Process control method and apparatus

Patent metadata

Field	Value
Publication number	US-2025332684-A1
Application number	US-202418644846-A
Country	US
Kind code	A1
Filing date	Apr 24, 2024
Priority date	Apr 24, 2024
Publication date	Oct 30, 2025
Grant date	—

Abstract

A method of machining a workpiece using an ultrasonic vibration tool to engage abrasive particles in a slurry includes capturing a power output from the ultrasonic vibration tool. The power output is related to a vibration amplitude of a tool tip of the ultrasonic vibration tool. A controller connected to an ultrasonic power supply receives the captured power output. The ultrasonic power supply supplies power to the ultrasonic vibration tool. The controller determines the captured power output when it has reached a specified level. A control signal from the controller to the ultrasonic power supply is used to modify the power to the ultrasonic vibration tool.

First claim

We claim:

1 . An ultrasonic impact grinding system comprising:
an ultrasonic vibration tool having a tool tip; a slurry component having a slurry nozzle to deliver a slurry having abrasive particles in an area of the tool tip, wherein the tool tip of the ultrasonic vibration tool engages the abrasive particles to machine a workpiece; an ultrasonic power supply to provide power to the ultrasonic vibration tool; and a controller to receive captured power output by the ultrasonic vibration tool and to control a feed rate to the ultrasonic vibration tool from the ultrasonic power supply, wherein the power output includes a vibration amplitude as the tool tip engages the abrasive particles, wherein the controller is configured to
determine when the captured power output based on the vibration amplitude reaches a specified level, and
modify the feed rate to the ultrasonic vibration tool based on reaching the specified level.

2 . The ultrasonic impact grinding system of claim 1 , wherein the controller is configured to modify the feed rate by either lowering the feed rate to meet a set power level or increasing the feed rate to achieve desired material remove rates.

3 . The ultrasonic impact grinding system of claim 1 , wherein the captured power output includes a vibration frequency.

4 . The ultrasonic impact grinding system of claim 3 , wherein the controller is further configured to determine the captured power output using the vibration amplitude and the vibration frequency.

5 . The ultrasonic impact grinding system of claim 1 , wherein the controller is a computer numerical control controller.

6 . The ultrasonic impact grinding system of claim 1 , wherein the vibration amplitude of the tool tip is captured using a data acquisition device.

7 . The ultrasonic grinding system of claim 1 , further comprising an on-machine tool measurement system to measure a tool length of the tool tip of the ultrasonic vibration tool.

8 . The ultrasonic grinding system of claim 7 , wherein the on-machine tool measurement system is configured to measure the tool length when the vibration amplitude reaches the specified level.

9 . The ultrasonic grinding system of claim 1 , wherein the controller is configured to capture a position of the tool tip.

10 . The ultrasonic grinding system of claim 9 , wherein the controller is further configured to turn off power to the ultrasonic vibration tool based on the position of the tool tip.

11 . A method comprising:
machining a workpiece using an ultrasonic vibration tool to engage abrasive particles in a slurry; capturing a power output from the ultrasonic vibration tool, wherein the power output is related to a vibration amplitude of a tool tip of the ultrasonic vibration tool; receiving the captured power output at a controller connected to an ultrasonic power supply that supplies power to the ultrasonic vibration tool; determining the captured power output has reached a specified level; and modifying power to the ultrasonic vibration tool by a control signal from the controller to the ultrasonic power supply.

12 . The method of claim 11 , further comprising using the control signal to control a feed rate for the ultrasonic vibration tool.

13 . The method of claim 11 , further comprising using the control signal to stop the ultrasonic vibration tool.

14 . A method comprising:
repetitively determining a magnitude of a power output signal used to power an ultrasonic vibration tool used in an ultrasonic impact grinding machine to generate a corresponding data signal; repetitively determining an x-y-z position of the ultrasonic vibration tool during a grinding operation to generate a corresponding position signal; and adaptively processing the corresponding data signal and the corresponding position signal to generate a control signal for controlling an operation of a drive feed system for the ultrasonic vibration tool.

15 . The method of claim 14 , further comprising filtering the corresponding data signal in order to remove at least one unwanted signal artifact.

16 . The method of claim 14 , further comprising filtering the corresponding position signal in order to remove at least one unwanted signal artifact.

17 . The method of claim 14 , further comprising generating the control signal autonomously in response to a state of the corresponding data signal over a predetermined period of time.

18 . The method of claim 14 , further comprising generating the control signal autonomously in response to a state of the corresponding position signal over a predetermined period of time.

19 . The method of claim 14 , further comprising generating the control signal autonomously in response to a state of the corresponding data signal and a state of the corresponding position signal over a predetermined period of time.

20 . The method of claim 14 , further comprising generating the control signal autonomously in response to a state of the corresponding data signal as compared to a state of the corresponding position signal over a predetermined period of time.

Assignees

• Rtx Corp

Inventors

• Wang Zhigang
• Kuczek Andrzej E
• Guo Changsheng
• Tacneau Darian
• Fernandez Robin H
• Barron Alan C
• Abdi Ahmed Abdillahi

Classifications

• B24B49/10 Primary

  involving electrical means (B24B49/02, B24B49/08 take precedence) · CPC title

• B24B49/18

  taking regard of the presence of dressing tools · CPC title

• B24B1/04 Primary

  subjecting the grinding or polishing tools, the abrading or polishing medium or work to vibration, e.g. grinding with ultrasonic frequency (involving oscillating or vibrating containers B24B31/06; superfinishing surfaces on work, e.g. by means of abrading blocks reciprocating with high frequency, B24B35/00) · CPC title