary
The invention relates to a device and a method for processing a workpiece (W), consisting of a base frame (10) with a slide (12), using ultrasound. A tool mounting (14) is connected to the slide (12) via two parallel leaf springs (16, 18), wherein a stroke device (20) can move the tool mounting (14) and the slide (12) together (setting stroke), and if the slide (12) is fixed, e.g. preferably resting against a stop (22), the stroke device (2) can move the tool holder (14) relative to the slide (12) (working stroke). By virtue of the device, two material webs can be welded together for example.