With the increasing popularity of high-speed machining, tool balancing has become a key issue, which is related to machining efficiency, operational safety and tool life.
Commonly used tool balancing methods are: avoiding imbalance from structural design; using the drilling (milling) method to de-weight the shank; attaching a counterweight; setting a radially adjustable balance screw; Adjust the balance ring to balance the tool. All of these methods have a common problem, that is, they must be used in conjunction with the balancer, which increases the cost of purchasing equipment and requires a considerable balance time; and the balanced object is limited to the components of the tool and the shank, without consideration. The imbalance of the machine tool spindle and the imbalance caused by the dissimilarity of the installation when the tool is loaded into the machine spindle.
In order to overcome the problems of the above balancing methods, it is necessary to propose a new balancing concept and develop a new balancing method. To this end, Kennametal Hertel has introduced a Total Automatic Balancing System (TABS), which uses electromagnetic technology to automatically balance the cutting tool with the machine spindle as a whole, which enables the tool to be loaded into the machine spindle. Automatic balancing on the machine with the spindle. When balancing, the tool rotates with the spindle at the working speed, and the entire balancing process takes no more than 2 seconds. This on-board balancing method achieves a balance that includes the entire rotating system consisting of the tool, the tool holder and the machine tool spindle.
This balancing method relies on the kennametal/Baadyne electromagnetic balancing system on existing machines and the balance of the entire rotating system with Kennametal Hertel's electromagnetic balancing shank.
Principle and composition of the system When working, two sensors for measuring vibration are mounted on the outer casing of the machine tool spindle to measure the vibration of the machine tool spindle in two planes. The controller processes the vibration sensor from the spindle housing and the signal from the position of the balance ring on the tool holder. With these three signals, the controller can measure the spindle speed, phase angle and balance ring position and display their values. .
In order to reduce vibration, the controller first performs an automatic balancing procedure: the vibration value measured from the machine spindle is compared with an allowable rating. The controller then sends a pulse signal that transmits the energy to help balance the rotor (balance ring) ) Rotate to the position calculated by the controller; finally, by repeated measurement, comparison and adjustment, gradually approach and finally reach the allowable rating.
The rotatable gimbal on the shank is a two-weighted rotor, and changing the relative position of the two causes the entire imbalance to be corrected. Normally, the two rotors are held in a position by permanent magnets, which can change their position even with very large rotational speed changes or severe vibrations, and their position is changed only under the corresponding program command.
In this system there is also an adjustment frame with a coil ring corresponding to the position of the balance ring of the tool holder, which is equivalent to the stator. When in use, it is mounted on the machine table, within the reach of the machine's spindle stroke, but does not interfere with the machining process and tool change.
Balancing process In order to achieve balance, the shank (with) with the balance ring enters the adjustment frame, and the controller performs non-contact measurement of the spindle's rotational speed, phase angle, and initial position of the balance ring. The controller then performs an automatic balancing procedure to calculate the position of the balance ring on the shank. Then the controller sends a pulse of energy to transmit the energy from the fixed adjustment coil coil to the balance ring of the counterweight without contact, and uses the generated magnetic force to change the relative position of the two balance rings to achieve a balanced effect.
The balance adjustment can be completed in 2 seconds while the spindle is still rotating at the working speed. The controller repeats the measurement and adjustment cycles until the desired balance is reached.
The controller communicates with the machine numerical control system through the standard cutting parameter output/inlet or RS232 serial port. With the online identification and adaptive control parameters, the machine tool spindle tool can quickly reach a reasonable balance quality. The controller can accurately set the working mode of the system, the threshold value and the allowable value of the user by changing the parameters.
The controller can be used simultaneously with the software that controls the machining, displaying relevant data and graphics in real time, such as spindle speed, vibration magnitude, angular position of the counterweight, balance correction vector, vibration alarm and fault signal. In addition, the system has the function of controlling the balance system with the mouse and adjusting the position of the balance weight by hand.
The actual effect uses the electromagnetic method to balance the tool and the spindle to realize the balance adjustment of the grade G on the machine tool according to the magnitude of the rotation speed and the weight of the spindle cutter with a step of 0.4 to 1. This balancing method is an innovation compared to the existing balancing method by reducing the imbalance of the tool at high speed, thereby improving the machining accuracy and surface quality, extending the tool life and maintaining the accuracy of the machine tool spindle.
Commonly used tool balancing methods are: avoiding imbalance from structural design; using the drilling (milling) method to de-weight the shank; attaching a counterweight; setting a radially adjustable balance screw; Adjust the balance ring to balance the tool. All of these methods have a common problem, that is, they must be used in conjunction with the balancer, which increases the cost of purchasing equipment and requires a considerable balance time; and the balanced object is limited to the components of the tool and the shank, without consideration. The imbalance of the machine tool spindle and the imbalance caused by the dissimilarity of the installation when the tool is loaded into the machine spindle.
In order to overcome the problems of the above balancing methods, it is necessary to propose a new balancing concept and develop a new balancing method. To this end, Kennametal Hertel has introduced a Total Automatic Balancing System (TABS), which uses electromagnetic technology to automatically balance the cutting tool with the machine spindle as a whole, which enables the tool to be loaded into the machine spindle. Automatic balancing on the machine with the spindle. When balancing, the tool rotates with the spindle at the working speed, and the entire balancing process takes no more than 2 seconds. This on-board balancing method achieves a balance that includes the entire rotating system consisting of the tool, the tool holder and the machine tool spindle.
This balancing method relies on the kennametal/Baadyne electromagnetic balancing system on existing machines and the balance of the entire rotating system with Kennametal Hertel's electromagnetic balancing shank.
Principle and composition of the system When working, two sensors for measuring vibration are mounted on the outer casing of the machine tool spindle to measure the vibration of the machine tool spindle in two planes. The controller processes the vibration sensor from the spindle housing and the signal from the position of the balance ring on the tool holder. With these three signals, the controller can measure the spindle speed, phase angle and balance ring position and display their values. .
In order to reduce vibration, the controller first performs an automatic balancing procedure: the vibration value measured from the machine spindle is compared with an allowable rating. The controller then sends a pulse signal that transmits the energy to help balance the rotor (balance ring) ) Rotate to the position calculated by the controller; finally, by repeated measurement, comparison and adjustment, gradually approach and finally reach the allowable rating.
The rotatable gimbal on the shank is a two-weighted rotor, and changing the relative position of the two causes the entire imbalance to be corrected. Normally, the two rotors are held in a position by permanent magnets, which can change their position even with very large rotational speed changes or severe vibrations, and their position is changed only under the corresponding program command.
In this system there is also an adjustment frame with a coil ring corresponding to the position of the balance ring of the tool holder, which is equivalent to the stator. When in use, it is mounted on the machine table, within the reach of the machine's spindle stroke, but does not interfere with the machining process and tool change.
Balancing process In order to achieve balance, the shank (with) with the balance ring enters the adjustment frame, and the controller performs non-contact measurement of the spindle's rotational speed, phase angle, and initial position of the balance ring. The controller then performs an automatic balancing procedure to calculate the position of the balance ring on the shank. Then the controller sends a pulse of energy to transmit the energy from the fixed adjustment coil coil to the balance ring of the counterweight without contact, and uses the generated magnetic force to change the relative position of the two balance rings to achieve a balanced effect.
The balance adjustment can be completed in 2 seconds while the spindle is still rotating at the working speed. The controller repeats the measurement and adjustment cycles until the desired balance is reached.
The controller communicates with the machine numerical control system through the standard cutting parameter output/inlet or RS232 serial port. With the online identification and adaptive control parameters, the machine tool spindle tool can quickly reach a reasonable balance quality. The controller can accurately set the working mode of the system, the threshold value and the allowable value of the user by changing the parameters.
The controller can be used simultaneously with the software that controls the machining, displaying relevant data and graphics in real time, such as spindle speed, vibration magnitude, angular position of the counterweight, balance correction vector, vibration alarm and fault signal. In addition, the system has the function of controlling the balance system with the mouse and adjusting the position of the balance weight by hand.
The actual effect uses the electromagnetic method to balance the tool and the spindle to realize the balance adjustment of the grade G on the machine tool according to the magnitude of the rotation speed and the weight of the spindle cutter with a step of 0.4 to 1. This balancing method is an innovation compared to the existing balancing method by reducing the imbalance of the tool at high speed, thereby improving the machining accuracy and surface quality, extending the tool life and maintaining the accuracy of the machine tool spindle.
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