Patent Publication Number: US-2020299856-A1

Title: Non-uniform circular motion for electroplating barrels and methods of use

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims priority to U.S. provisional application Ser. No. 62/822,346, filed Mar. 22, 2019, herein incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     The invention generally relates to non-uniform circular motion and more particularly to non-uniform circular motion for electroplating barrels. 
     In a conventional cylinder, the load travels along a fixed rotational path around the inside of the cylinder wall. Some plating parts that require extremely close tolerances, while still having faster and more consistent plating. Improvements in the load distribution and exposures to all sides of all parts are needed for a more uniform amount of current and plating deposit. 
     The present invention attempts to solve these problems, as well as others. 
     SUMMARY OF THE INVENTION 
     Provided herein are systems, methods and apparatuses for a Non-Uniform Circular Motion system and methods of use. An Non-Uniform Circular Motion system is disclosed and generally comprises an electrical circuit operably coupled to a motor and a battery, wherein the 
     A non-uniform circular motion system is disclosed herein and comprises: an electrical circuit operably coupled to a motor, wherein the electrical circuit provides a non-uniform circular motion for an electroplating barrel; the motor operably coupled to a first gear, the first gear rotatably drives a second gear; and the second gear operably coupled with a first nautilus gear and the first nautilus gear rotatably coupled with a second nautilus gear; the second nautilus gear operably coupled with an electroplating barrel, such that the rotation of the second nautilus gear rotates the electroplating barrel in a non-uniform circular motion. 
     A method of providing non-uniform circular motion to an electroplating barrel is disclosed herein and comprises: providing a motor to deliver rotational force; delivering the motor&#39;s rotational force to a first gear, and rotatably driving a second gear; and operably coupling the second gear with a first nautilus gear and rotatably coupling the first nautilus gear with a second nautilus gear; operably coupling the second nautilus gear with an electroplating barrel, and rotating the second nautilus gear and the electroplating barrel in a non-uniform circular motion. 
     The methods, systems, and apparatuses are set forth in part in the description which follows, and in part will be obvious from the description, or can be learned by practice of the methods, apparatuses, and systems. The advantages of the methods, apparatuses, and systems will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the methods, apparatuses, and systems, as claimed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the accompanying figures, like elements are identified by like reference numerals among the several preferred embodiments of the present invention. 
         FIG. 1  is a perspective view of the electroplating barrel including the non-uniform circular motion system. 
         FIG. 2  is a side view of the non-uniform circular motion system showing the first and second gears operably coupled with the first and second nautilus gears. 
         FIG. 3  is a side view of the oscillating system. 
         FIG. 4  is a side view of the oscillating Barrel cylinder showing the load distribution during oscillation. 
         FIG. 5  is a perspective side view of the sizing of the tank for the oscillating system and barrel. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The foregoing and other features and advantages of the invention are apparent from the following detailed description of exemplary embodiments, read in conjunction with the accompanying drawings. The detailed description and drawings are merely illustrative of the invention rather than limiting, the scope of the invention being defined by the appended claims and equivalents thereof. 
     Embodiments of the invention will now be described with reference to the Figures, wherein like numerals reflect like elements throughout. The terminology used in the description presented herein is not intended to be interpreted in any limited or restrictive way, simply because it is being utilized in conjunction with detailed description of certain specific embodiments of the invention. Furthermore, embodiments of the invention may include several novel features, no single one of which is solely responsible for its desirable attributes or which is essential to practicing the invention described herein. 
     The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. It will be further understood that the terms “comprises,” “comprising,” “includes,” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. 
     Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. The word “about,” when accompanying a numerical value, is to be construed as indicating a deviation of up to and inclusive of 10% from the stated numerical value. The use of any and all examples, or exemplary language (“e.g.” or “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any nonclaimed element as essential to the practice of the invention. 
     References to “one embodiment,” “an embodiment,” “example embodiment,” “various embodiments,” etc., may indicate that the embodiment(s) of the invention so described may include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase “in one embodiment,” or “in an exemplary embodiment,” do not necessarily refer to the same embodiment, although they may. 
     As used herein the term “method” refers to manners, means, techniques and procedures for accomplishing a given task including, but not limited to, those manners, means, techniques and procedures either known to, or readily developed from known manners, means, techniques and procedures by practitioners of the mechanical and electrical arts. 
     Generally speaking, the non-uniform circular motion system  100  comprises an electroplating barrel  120  that is rotatably driven and it is journaled by means of bearing members that are disposed in the center of the end plates  124 ,  126  and are rotatably driven by a motor  150  and gears  152  as seen in U.S. Pat. No. 4,740,286 as well as any number of previously built electroplating barrels. Generally, the electroplating barrels  120  reside in a bath of electrolyte solution of conventional design so as to permit the interior of the electroplating barrel  120  to be substantially filled with such solution, the solution passing into electroplating barrel  120  through the perforations in the panels of the electroplating barrel  120 . An electrical potential is applied to the parts loaded in the barrel by means of the cathode points which are accessed to the barrel by means of insulated conductors that protrude through the bearing members of the end plates  124  and  126  and are connected to electrical power generating means in accordance with known ways for providing electroplating action to articles within the electroplating barrel  120 . 
     Non-uniform circular rotation of a barrel used for metal finishing i.e. plating, electroless process, cleaning, phosphating or black oxide is critical for uniformity of finish on each part. Not turning during critical tank positions will not allow liquid to reach all areas of the parts thus causing rejects. The rotational means of the Barrel cylinder is generated either from a motor attached to the barrel with or by the barrel making mechanical contact by means of an external drive shaft which extends out to a gear which mates with a gear on the tank of which is driven by a gear motor. Motors on the barrel require electrical power brought to the motor, according to one embodiment. 
     The electroplating barrel  120  is operably coupled with a motor  150  to provide the torque and rotating power to the electroplating barrel  120 . In one embodiment, motor  150  is operably coupled to a first gear  170  which then rotatably drives a second gear  178 . The second gear  178  is operably coupled with a first nautilus gear  180  and the first nautilus gear  180  is rotatably coupled with a second nautilus gear  190 . The second nautilus gear  190  is operably coupled with the electroplating barrel, such that the rotation of the second nautilus gear  190  rotates the electroplating barrel  120 . 
     As shown in  FIG. 2 , the first nautilus gear  180  includes a first spiral side  182  and a first flat side  184 . The second nautilus gear  190  includes a second spiral side  192  and a second flat side  194 . The first and second spiral side  182 ,  192  are designed from the Fibonacci spiral and must be identical. The first and second flat sides  184 ,  194  are nearly flat and identical. The result is that at the very end of a rotation, the first flat side  184  and the second flat side  194  hit against each other before the next turn starts. If the first nautilus gear is moving at a constant speed, the second nautilus gear  190  will speed up and slow down during the course of its rotation based on the Fibonacci curves of the two sets. The speed of speeding up may be between about 1 RPM and about 10 RPM, while the speed of slowing down may be between about 1 RPM and about 10 RPM. 
     This allows the electroplating barrel to rotate slow during the rotation along the second spiral side  192  and then speed up once rotating along the second flat side  194 . Alternatively, the first flat side  184  and the second flat side  194  are curved at an angle greater than about 2-10 degrees. 
     An electrical circuit  160  provides a voltage to the motor  150  in order to provide a constant rotational motion by the motor  150  for the electroplating barrel  120 , according to one embodiment. A constant rotational motion or RPM is required for proper electroplating barrel operation. Alternatively, the electrical circuit can provide erratic or non-uniform voltage, according to one embodiment. Electronic circuits usually use direct current sources. The load of an electronic circuit may include a few resistors, capacitors, all connected together. Or an electronic circuit can be complicated, connecting thousands of resistors, capacitors, and transistors. It may be an integrated circuit such as the microprocessor in a computer or controller. 
     The electroplating barrel  120  is operably coupled to the electrical circuit  160  that pulls amps from the battery and providing a voltage to the motor to provide the rotational movement of the first gear and RPM to the electroplating barrel. A rotation along the second spiral side  192  guarantees plating uniformity while the rotation along the second flat side  194  is a non-uniform and high speed plating. The RPM may range from about 2 to about 10 RPM; alternatively between about 1 to about 100 RPM. The constant RPM or non-constant RPM may be selected based upon the type of plating process being performed. The plating process include, but are not limited to: Copper plating, nickel plating, electroless nickel phosphorous, palladium plating, palladium-nickel, silver plating, tin, tin-lead, tin-zinc, zinc electroplating, zinc-nickel, soft and cobalt hardened gold including the SPC plating array. 
     In one embodiment, the non-uniform circular motion system the motor will be able to achieve angular velocity (speed) changes by accepting programmed signals from a motor controller. 
     The first and second nautilus gears  180 ,  190  may be generated by applying a cosine gear and pitch function along the curve of a logarithmic spiral using a growth rate of about 1.17. Varying either the length of the first and second flat sides  184 ,  194  and varying the logarithmic spiral growth rate of the first and second spiral sides  182 ,  192  modifies the constant and sped up rotation of the second nautilus gear  190 . 
     The Non-uniform circular motion denotes a change in the speed of rotation moving along the nautilus gears circular path. Since the speed is changing, there is tangential acceleration in addition to normal acceleration. The speed is necessarily given by the angular velocity (ω) in non-uniform circular motion is not constant, as ω=v/r, and v varies and r is the radius. 
     In one embodiment, the non-uniform circular motion system  100  is operably coupled with an oscillating system  200 , as shown in  FIG. 3 . The center axis  210  of the electroplating barrel  120  is offset within the barrel tank by including an off-center gear connection on the second gear  178  for the barrel. The electroplating barrel  120  is a cylinder or barrel cylinder. The resulting “off center” oscillating motion of the electroplating barrel  120  causes a better distribution of parts within the electroplating barrel  120 . As a result, the parts achieve more uniform contact with the danglers. This yields less weight variance within the load while reducing the overall plating time. In a conventional barrel, the load travels along a fixed path around the inside of the barrel wall. In an Oscillating barrel, the load travels in a path P that resembles an expanded  FIG. 4 . This improves the load distribution and exposes all sides of all parts to a more uniform amount of current and plating deposit. The size of the electroplating barrel  120  and its angle of offset A from normal rotation, as shown in  FIG. 4 , which is dependent on the current swing clearance  240  of the barrel tank  250 , as shown in  FIG. 5 . In order to fit a tilted electroplating barrel  120  with a swing clearance  240 , the electroplating barrel  120  size must be slightly reduced. This small loss in volume is more than compensated for by the resulting speed and quality of each run. The angle of offset A may be between about 5 degrees and about 70 degrees; alternatively, between about 10 degrees and about 60 degrees; alternatively between about 15 degrees and 50 degrees. The swing clearance  240  may be between about 1 inch and about 10 inches; alternatively, between about 2 inches and about 8 inches; alternatively, between about 2.5 inches and about 7 inches. The tank includes a width W, a height H, and a length L in which to fit the electroplating barrel  120  or other Barrel cylinder. The electronic circuit  160  may monitor the oscillation of the oscillating system  200  to ensure the angle of offset A maintains proper oscillation. 
     Motor 
     In one embodiment, the motor is a DC motor. An electric motor is an electrical machine that converts electrical energy into mechanical energy. Most electric motors operate through the interaction between an electric motor&#39;s magnetic field and winding currents to generate force. Electric motors can be powered by direct current (DC) sources, such as from batteries, motor vehicles or rectifiers, or by alternating current (AC) sources, such as from the power grid, inverters or generators. Electric motors operate on three different physical principles: magnetic, electrostatic and piezoelectric. By far the most common is magnetic. All self-commutated DC motors run on DC electric power. Most DC motors are small permanent magnet (PM) types. They contain a brushed internal mechanical commutation to reverse motor windings&#39; current in synchronism with rotation. In magnetic motors, magnetic fields are formed in both the rotor and the stator. The product between these two fields gives rise to a force, and thus a torque on the motor shaft. One, or both, of these fields must be made to change with the rotation of the motor. This is done by switching the poles on and off at the right time, or varying the strength of the pole. 
     Mathematical formulas and program modules were developed to factor in all critical areas needed to guarantee operation sent by a motor controller through programmed signals or program modules. It is then by design, constraints, and factors that a Non-uniform circular motion is maintained over a specified period of time by the motor controller through specific input and output parameters. The Non-uniform circular motion system  100  includes a unique circuitry that allows for a Non-uniform circular motion either by way of the nautilus gears, regular gearing, or oscillating system, or a combination thereof. 
     Generally, mathematical formulas and program modules used by the motor controller include routines, programs, components, data structures, etc., that perform particular tasks or implement particular abstract data types by the motor controller. Moreover, those skilled in the art will appreciate that the inventive methods can be practiced with other controller system configurations, including single-processor or multiprocessor computer systems, minicomputers, mainframe computers, as well as personal computers, hand-held computing devices, microprocessor-based or programmable consumer electronics, and the like, each of which can be operatively coupled to one or more associated devices. 
     The mathematical formulas and program modules used by the motor controller may include constraints provided by customer and engineering design factors to achieve customer constraints and maintain the Non-uniform circular motion over a specified period of time. The constraints used by the motor controller and provided by customer to maintain the Non-uniform circular motion over a specified period of time may include, but are not limited to: Electroplating Cylinder diameter, Barrel Cylinder revolutions per minute, Weight of parts load, Volume of parts load, Interval between battery charges. The engineering design factors used by the motor controller to achieve customer constraints to maintain the Non-uniform circular motion over a specified period of time may include, but are not limited to: Barrel drive gear size, Barrel cylinder gear size, DC volts supplied to motor, Gearmotor nameplate volts, Gearmotor nameplate RPM, Gearmotor nameplate full load amps, Gearmotor nameplate full load torque, Battery pack voltage and ampere hour rating. 
     Given the Barrel cylinder diameter, the weight of parts of the load, and the volume of the parts of the load and various combinations of barrel drive gear size and barrel cylinder gear size are used by the motor controller to calculate required gearmotor output torque(s) to maintain the Non-uniform circular motion over a specified period of time. The mathematical formulas and program modules used by the motor controller consider the available DC gearmotors with a minimum required output torque at various volts for the DC volts supplied to the motor to maintain the Non-uniform circular motion over a specified period of time. The mathematical formulas and program modules used by the motor controller to maintain the Non-uniform circular motion over a specified period of time use and consider the available DC gearmotors with output speed for the Barrel cylinder revolutions per minute given various barrel drive gear sizes and various barrel cylinder gear sizes. The mathematical formulas and program modules used by the motor controller to maintain the Non-uniform circular motion over a specified period of time use and consider the available DC gearmotors with ampere draw that satisfy the Interval between battery charges given available Battery pack voltage and ampere hour rating. The mathematical formulas and program modules used by the motor controller to maintain the Non-uniform circular motion over a specified period of time use and select the DC gearmotor that satisfies torque, speed and power draw. The mathematical formulas and program modules to maintain the Non-uniform circular motion over a specified period of time select the battery pack(s) to match the Interval between battery charges, the DC volts supplied to the motor, and the Battery pack voltage and ampere hour rating. 
     The mathematical formulas and program modules to maintain the Non-uniform circular motion over a specified period of time use and specify gears for the Barrel drive gear size and Barrel cylinder gear size, the gearmotor and battery pack to satisfy Barrel Cylinder diameter, Barrel Cylinder revolutions per minute, the Weight of parts load, the Volume of parts load, the Interval between battery charges when DC volts is supplied to the gearmotor. 
     A method of providing non-uniform circular motion to an electroplating barrel is disclosed herein and comprises: providing a motor to deliver rotational force; delivering the motor&#39;s rotational force to a first gear, and rotatably driving a second gear; and operably coupling the second gear with a first nautilus gear and rotatably coupling the first nautilus gear with a second nautilus gear; operably coupling the second nautilus gear with an electroplating barrel, and rotating the second nautilus gear and the electroplating barrel in a non-uniform circular motion. The method of further comprises including a first spiral side and a first flat side with the first nautilus gear; including a second spiral side and a second flat side with the second nautilus gear, and including a Fibonacci spiral for the first and the second spiral side; and including identical first spiral side and the second spiral side. 
     The method further comprises including identical first and second flat sides, abutting the first flat side and the second flat side against each other before the next rotation starts, moving the first nautilus at a constant speed, and speeding up the second nautilus gear speeds up and slow downing the second nautilus gear during the course of its rotation based on the Fibonacci spiral of the second spiral side. 
     The method further comprises rotating the electroplating barrel slow during the rotation along the second spiral side and then speeding up the rotation of the second nautilus gear once rotating along the second flat side. 
     The method further comprises providing a curved first flat side and a curved second flat side. The method further comprises alarming an indicator alarms at a threshold RPM and adjusting the motor RPM for the first gear. The method comprises including the RPM in a range from about 2 to about 10 RPM. The method further comprises offsetting the center axis of the electroplating barrel by including an off-center gear connection on the second gear for the electroplating barrel. The method comprises achieving angular velocity changes of the electroplating barrel by accepting programmed signals from a motor controller. 
     The method wherein the motor controller includes constraints selected from the group consisting of: Barrel Cylinder diameter, Barrel Cylinder revolutions per minute, Weight of parts load, Volume of parts load, Interval between battery charges; Barrel drive gear size, Barrel cylinder gear size, DC volts supplied to motor, Gearmotor nameplate volts, Gearmotor nameplate RPM, Gearmotor nameplate full load amps, Gearmotor nameplate full load torque, Battery pack voltage and ampere hour rating. 
     The further comprises calculating a required gearmotor output torques using the Barrel cylinder diameter, a weight of parts of the load, and a volume of the parts of the load, and various combinations of a barrel drive gear size and a barrel cylinder gear size; and the motor controller considers an available DC gearmotor with a minimum required output torque at various volts for the DC volts supplied to the motor to maintain the Non-uniform circular motion over a specified period of time; using the available DC gearmotor with output speed for a Barrel cylinder revolutions per minute given various barrel drive gear sizes and various barrel cylinder gear sizes to maintain the Non-uniform circular motion over a specified period of time; using the available DC gearmotor with ampere draw that satisfy an Interval between battery charges given available Battery pack voltage and an ampere hour rating to maintain the Non-uniform circular motion over a specified period of time; selecting the available DC gearmotor that satisfies torque, speed and power draw to maintain the Non-uniform circular motion over a specified period of time; and selecting a battery pack to match the Interval between a battery charge, the DC volts supplied to the motor, and the Battery pack voltage and ampere hour rating to maintain the Non-uniform circular motion over a specified period of time. 
     The method further comprises specifying the first and second nautilus gears for the Barrel drive gear size and the Barrel cylinder gear size, the gearmotor and battery pack to satisfy a Barrel Cylinder diameter, a Barrel Cylinder revolution per minute, the Weight of parts load, the Volume of parts load, the Interval between battery charges when a DC volt is supplied to the gearmotor to maintain the Non-uniform circular motion over a specified period of time. 
     All publications and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference. 
     While the invention has been described in connection with various embodiments, it will be understood that the invention is capable of further modifications. This application is intended to cover any variations, uses or adaptations of the invention following, in general, the principles of the invention, and including such departures from the present disclosure as, within the known and customary practice within the art to which the invention pertains.