Application Cases

Experiment Name: Stability Control Method Based on Ultrasonic Elliptical Vibration Cutting Device

Test Purpose: As a special machining technology, the working state of ultrasonic elliptical vibration cutting is more complex than that of conventional cutting, and the cutting effect is influenced by multiple vibration parameters of the cutting device. Therefore, to achieve stable control of the ultrasonic elliptical vibration cutting state, it is not sufficient to control a single parameter such as vibration frequency or output displacement. Instead, the stability of these parameters must be considered simultaneously. Based on research findings, a stability control method for the state of ultrasonic elliptical vibration cutting has been designed by integrating several methods.

Testing Equipment: Voltage amplifier, signal generator, ultrasonic vibration cutting device, etc.

Figure 1: Schematic Diagram of the Stability Control Process for Ultrasonic Elliptical Vibration Cutting

Experiment Process:

A stability control system was set up. After completing the module design of the stability control system, it was necessary to test it before proceeding to the experimental stage. This was to ensure that the established control system could effectively implement the control method and to optimize some parameters within the control system, providing data support for subsequent experiments.

Simulation Testing:

Figure 2: Output Waveform of the Simulated Elliptical Vibration Cutting Device

A virtual elliptical vibration cutting device with a resonance frequency of 20 kHz and a displacement amplitude of 3 μm was used as the adjustment target for simulation analysis. During the control process, a waveform chart program running on the NIUSB-6361 multifunctional I/O device was used to collect and display the device's voltage, current, and estimated amplitude, with a sampling rate of 200 kHz, which is comparable to that in the actual experiment.

The simulation initially provided an initial excitation voltage to the ultrasonic elliptical vibration cutting device to bring it into resonance in the no-load state. Then, during operation, a sudden change was manually applied to the current displacement of the ultrasonic elliptical vibration device to simulate the effects of cutting load and other factors on the amplitude during the cutting process. The effectiveness of the control system was assessed by observing the waveform curves on the waveform chart.

Experimental Results:

As shown in Figure 2, the output signal of the simulated elliptical vibration cutting device represents the changes in frequency and amplitude during the simulation process. At point 1 in the figure, the device reaches a stable state for the first time after startup, simulating the startup of the device in no-load conditions. At points 2 (2.5 ms) and 3 (5.0 ms), disturbances were applied, causing the device's operating frequency to deviate from the resonance frequency and the amplitude to drop. However, under the adjustment of the stability control system, the device quickly stabilized back to the target state. For the frequency change curve, the initial stabilization took about 0.4 ms, and a subsequent large jump of 100 Hz stabilized in about 0.3 ms. For the amplitude change curve, the initial stabilization took about 1 ms, and a subsequent large jump of 0.5 μm stabilized in about 0.5 ms.

Voltage Amplifier Recommendation: ATA-2048

Figure: Specification Parameters of the ATA-2048 High-Voltage Amplifier

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