Documente Academic
Documente Profesional
Documente Cultură
Slocum
Aesops1 Surface Self Compensated Profile Rail Linear Hydrostatic Bearing System: The HydroRail
Patents pending. Aesop, Inc. PO Box 2126, Concord, NH 03302-2126, Fax 603-224-5369
18-25
The carriage contains all the hydrostatic compensation and pockets on its unique surface shape2
This patented design was the subject of Ntahn Kanes Ph.D. thesis with Prof. Slocum at MIT.
18-26
The small protrusion on the rail center acts as the surface self compensation system:
18-27
Performance of a size 45 HydroRailTM bearing verses a high end rolling element linear guide.
The HydroRailTM Vs. a high end rolling element bearing
Size 45, @1190 psi HydroRail
TM
Bearing
Nominal gap = 0.001 in. Compress. Static Load which causes permanent damage Dynamic Load Capacity at given Life Life Static Stiffness Dynamic Stiffness at Resonance Q (Damping Factor) Maximum Speed Maximum Acceleration Static Friction Motion Resolution Friction @ 0.5 m/s Friction Power @ 0.5 m/s Straightness (over 15.5 inches travel) 9 Straightness Repeatability Hydraulic Oil Flow (m=76 cSt @ 90 F) Pumping Power required
9 10
250,000 2,500 2,3 no limit 3.0 3 2.03,4 1.5 4 no limit no limit none infinite 4.2 3 9.4 3 20 4 84 0.2 3 100 3
Will cause permanent carriage deformation according to FEA analysis 2 Load which causes 50% closure of bearing gap 3 From fluid circuit mathematical model 4 Based on data from past non-modular hydrostatic bearings designed at MIT All analysis done by Nathan R. Kane at MIT
Will cause permanent deformation of rollers and races 6 Equal to theroetical dynamic load divided by load factor of 3 to account for the most demanding applications 7 Based on product catalogue data 8 Based on experimental data obtained by Nathan R. Kane at MIT
Defined as max. deviation of carriage relative to rail reference edges Quantity shown is typical for rolling element guides, according to S. Futami, A. Furutani, and S. Yoshida, Nanometer Positioning and its Microdynamics, Nanotechnology, Vol. 1, No. 1, 1990, pp.31-37
18-28
Estimated Carriage and Rail Costs Bearing Size 35 45 55 Per Carriage Per meter of rail
1 2
6 5 To Power 4 Carriages of any $3,800 size $570 $600 $650 $700 To Power 8 Carriages of any $4,800 size $770 $800 $850 $900 To Power 12 Carriages of any $5,600 size
Estimates are based on an ultra precision rolling element linear guide system with similar manufacturing complexity Includes DC permanent magnet motor (1 hp per 4 carriages), power supply, gear pump, 3m high pressure filter, properly sized oil chiller with a 10 gallon tank, pressure relief value, a pressure measurement and control system, 10 foot hydraulic hose, and 15 gallons of hydraulic oil. Does not include fittings and hoses going to individual trucks, fluid gutters and drains, or a way protection system such as bellows.
18-29
Upgrade an Entire Product Line Quickly and Inexpensively With minimal additions (such as adding drainage gutters for hydraulic oil), an old product line that uses standard linear guides can be rejuvenated by equipping the machines with HydroRailTM bearings. Introduce A New Ultra Performance Machine Tool Which is Very Cost Competitive Design a new ultra performance high speed machining center which takes full advantage of the performance capabilities of the HydroRailTM bearing. Promote the unique crash resistant, accuracy enhancing, and long bearing life features, and also the high value added to the machine tool by the HydroRailTM technology, which translates directly into a great value for the customer. Replace Costly Hand Scraped Way Systems In an effort to reduce assembly time and costs, countless machine tool manufacturers have spent thousands of R&D dollars trying to make rolling element guides work for them, only to give up and go back to using their old labor intensive, costly custom way systems (such as sliding and hydrodynamic systems which require hand scraping). For many of these companies, the HydroRailTM can offer the ultra high performance they require while also providing them with much of the savings that they are looking for.
Retrofit a Machine to Bring it to A New Level of Accuracy During a rebuild, a machine that uses standard linear guides can be economically upgraded to HydroRailTM bearings. For a modest investment, the machine can then can perform at a new level of accuracy.
Retrofit a Machine to Greatly Increase Bearing Life in Abrasive Environments When grinding ceramics or other hard materials, the abrasive swarf created always gets past even the best bearing seals, and then quickly wears the surfaces of rolling elements and races. Retrofitting such a machine with HydroRailTM bearings can eliminate this problem, since the bearing gap is large enough to allow swarf particles to pass through freely.
18-30
Po
Pa
Since air has a very low viscosity, bearings gaps are small, on the order of 1-10 microns. Aerostatic bearings bearings can be configured in virtually all the ways hydrostatic bearings can. Because air bearings have essentially zero friction and are very clean running: They have extensive use in metrology equipment and in machines used in clean rooms.
18-31
Modular fluidstatic bearing systems can be easily made from off-the-shelf components:3 Porous graphite bearing pads (e.g., from Devitt Machinery in Aston PA). Ceramic Hydroguide pads from Wilbanks International. Hollow alumina beams (e.g., from Wilbanks International in Hillsboro OR). Hollow cast iron square tube (e.g., from Smith Tool Co. in Manasquan, NJ) Epoxy potting compound (with metal fillers to increase modulus) (e.g., DWH epoxy from Devitt Machinery).
Outer structure Potting epoxy Steel backing Porous graphite Moving member
Patent by Drew Devitt, Devitt Machinery, Aston, PA, "Method for Manufacturing Externally Pressurized Bearing Assemblies", #5,488,771, Feb. 6, 1996. 18-32
Assembly procedure: The outside of the cast iron tube is finish ground. The modular porous graphite air bearing pads are held to the precision alumina beam by a vacuum. The beam is positioned with jigs with respect to the outside of the cast iron tube. The potting epoxy is injected between the pads and the cast iron.
After curing, when the air is off, the alumina beam is locked in place (self-braking). When air is applied, the cast iron tube expands a few m and the alumina beam floats.
18-33
Since 1986, Prof. Slocum has been working on self compensated hydrostatic bearings. Dr. Kevin Wasson earned his Ph.D. working with Prof. Slocum on high speed hydrostatic bearings. Dr. Wasson has developed advanced designs and mathematical models, that allow him to deterministically design high speed surface self comepnsated hydrostatic bearings. These bearings can run on oil, water, or cryogenic fluids. These bearings have widespread application, from machine tool spindles, to rocket motors!
This section was prepared by Dr. Kevin Wasson, Principal Engineer, Aesop, Inc. PO Box 2126, Concord, NH 03302.
18-34
Compensation Resistance
Some type of external compensation resistances are required: Orifices. Capillaries. Servo Valves.
18-35
18-36
18-37
C L
C L
Eliminates clogging. Enables higher bearing stiffness. Eliminates the need to hand-tune inlet restrictors. Bearing load capacity is independent of the clearance. Enables the bearings to be located on the surface of the shaft; much more easy to manufacture.
18-38
Pulley-Drive Shaft
56 mm
Air Seal
Thrust Flange
Rear Bearing Front Bearing Rear Bearing Through-the-Tool Compensator Coolant Supply Channel
Unique features: Self-compensated hydrostatic bearings. All bearing detail CNC-milled into the outer surface of the shaft with a ball end mill. Damping areas left in the centers of the bearing pockets. Unique thrust bearing provides preferential load capacity in the pushing direction. Air seals on front and rear of spindle prevent coolant leakage. Unique method to supply through-the-tool coolant.
18-39
h pad
R2b R1b
R3b
18-40
fa
Complications: Often many changes in cross-section. Shear deformations are not negligible for short spindles. Bearing characteristics are a strong function of the shaft bending.
18-41
La
R5
18-42
fa
Front Bearing
Rear Bearing
Pulley Bearing
18-43
Pump Noise
Resonance
18-44
18-45
Flow on the lands typically remains laminar up to speeds of 2 million DN. Flow in the pockets typically becomes turbulent at speeds greater than 0.1 million DN.
Experimental Data for Pocket Depth of: 2.06 mm 1.04 mm 0.53 mm
Re
18-46
Manufactured
bm
bm
bm Bearing Pocket
18-47
0.005 Nm/s
0.0013 Nm/s
0.0008 Nm/s
18-48
Temperature Rise
18-49