Patent Description:
The present invention can advantageously be applied to a system for controlling the machining of a mechanical piece in a machine tool, in which a contactless connection system puts in communication a control unit and a balancing head mounted on a rotating spindle which supports (at least) a grinding wheel, to which the following discussion will make explicitly reference without losing generality.

The present invention can also be applied to a control system without a balancing head and comprising a vibration sensor, for example an acoustic sensor, and/or other sensors or devices in the movable part that need to be powered.

As described for example in patent applications No. <CIT>, <CIT> and <CIT>, a rotating spindle (hub) of a machine tool (in particular a grinding machine) which supports (at least) a grinding wheel and is provided with a balancing head housed in an axial cavity is known. The balancing head includes at least one balancing mass eccentric with respect to the rotation axis, the position of which is adjustable and is controlled by an electric motor.

Generally, the balancing head also comprises a vibration sensor (i.e. a microphone) for detecting the ultrasonic acoustic emissions caused by the contact between the grinding wheel and the workpiece or between the grinding wheel and a dressing tool (dresser). The electrical signals generated by the vibration sensor are used (in a known way) to control the machining cycles.

There is a two-way contactless communication system that transmits analog and digital information between the balancing head mounted on the spindle and a control unit placed in a fixed position. In particular, the communication system is used by the control unit to send digital control signals to the balancing head (for example to activate/ deactivate the reading of the vibration sensor or to control the electric motors that move the balancing masses) and is used in the opposite direction by the balancing head to send digital diagnostic signals and the analogue reading of the vibration sensor to the control unit.

A contactless power transmission system provides the necessary power supply to the balancing head. Generally, the power transmission system comprises an air-coupled transformer which has the primary coil arranged in an element (stator) integral with a stationary part of the machine, and the secondary coil arranged in an element (rotor) integral with a movable part of the machine, for example the rotating spindle. Between the two coils of the air-coupled transformer there is a distance (usually a few millimeters, for example between <NUM> and <NUM>) which must be neither too small (in order to avoid the risk that the rotor is touched by the stator when the spindle is rotated, for example due to thermal expansion of the spindle, and that both are damaged), nor too large (in order to prevent the air-coupled transformer from being unable to transfer sufficient electrical power to the rotor because of the too large air gap). Generally, at the design stage for each balancing system a range of distance between stator and rotor (i.e. the distance between the two coils of the air-coupled transformer) which must be complied with for correct operation can be defined.

After the spindle has been mounted (typically after maintenance or repair), the distance between the stator and the rotor must be measured with sufficient accuracy to ensure that it is within the range defined at the design stage. However, the manual measurement of the distance between stator and rotor is not always easy to carry out as there may be protective casings that block access with an external manual gauge.

Also during the machine operation it is useful to monitor and measure cyclically and with sufficient accuracy the distance between stator and rotor to ensure that it is within the range defined at the design stage, In fact, the rotor and stator could move closer than the condition set at the installation stage due to thermal expansion of the spindle. Or, when the grinding wheel is replaced due to wear or retooling for different processes, the wheel support could have a different thickness and cause a change in the distance between rotor and stator.

For these reasons, a "contactless" electronic measuring device (for example a laser measuring device) or one or more sensors that can measure the distance between stator and rotor may be installed on the stator. However, this installation results in an increase in costs and dimensions and can cause problems in some applications where the space available is very limited.

The object of the present invention is to provide a method for contactless power transmission between a stationary part and a movable part, for example a rotating part, an electrical power supply circuit that allow to easily monitor the distance between such stationary and a movable parts, and a contactless connection system including said circuit, the method and circuit allowing to determine the distance with sufficient accuracy and without significant increases in cost and space.

The present invention provides a method for contactless power transmission, an electrical power supply circuit and a contactless connection system including such a circuit, as defined in the attached claims.

The claims describe embodiments of the present invention and form an integral part of the present description.

The present invention is described with reference to the attached drawings, which illustrate non-limiting examples of embodiment, in which:.

In <FIG>, the reference number <NUM> indicates as a whole a machine tool (in particular a grinding machine), only some components of which are shown.

The machine tool <NUM> comprises a frame <NUM> which supports in a rotatable way (by means of bearings arranged therebetween) a rotating spindle <NUM> which rotates about a rotation axis <NUM>.

The spindle <NUM> supports a grinding wheel <NUM> by means of a corresponding grinding wheel hub which is fixed to the spindle <NUM> in a removable way using known and not illustrated means and comprising, for example, a cone coupling. The spindle <NUM> has in the center an axial opening <NUM>. A balancing head <NUM> is connected to the spindle <NUM> and can rotate with it, more specifically the balancing head <NUM> is housed in the axial opening <NUM>. The balancing head <NUM>, of a known type, comprises two balancing masses <NUM> which are eccentric with respect to the rotation axis <NUM>, and relative electric motors <NUM> for adjusting the angular position of the balancing masses <NUM>. In the balancing head <NUM> is also housed an acoustic sensor <NUM>, or vibration sensor.

Typically, the function of the balancing head <NUM> is to balance the grinding wheel <NUM> (this operation is carried out whenever the grinding wheel <NUM> is replaced and when it is necessary as a result of the wear of the grinding wheel <NUM>), while the acoustic sensor <NUM> housed in the balancing head <NUM> allows to perform a process monitoring.

The balancing head <NUM> comprises a control device <NUM> which controls the operation of the balancing head <NUM> and of the acoustic sensor <NUM>.

A contactless connection system <NUM> is provided and has a dual function: it supplies electrical power to the balancing head <NUM> and enables a two-way communication to transmit analogue and digital information between the control system <NUM> of the balancing head <NUM> mounted on the spindle <NUM> and a control unit <NUM> connected to the frame <NUM> of the machine tool <NUM> and arranged between the contactless connection system <NUM> and the numerical control of the machine tool <NUM> (not shown in the figure).

The contactless connection system <NUM> comprises a stationary part <NUM>, or stator, mounted on the frame <NUM> of the machine tool <NUM> which is connected by means of a cable to the control unit <NUM> and a movable part, preferably a rotating part <NUM>, or rotor mounted on the spindle <NUM> which is connected to the balancing head <NUM> by means of, for example, a coiled electric cable <NUM> running along the axial opening <NUM>. Furthermore, the contactless connection system <NUM> comprises an electrical power supply circuit <NUM> (partly arranged in the stator <NUM> and partly arranged in the rotor <NUM>) which transmits electrical power to the balancing head <NUM> and a communication device <NUM> (partly arranged in the stator <NUM> and partly arranged in the rotor <NUM>) preferably of the optical type (for example according to one of the alternatives described in patent No. <CIT>).

The communication device <NUM> is used by the control unit <NUM> to send control signals (for example to activate/deactivate the reading of the acoustic sensor <NUM> or to control the electrical motors <NUM> displacing the balancing masses <NUM> of the balancing head <NUM>) to the control device <NUM> of the balancing head <NUM>, and it is used in the opposite direction by the control device <NUM> of the balancing head <NUM> to transmit to the control unit <NUM> diagnostic signals and/or signals provided by the acoustic sensor <NUM> and relating to vibrations to which the spindle is subjected.

As shown in <FIG>, the electrical power supply circuit <NUM> comprises an air-coupled transformer <NUM> (shown in more detail in <FIG>) which has a primary coil <NUM> with inductance L<NUM> arranged in the stator <NUM> and a secondary coil <NUM> with inductance L<NUM> which is arranged in the rotor <NUM> and is coupled magnetically to the primary coil <NUM> (i.e. the magnetic field generated by the primary coil <NUM> is linked to the secondary coil <NUM>). Between the two coils <NUM> and <NUM> there is a distance d (normally a few millimeters, for example between <NUM> and <NUM>) which must be neither too small (in order to avoid the risk that the rotor <NUM> is touched by the stator <NUM> when the spindle <NUM> is rotated, for example due to thermal expansion of the spindle, and that both are damaged), nor too large (in order to prevent the air-coupled transformer <NUM> from being unable to transfer sufficient electrical power to the rotor <NUM> because of the too large air gap).

A primary resonant circuit includes the primary coil <NUM> and a first capacitor with capacitance C<NUM>, which are connected in series. Similarly, a secondary resonant circuit includes the secondary coil <NUM> and a second capacitor with capacitance C<NUM>, which are connected in series. Resonant circuit means a circuit that is adapted to operate in resonance conditions. In particular, the primary and secondary resonant circuits are series resonant circuits.

Alternatively, it is possible to use resonant circuits of different types, for example parallel resonant circuits or a combination of series and parallel resonant circuits.

The electrical power supply circuit <NUM> also comprises an inverter <NUM> which receives direct current electrical energy from a power supply device <NUM> and applies to the primary resonant circuit a primary alternating electrical voltage V<NUM> which has a variable frequency F and causes the circulation of a primary electrical current I<NUM>.

The electric current I<NUM> which circulates in the primary resonant circuit induces in the secondary resonant circuit a secondary alternating electrical voltage V<NUM> which has the same variable frequency F as the primary electrical voltage V<NUM> and causes the circulation of a secondary electric alternating current I<NUM>.

According to a preferred embodiment, the electrical power supply circuit <NUM> comprises a diode rectifier <NUM> that transforms the secondary alternating electrical voltage V<NUM> and the secondary alternating electrical current I<NUM> into a corresponding direct voltage VOUT and into a corresponding direct current IOUT. The rectifier <NUM> supplies a DC/DC electronic power converter <NUM> to which the balancing head <NUM> is connected (through the electric cable <NUM>).

Preferably, a capacitor with stabilization capacitance COUT is connected in parallel to the rectifier <NUM> to stabilize the voltage VOUT (i.e. reduce the ripple of the VOUT). Alternatively, the function performed by the capacitor with capacitance COUT can be integrated into the rectifier <NUM>.

A sensor device <NUM> is connected to the primary resonant circuit and detects a phase shift Δϕ between the primary electrical voltage V<NUM> and the primary electrical current I<NUM>. Preferably, the sensor device <NUM> is itself connected to a signal conditioning device, represented in <FIG> in a very schematic way by box <NUM>.

Finally, the electrical power supply circuit <NUM> comprises a controller <NUM> which receives the phase shift Δϕ between the primary electrical voltage V<NUM> and the primary electrical current I<NUM> as input, and controls the inverter <NUM> in such a way as to adjust the frequency F of the primary electrical voltage V<NUM> (therefore of the primary electric current I<NUM>) depending on the phase shift Δϕ between the primary electrical voltage V<NUM> and the primary electric current I<NUM>.

In operation, the controller <NUM> varies the frequency F of the primary electrical voltage V<NUM> (therefore of the primary electrical current I<NUM>) in such a way as to cancel the phase shift Δϕ between the primary electrical voltage V<NUM> and the primary electrical current I<NUM>, i.e. in such a way as to operate in resonance condition (in which the capacitive impedance is equal to the inductive impedance and therefore the primary electrical voltage V<NUM> is perfectly in phase with the primary electric current I<NUM>). The value of the frequency F at which the resonance condition occurs is called the resonance frequency FR.

It should be noted that the controller <NUM> adjusts the frequency F of the primary electrical voltage V<NUM> to follow the resonance condition (i.e. to identify the resonance frequency FR which cancels the phase shift Δϕ between the primary electrical voltage V<NUM> and the primary electrical current I<NUM>) in a substantially continuous way (i.e. always, dynamically). When the distance d between the stator <NUM> and the rotor <NUM> must be measured or monitored, this distance is obtained from the frequency set to maintain the resonance condition, that is from the resonance frequency FR.

<FIG> schematically shows an equivalent electrical circuit referred to the primary side corresponding to the electrical power supply circuit <NUM> of <FIG>. Such circuit comprises the inverter <NUM> which generates the primary electrical voltage V<NUM>, an electrical resistance R<NUM> (corresponding to the parasitic electrical resistance of the inverter <NUM> and of the primary coil <NUM>), the capacitance C<NUM>, the inductance L<NUM> of the primary coil <NUM>, and the impedance Z<NUM> corresponding to the secondary coil <NUM> and to everything that is connected to the secondary coil <NUM> referred to the primary side.

The resonance condition occurs when: <MAT>.

L<NUM> is the inductance of the primary coil <NUM> and depends on the characteristics of the primary coil <NUM> (i.e. the number N of turns) and of the magnetic circuit of the air-coupled transformer <NUM> (schematically shown in <FIG>). Such magnetic circuit has an overall magnetic reluctance <IMG> which varies by changing the distance d between the stator <NUM> and the rotor <NUM>: <MAT>.

From the schematic representation of the magnetic circuit of the air-coupled transformer shown in <FIG>, it is possible to deduce that: <MAT> <MAT> <MAT> <MAT>.

The magnetic permeabilities of the ferrite cores F1 and F2 on which the coils <NUM> and <NUM> are wound are much greater than the magnetic permeability of the air, therefore the overall magnetic reluctance <IMG> mainly depends on the magnetic reluctance RAIR of the air gap.

Since the magnetic reluctance RAIR of the air gap is proportional to the distance d between the stator <NUM> and the rotor <NUM>, it is possible to deduce that the inductance L<NUM> of the primary coil <NUM> is inversely proportional to the distance d. In turn, the resonance frequency FR of the primary circuit is proportional to the square root of the distance d between the stator <NUM> and the rotor <NUM> (i.e. between the two coils <NUM> and <NUM>).

In conclusion, knowing the value of an electrical variable influencing the achievement of the resonance condition, such as the resonance frequency FR, it is possible to determine the distance d between the stator <NUM> and the rotor <NUM> (i.e. between the two coils <NUM> and <NUM>). Therefore, it is possible to monitor, and more specifically to measure or determine, the distance d between the stationary part <NUM> and the movable part <NUM> without the need of any external probe or device, but by means of a measuring system including the processing unit that detects a value of the frequency influencing the achievement of the resonance condition (i.e. the frequency of resonance FR) and determines the distance d as a function of such value of the frequency. More specifically, the controller <NUM> adjusts the frequency F of the primary electric voltage V<NUM> in such a way that the primary circuit operates in a resonance condition (in which the primary electrical voltage V<NUM> is in phase with the primary electric current I<NUM>). A processing unit, for example the control unit <NUM>, detects a value taken by the frequency F of the primary electrical voltage V<NUM>, that is the resonance frequency FR, and determines the distance d between the stator <NUM> and the rotor <NUM> depending on such value.

The processing unit, which receives the information of the resonant frequency FR and determines the distance d between the stator <NUM> and the rotor <NUM>, can be included in the control unit <NUM> as described and shown in the figure, or it can be integrated into the controller <NUM> so as to ease processing operations carried out by the control unit <NUM>.

It is possible to monitor, and more specifically to measure or determine, the distance d between the stator <NUM> and the rotor <NUM> without the need of any external probe or device, starting from an electrical variable other than the frequency, in any case an electrical variable that influences the achievement of the resonance condition, such as the overall inductance or the overall capacitance referred to the primary resonant circuit.

Overall inductance and overall capacitance mean the inductance or capacitance (depending on which physical quantity is considered) referred to the primary resonant circuit which are modified to achieve the resonance condition. In particular, the inductance or capacitance values of the primary resonant circuit can be adjusted in a known way to operate in resonance conditions by using a suitable circuitry.

The processing unit, included for example in the control unit <NUM>, determines, when operating in a resonance condition, the distance d between the stator <NUM> and the rotor <NUM> as a function of a value (FR) taken by the frequency F or by the overall inductance or by overall capacitance both referred to the primary resonant circuit.

In conclusion, knowing the resonant frequency FR or the value of another electrical variable that influences the achievement of the resonance condition, such as the overall inductance or the overall capacitance referred to the primary resonant circuit, it is possible to determine the distance d between the stator <NUM> and rotor <NUM> (i.e. between the two coils <NUM> and <NUM>).

According to the preferred embodiment, the achievement of the resonance condition, and the measurement of the distance between the stator <NUM> and the rotor <NUM>, are carried preferably on the basis of the frequency as it is the most advantageous solution in terms of simplicity of application, of the necessary circuitry and therefore of dimensions and costs. Capacitance and inductance can also be used to achieve the resonance condition and thus to determine the distance between the stator <NUM> and the rotor <NUM>, even if acting on one of these electrical variables is more complex when the system is in operation, and entails larger dimensions and higher costs.

It is also possible to act simultaneously on several electrical variables, even if this solution is more complex.

According to a preferred embodiment, an experimental law is used (shown for example in <FIG> and <FIG>) which links the distance d between the stator <NUM> and the rotor <NUM> and the value taken by the electrical variable influencing the achievement of the resonance condition. In other words, it expresses the distance d as a function of the frequency F (<FIG>) or as a function of the overall inductance L<NUM> (<FIG>) or of the overall capacitance of the primary resonant circuit (<FIG>). The experimental law is obtained, for example, from appropriate tests previously carried out.

The information of the resonant frequency FR (and/or of the other electrical variables) is in the controller <NUM>. The controller <NUM> can make it available through registers that can be read by the logic circuits of the control unit <NUM> of the machine tool <NUM>, the control unit <NUM> dealing with the corresponding signaling.

Due to tolerances set for inductive components and capacitances, this technique may require a calibration phase to provide absolute distance measurements. However, this calibration should concern only the stator <NUM> with the advantage that if the rotor <NUM> is replaced on site it is not necessary to repeat the calibration. This applies to cases where the new rotor <NUM> does not have values of inductance L<NUM> and capacitance C<NUM> very different from those nominally expected.

A possible limitation of this technique concerns the phenomenon known in literature as "Frequency splitting" consisting in a resonance frequency splitting in an "overcoupled" system condition. The "overcoupling" condition is reached when the electrical resistance of the load (i.e. the equivalent electrical resistance of the balancing head <NUM>) becomes particularly small while mutual inductance values are relatively high. To avoid this problem, the controller <NUM> is designed in such a way as to remain locked to the resonance peak with a lower frequency in the event of resonance frequency splitting, that is when operating in "overcoupling" condition, in order to avoid frequency jumps.

As a consequence, given the type of control carried out, should the "overcoupling" condition arise, the resonance frequency chosen by the system would be lower than the nominal value determined exclusively by the values of the inductance L<NUM> and the capacitance C<NUM>.

In general, in order to minimize the effects that the frequency shift has on the determination of the distance d, it is preferable to carry out the evaluation in a light load condition (i.e. a condition of high electrical resistance of the load). In fact in this condition the resonance frequency depends only on the reluctance<IMG> of the air-coupled transformer <NUM> as previously described. In other words, the measurement of the distance d is preferably carried out when the balancing head <NUM> is not operating (i.e. it is switched on in a standby condition) and therefore provides a modest electrical load.

If the measurement of the distance d is carried out in heavy load conditions (that is, a condition of low electrical resistance of the load) and high mutual inductance values, which can be obtained when the distance d is small, the measurement of the distance d might be underestimated. That would be however the safest situation, when the distance d between the stator <NUM> and the rotor <NUM> is small.

<FIG> shows a diagram which has been obtained experimentally and shows the correlation between the distance d and the overall inductance (indicated with ΔL) referred to the primary resonant circuit once the condition of resonance has been reached.

<FIG> shows a diagram which has been obtained experimentally and shows the correlation between the distance d and the frequency F of the primary electrical voltage V<NUM>.

<FIG> shows a preferred embodiment of the electrical power supply circuit <NUM>. This circuit can be made in a different way according to the type of electronics that is used, for example the rectifier device <NUM> and the converter <NUM> can be omitted.

In the experimental tests that have been carried out, the "overcoupling" phenomenon rarely occurs even with heavy loads. Its presence begins to appear when the rotor and stator are in close proximity. In this case, in fact, the measured frequency F slightly decreased as compared with the expected one but, as previously mentioned, the error committed would be estimating a distance d smaller than the real one. This would thus provide a more precautionary result to avoid unwanted contacts between the stator <NUM> and the rotor <NUM>.

In the embodiment shown in the attached figures, the above described method for contactless power transmission is implemented in a contactless connection system <NUM> which, in a machine tool <NUM>, connects a control unit <NUM> to a balancing head <NUM> of a rotating spindle <NUM>, the latter supporting (at least) one grinding wheel <NUM>. According to other embodiments not shown, the above described method can be implemented in a contactless connection system mounted on a different type of application.

The method for contactless power transmission and the electrical supply circuit are so far described and illustrated with reference to a system for controlling the machining of a mechanical part in a machine tool comprising a balancing head. They can also be applied to a control system without a balancing head and comprising a vibration sensor, for example an acoustic sensor, and/or other per se known sensors or devices in a movable/rotating part that need to be powered.

The embodiments described herein can be combined with each other without departing from the scope of protection of the present invention.

The method and the circuit described above provide several advantages.

In the first place, the method and circuit described above allow to measure the distance d with sufficient accuracy (i.e. the measurement of the distance d between the stator <NUM> and the rotor <NUM> is sufficiently accurate for the specific requirements of this type of application). In particular, the method and circuit described above are particularly accurate when a high accuracy is required, that is when the distance d is smaller and the risk of accidental and potentially destructive contacts between the stator <NUM> and the rotor <NUM> is greater.

Furthermore, the method and circuit described above do not entail a significant increase in cost and space, as the actual value of the distance d can be determined without requiring any hardware elements in addition to those already present and without involving the rotor <NUM> or the communication protocol used by the communication device <NUM> in the measurement.

Furthermore, the method and the circuit described above are extremely flexible, since they can be easily customized and adapted to variations in the geometries of the rotor <NUM> and stator <NUM> according to the application requirements.

Claim 1:
Method for contactless power transmission between a stationary part (<NUM>) and a movable part (<NUM>), with an electrical power supply circuit (<NUM>) comprising an air-coupled transformer (<NUM>) provided with a primary resonant circuit with a primary coil (<NUM>) supported by the stationary part (<NUM>) and a secondary resonant circuit with a secondary coil (<NUM>) facing the primary resonant circuit and supported by the movable part (<NUM>);
the method comprising the steps of
- feeding the primary resonant circuit with a primary alternating electrical voltage (V<NUM>) causing a primary electrical current (n) to circulate, said primary electrical current inducing in the secondary resonant circuit a secondary alternating electrical voltage (V<NUM>) that causes a secondary electrical current (I<NUM>) to circulate;
- adjusting at least one electrical variable influencing the achievement of a resonance condition wherein the primary electrical voltage (V<NUM>) is in phase with the primary electrical current (I<NUM>); and
- monitoring the distance (d) between the stationary part (<NUM>) and the movable part (<NUM>),
the method is characterized in that the step of monitoring the distance (d) between the stationary part (<NUM>) and the movable part (<NUM>) comprises:
- detecting a value of said at least one electrical variable influencing the achievement of the resonance condition; and
- determining said distance (d) between the stationary part (<NUM>) and the movable part (<NUM>) as a function of the value of said at least one electrical variable.