A new servo drive for electro discharge machining industrial applications is presented in this paper. The development processes of the servo feed drive have passed through three main stages. The first stage focused on design and development of a linear piezoelectric ultrasonic motor. The second one concentrated on development of an electronic driver and its embedded software. The integration, testing, and validation in electro discharge machining system, was the last stage of the development iifecycle. The linear piezoelectric ultrasonic motor consists of three main parts, the stator, rotor, and sliding element. The motor design process, basic configuration, principles of motion, finite element analysis, and experimental examination of the main characteristics are discussed in this paper. The electronic driver of the ultrasonic motor consists of two main stages, the booster and piezoelectric amplifier. The piezo amplifier consists of four output transistors, a push-pull and bridge, connected in order to achieve the necessary electrical parameters to drive and control the motor servo feed drive traveling speed. The essential expérimentai arrangement to implement arjd examine the developed ultrasonic servo feed drive in an electro discharge machining system was carried out. The initial results showed that the servo drive is abie to provide: a r-eversible directional of motion, no-load traveling speed equal to 28 mm per s. maximum load of 0.78N, a resolution <50p.m, arid a dynamic time response <10ms. The electr-on microscopic micrv examination into the machined samples showed that: ultr-asonic servo drive showed a clear improvement in the surface profile finish, a notable reduction in the stability, processing time, material removal rate, ar-cing, and short-circuiting teething phenomena. This was verified by assessing the electrode movements, the variations of the inter electrode gap voltage, current, and feedback control signals.
This paper presents a standing wave piezoelectric ultrasonic using a flexural vibration transducer. The motor consists of three main parts, stator, rotor and sliding element. The stator is a single piezoceramic flexural vibration bar. The rotor is made up of the motor driving wheel and the shaft. A computer simulation and modelling using finite element analysis for the proposed motor is discussed and used in the motor design development process. Finite element analysis has been used to evaluate the motor structure by performing an algebraic solution of a set of equations, describing an ideal model structure, with a finite number of variables. The established simulation and modelling for ultrasonic motor using finite element analysis enabled to select, the material of the flexural transducer, defining the operating parameters for the motor, determining the principles of motion and proposing an innovative technique to control the direction of motion, by controlling the phase between the two modes of vibrations. This enabled to create two directions of motion from a single vibration bar. A prototype of the proposed motor was fabricated and measured. This showed that operating parameters of the fabricated prototype are: frequency equal to 40.7 KHz, voltage: 50: 100 volt and current: 50: 100 m-amperes. This is showed a close agreement with FEA. Typical output of the prototype is no-load travelling speed of 28 mm/s, a resolution on the order of micrometers and a dynamic response <100 μsec. The motor is able to carry a load equal to 0.78 Newton. The developed motor has been used successfully in EDM industrial applications.
This paper presents an innovative tactile interactive interface graphical display for visually impaired people, information technology (IT) access application. The display consists of matrix of dots. Each dot is an electro rheological fluid micro actuator. The micro-actuator designed based on linear vertical movement principles. The actuator design and development process is presented in this paper. An advanced software tools and embedded system based on voltage matrix manipulation are developed to provide the display near real time control. Prototype size 124x4 dots, on a matrix form, of 2.54mm pitch, was manufactured. The experimental tests carried out into the prototype showed that each actuator of the matrix was able to provide a vertical holding force of 100 to 200 mN and vertical movement of 0.7 mm. The stroke and dynamic response tests showed the practicability of the developed micro actuation system, for tactile display IT access applications.
This paper demonstrates the investigation carried out into the influence of ultrasonic servo feed drive technology, in electro discharge processing systems, industrial applications. The drive was mainly designed to replace the existing servo control drive using electromagnetic servo technology. This was aimed to improve the electro discharge servo control system stability, quality of the machined products surface profiles, and system dynamic time response. Evaluation has been undertaken to examine the developed servo control feed drive, in two industrial applications, electro discharge machining and electro discharge texturing. Two arrangements were used, in this investigation. The existing servo control feed drive system, which uses electromagnetic servo drive, and the developed system, which uses piezoelectric ultrasonic feed drive. The electro discharge processing parameters, including current level, the on-off time and the duty cycle of the machining pulse were the main processing parameters of this investigation. The electron microscopic micro examination into the machined and textured samples showed that: piezoelectric ultrasonic feed drive showed a clear improvement in the quality of surface finish of the machined samples, due to the fast dynamic time response of the developed drive. This was accompanied with a notable reduction in the arcing and short-circuiting teething phenomena. This was verified by assessing the electrode movements, the variations in the inter electrode gap voltage, current and feedback control signals.
This paper presents the research has been undertaken, to design and develop a micro actuator using electro rheological fluid technology, for visually impaired tactile display information technology, access applications. The micro actuator consists of a small cylinder made of ABS plastic material with 1.5 mm diameter and 10 mm long. The inner surface of the cylinder is coated by nickel using electroless coating process. A coaxial conducting rod of 1.02 mm diameter and 10 mm long is fitted vertically in the centre of the cylinder. The coated surface is used as first electrode and the coaxial conducting rod used as a second electrode, to form the micro actuation high voltage area. The microactuator structure has been used to develop a tactile display of a large scale in a matrix form of 124×4 actuators. An advanced software tools and embedded system based on voltage matrix manipulation has been developed to provide the display the near real time control. The new micro actuator development process, software control tools and actual developed prototype is presented in this paper. Prototype size 124×4 micro actuators, on a matrix form, with a separation distance of 2.54 mm, was manufactured. The experimental tests carried out into the prototype showed that each micro actuator was able to provide a vertical movement of 0.7 mm and a vertical holding force of 100 to 200mN. These results meet the necessary standard requirement of Braille applications. Stroke and dynamic response test showed the practicability of the developed micro actuator for electronic refreshable high resolution graphical tactile display, for visually impaired and blind information technology access applications.
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