Abstract
In rotary ultrasonic machining (RUM), the contactless energy transfer (CET) system based on the rotary transformer can replace the well-established slip ring technology to supply power for the revolving ultrasonic vibrator. However, the transfer efficiency and power output capability of the CET system is usually a pair of contradictions. The high voltage of the compensation element is prone to occur, especially in high power applications, which is dangerous. In this paper, for four basic compensation topologies, the mathematical models of the transfer efficiency, the load impedance and the compensation elements' voltages are presented. The compensation elements are optimized for improving the transfer efficiency. The effects of coil turns on the transfer efficiency, the load impedance and the compensation elements' voltages are researched. The coil turns are optimized to control the load impedance of the power supply and the voltages of the compensation elements. The experimental results basically agree with the theoretical results. The optimized CET system not only has high transfer efficiency, but also has high power output capability. At the same time, the high voltages of compensation elements are avoided effectively and the safety of the system is guaranteed.
Highlights
Rotary ultrasonic machining (RUM) is a precise and efficient processing method for hard and brittle materials
The optimization method of the rotary transformer’s coil turns is put forward and is verified by experiments. Both theory and experiment prove that the optimized contactless energy transfer (CET) system has high transfer efficiency, high power output capability and the local high voltages of compensation elements are avoided effectively
How to improve the transfer efficiency and power output ability of the CET system together is an urgent problem at present
Summary
Rotary ultrasonic machining (RUM) is a precise and efficient processing method for hard and brittle materials. In [22], for the secondary self-compensation topologies of rotary transformer used in RUM, the mathematical models of transfer efficiency and load impedance are developed. For the four basic compensation topologies: SS, SP, PS and PP topologies, under the mathematical models of the compensation elements for maximum transfer efficiency, the effects of coil turns on the transfer efficiency, the load impedance and the compensation elements’ voltages are researched. The compensation elements and coil turns are optimized together to achieve high transfer efficiency and high power output capability. The optimization method of the rotary transformer’s coil turns is put forward and is verified by experiments Both theory and experiment prove that the optimized CET system has high transfer efficiency, high power output capability and the local high voltages of compensation elements are avoided effectively
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