Vibratory Machining Device with Electromechanical Actuator
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Solution Overview
Problem
Conventional drilling devices face challenges in efficiently breaking up and evacuating chips during drilling, especially when dealing with deep bores or multimaterial stacks, due to fixed rotational and feed movement ratios, leading to tool wear and reduced productivity, and lack adaptability for varying machining configurations.
Innovation Solution
A machining device with a transmission shaft and drive mechanism that incorporates an electromechanical actuator to generate axial oscillations, allowing for adaptable and real-time control of oscillation frequency and amplitude, which can be superimposed on the feed movement to break up chips effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a cam/cam follower assembly is used to displace the feed pinion, then axial oscillations are imposed on the feed movement to break up chips, but friction at the cam causes heat, wear and noise
Solution Approach 1:
The patent replaces the cam/cam follower mechanical system with an electromechanical actuator (such as a voice coil actuator, piezoelectric actuator, or magnetic actuator) to generate axial oscillations of the feed pinion. This substitution eliminates the sliding friction inherent in cam mechanisms, thereby reducing heat generation, wear, and noise while maintaining the chip-breaking oscillation function.
Solution Approach 2:
The patent describes an embodiment using a pneumatic actuator (such as a pneumatic cylinder or pneumatic motor) to drive the axial oscillations of the feed pinion. By using compressed air to generate the oscillating motion, the system avoids the mechanical contact and friction of cam mechanisms, reducing wear and heat while maintaining effective chip breakup.
2Device complexity
If the oscillation frequency depends on the relative speed of rotation between the feed pinion and the tool-holding spindle, then the system is simple, but the number of oscillations per revolution remains constant and cannot be optimized for different materials
Solution Approach 1:
The patent employs a controllable electromechanical actuator that can dynamically adjust its oscillation frequency and amplitude independently of the rotational speeds of the feed pinion and tool-holding spindle. This dynamic control capability allows the system to optimize oscillation parameters for different materials and machining conditions, transforming the system from a fixed-ratio mechanical linkage to an adaptable active control system.
Solution Approach 2:
The patent utilizes actuators whose oscillation characteristics (frequency, amplitude, waveform) can be changed by modifying electrical parameters (voltage, current, pulse width modulation duty cycle). This allows real-time adjustment of oscillation parameters to match different machining requirements without changing the mechanical structure, enabling optimization for various materials and tool configurations.
3Adaptability or versatility
If the same tool needs to carry out drilling followed by the production of a bevel, then the oscillation excitation needs to be stopped, but conventional architectures do not make it possible to stop oscillation excitation
Solution Approach 1:
The electromechanical actuator can be independently controlled to start, stop, and modulate oscillation excitation based on the machining process requirements. Unlike mechanical cam systems that continuously impose oscillations, the controllable actuator allows selective application of oscillations only during drilling operations, and complete cessation during beveling operations, providing process-specific control without additional mechanical complexity.
4Ease of manufacture
If conventional drilling devices use fixed pinion ratios, then the operational parameters are constant, but this prevents optimal adaptation to different materials and drilling configurations
Solution Approach 1:
The patent transforms the static, fixed-ratio pinion system into a dynamic system where the feed pinion's axial position oscillates under actuator control. This dynamic oscillation allows the system to vary effective feed rate and chip thickness dynamically during operation, enabling adaptation to different materials and drilling configurations without changing the fundamental mechanical structure or pinion ratios.
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 solution enables improved chip evacuation, reduces tool wear, and enhances adaptability for different machining configurations by allowing real-time adjustment of oscillation characteristics, thereby increasing productivity and extending tool life.
Implementation Method 1
a means for generating axial oscillations, referred to as an electromechanical actuator, mounted at a fixed location, connected to said casing, said electromechanical actuator being able to be coupled axially to said second gearing member in order to make it oscillate translationally
Data Source
AI summary
A machining device including a casing, a transmission shaft (3) and a drive mechanism (1) including a first gearing member (13) that is able to rotate the shaft about its axis (A), a second gearing member (17) that is in a helicoidal connection with the shaft in order to drive the shaft translationally along its axis in a feed movement, depending on the relative rotational speed of the first and second gearing members, and means for generating axial oscillations. The second gearing member (17) is able to move translationally along the axis (A) with respect to the casing, the means for generating axial oscillations including an electromechanical actuator (20) mounted at a fixed location, connected to the casing, and able to be coupled axially to the second gearing member (17) in order to make it oscillate translationally, so as to superimpose an axial oscillation component on said feed movement.