Spindle device and machine tool having a spindle device

Abstract

The invention relates to a spindle device (100), comprising: a tool holder (14) for holding a tool or a tool interface; a spindle drive comprising a spindle rotor (130) for rotationally driving the tool holder (14); an electrical load (160), which is arranged on the side of the spindle rotor (130) facing the tool holder (14); and a coil unit (140) for supplying electrical energy to the electrical load (160); wherein the coil unit (140) is arranged on the side of the spindle rotor (130) facing away from the tool holder (14).

Claims

1. A spindle device comprising: a spindle stator; a spindle rotor rotatable relative to the spindle stator about a spindle axis defined by a centerline of the spindle rotor, wherein the spindle rotor has a first end and a second distal end, the first end and the second distal end being on axially opposite sides of the spindle rotor with respect to the extension of the spindle axis; a tool holder configured to hold a tool or a tool-holding tool interface at the first end of the spindle rotor, wherein said tool holder is mounted on said first end of said spindle rotor; a spindle drive for rotationally driving said spindle rotor, on which said tool holder is mounted, about said spindle axis relative to the spindle stator; at least one electrical load coupled between said spindle rotor and said tool holder; and a coil unit for supplying electrical energy to the at least one electrical load, wherein said coil unit is arranged facing away from said tool holder on said second distal end of said spindle rotor, wherein: said coil unit comprises a transmitter coil and a receiver coil for non-contact energy transfer from the transmitter coil to the receiver coil, energy transferred to the receiver coil travels axially inside said spindle rotor along said spindle axis from the receiver coil to the at least one electrical load, said receiver coil is attached to an end portion of said spindle rotor on the second distal end of said spindle rotor, said transmitter coil is fixedly connected to the spindle stator such that the receiver coil is rotating with respect to the transmitter coil when the spindle rotor is rotating with respect to the spindle stator, said electrical load comprises a vibration unit which is attached to said tool holder, said vibration unit is configured to drive vibrations of said tool holder in the axial direction and in a radial direction of said spindle device, and/or said vibration unit is configured to drive a vibration of said tool holder in a rotational direction of said spindle device, wherein the driven axial, radial, and/or rotational vibrations of said tool holder have a frequency in the ultrasonic range.

2. The spindle device of claim 1 wherein said coil unit comprises a gap located between said transmitter coil and said receiver coil for non-contact energy transfer.

3. The spindle device of claim 1 wherein said transmitter coil and said receiver coil are each formed as a full-circumference coil.

4. The spindle device of claim 1 wherein said transmitter coil is attached to a spindle housing which accommodates said spindle rotor.

5. The spindle device of claim 1 wherein said coil unit is connected to said electrical load by means of electrical lines, wherein at least one portion of said electrical lines is led axially along a rotational axis of said spindle rotor from said first end to said second distal end of said spindle rotor.

6. The spindle device of claim 5, wherein said spindle rotor comprises an axially arranged hollow shank element through which said at least one portion of said electrical lines is led axially along the rotational axis of said spindle rotor.

7. The spindle device of claim 1 wherein said electrical load comprises an electronic measuring device.

8. The spindle device of claim 1 wherein said vibration unit comprises a piezoelectric actuator or a plurality of piezoelectric actuators arranged successively in the axial direction.

9. The spindle device of claim 1 wherein said vibration unit is attached non-rotatably to said tool holder.

10. The spindle device of claim 1 wherein said tool holder is connected to said spindle rotor via a labyrinth coupling.

11. The spindle device of claim 1 wherein: said tool-holding tool interface to be held by said tool holder is a replaceable tool interface comprising a hollow shank taper tool interface or a steep taper interface.

12. A machine tool for machining a workpiece, the machine tool comprising: a spindle device including: a spindle stator; a spindle rotor rotatable relative to the spindle stator about a spindle axis defined by a centerline of the spindle rotor, wherein the spindle rotor has a first end and a second distal end, the first end and the second distal end being on axially opposite sides of the spindle rotor with respect to the extension of the spindle axis; a tool holder configured to hold a tool or a tool-holding tool interface at the first end of the spindle rotor, wherein said tool holder is mounted on said first end of said spindle rotor; a spindle drive for rotationally driving said tool holder and said spindle rotor about said spindle axis relative to the spindle stator; at least one electrical load coupled between said spindle rotor and said tool holder; and a coil unit for supplying electrical energy to the at least one electrical load, wherein said coil unit is arranged facing away from said tool holder on said second distal end of said spindle rotor, wherein: said coil unit comprises a transmitter coil and a receiver coil for non-contact energy transfer from the transmitter coil to the receiver coil, wherein energy transferred to the receiver coil travels axially inside said spindle rotor along the spindle axis from the receiver coil to the at least one electrical load, said receiver coil is attached to an end portion of said spindle rotor on the second distal end of said spindle rotor, said transmitter coil is fixedly connected to the spindle stator such that the receiver coil is rotating with respect to the transmitter coil when the spindle rotor is rotating with respect to the spindle stator, said electrical load comprises a vibration unit which is attached to said tool holder, said vibration unit is configured to drive vibrations of said tool holder in the axial direction and in a radial direction of said spindle device, and/or said vibration unit is configured to drive a vibration of said tool holder in a rotational direction of said spindle device, wherein the driven axial, radial, and/or rotational vibrations of said tool holder have a frequency in the ultrasonic range.

13. The machine tool of claim 12 wherein said coil unit comprises a gap located between said transmitter coil and said receiver coil for non-contact energy transfer.

14. The machine tool of claim 12 wherein said transmitter coil and said receiver coil are each formed as a full-circumference coil.

15. The machine tool of claim 12 wherein said transmitter coil is attached to a spindle housing which accommodates said spindle rotor.

16. The machine tool of claim 12 wherein said coil unit is connected to said electrical load by means of electrical lines, wherein at least one portion of said electrical lines is led axially along a rotational axis of said spindle rotor from one end of said spindle rotor to the other end of said spindle rotor.

17. The machine tool of claim 16 wherein said spindle rotor comprises an axially arranged hollow shank element through which said at least one portion of said electrical lines is led axially along the rotational axis of said spindle rotor.

18. The machine tool of claim 12 wherein said electrical load comprises an electronic measuring device.

19. The machine tool of claim 12 wherein said vibration unit comprises a piezoelectric actuator or a plurality of piezoelectric actuators arranged successively in the axial direction.

20. The machine tool of claim 12 wherein said vibration unit is attached non-rotatably to said tool holder.

21. The machine tool of claim 12 wherein said tool holder is connected to said spindle rotor via a labyrinth coupling.

22. The machine tool of claim 12 wherein: said tool-holding tool interface to be held by said tool holder is a replaceable tool interface comprising a hollow shank taper tool interface or a steep taper interface.

23. The spindle device of claim 1 wherein said receiver coil is attached on a surface of said spindle rotor, said surface of said spindle rotor facing away from said tool holder.

24. The machine tool of claim 12 wherein said receiver coil is attached on a surface of said spindle rotor, said surface of said spindle rotor facing away from said tool holder.

25. The spindle device of claim 1, further comprising one or more conductors electrically coupled to the receiver coil and to the at least one electrical load and positioned along the spindle axis, wherein energy travels axially along the one or more conductors from the receiver coil to the electrical load.

26. The machine tool of claim 12, further comprising one or more conductors electrically coupled to the receiver coil and to the at least one electrical load and positioned along the spindle axis, wherein energy travels axially along the one or more conductors from the receiver coil to the electrical load.

27. The spindle device of claim 1 wherein said spindle rotor has a surface at the second distal end, and wherein at least part of the coil unit is mounted to the surface at the second distal end.

28. The machine tool of claim 12 wherein said spindle rotor has a surface at the second end, and wherein at least part of the coil unit is mounted to the surface at the second distal end.

29. The spindle device of claim 27 wherein there is a gap between the coil unit and the spindle stator.

30. The machine tool of claim 28 wherein there is a gap between the coil unit and the spindle stator.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the drawings:

(2) FIG. 1A shows a schematic perspective view of a machine tool seen obliquely from above,

(3) FIG. 1B shows a schematic front view of the machine tool,

(4) FIG. 1C shows a schematic side view of the machine tool,

(5) FIG. 1D shows a schematic perspective view of the machine tool seen obliquely from below,

(6) FIG. 2 shows a schematic perspective view of a spindle device according to an embodiment of the present invention, and

(7) FIG. 3 shows a schematic sectional view of the spindle device according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS AND OF PREFERRED EMBODIMENTS OF THE INVENTION

(8) In the following, examples of the present invention will be described in detail with reference to the figures. Identical or similar elements in the figures are designated by the same reference signs. However, the present invention is not limited to the described embodiments, but also includes modifications of features of the described examples and combinations of features of various examples within the scope of the independent claims.

(9) FIGS. 1A to 1D show schematic views of an exemplary mobile machine tool 1 which is exemplarily equipped with a spindle device according to an embodiment.

(10) FIG. 1A shows a schematic perspective view of the machine tool 1 seen obliquely from above, FIG. 1B shows a schematic front view of the machine tool 1, FIG. 1C shows a schematic side view of the machine tool 1, and FIG. 1D shows a schematic perspective view of the machine tool 1 seen obliquely from below.

(11) As a basic frame, the machine tool 1 comprises, e.g., a rectangular or essentially square-shaped frame, which is formed, e.g., from a monolithically formed frame element 2 made of a fibre reinforced plastic, in particular from a carbon fibre reinforced plastic, on which optionally additional elements may be mounted such as cover plates or the like. Preferably, the frame width and/or the frame length are approximately 0.5 to 1.5 m.

(12) In the interior of the frame element 2, the machine tool 1 has a machining space, which is completely enclosed by the monolithic frame element 2. On two opposing frame portions of the four frame portions of the frame element 2, guides 3a and 3b extending in X-direction for a controllable X linear axis (first linear axis) are mounted directly on the two opposing frame portions of the frame element 2.

(13) An X carriage 4 movable in the X direction is guided by the guides 3a and 3b. Preferably, the X linear axis has a respective length measuring system on at least one and preferably on each of the two opposing frame portions on each of the guides 3a and 3b, so that the position of the X carriage 4 of the X linear axis can be determined on one and preferably on both sides.

(14) The X linear axis includes, for example, a respective screw drive with a respective screw shaft 3c or 3d on both sides of the X carriage. On the screw shafts 3c and 3d, drives 3e and 3f are held, which are attached or disposed laterally at the X carriage 4. The drives 3e and 3f are configured to move the X carriage 4 along the screw shafts 3c and 3d in the X direction.

(15) Thus, the X carriage 4 is guided movably in the X direction on the guides 3a and 3b on the frame element 2 of the machine tool frame by means of actuating the X linear axis and includes a monolithically formed frame element, which is formed, for example, from a fibre reinforced plastic, in particular from a carbon fibre reinforced plastic.

(16) On the outer sides of the frame element 2 of the frame of the machine tool, four foot elements 9 are arranged on each of the four frame portions. The foot elements serve to place the machine tool 1 on a surface, e.g., on a surface of a large-area workpiece.

(17) In FIGS. 1 to 5, a cap element 21 (cover element, or cover, optionally made of plastics) is arranged or mounted on the X carriage 4 in order to cover or protect the underlying components. In addition, the cap element 21 has the advantage of providing protection against contact for operators of the machine tool 1. However, it is also possible to provide embodiments without a cap element 21.

(18) The frame element of the X carriage 4 has two transverse beams 4a and 4b each extending from the guide 3a on a frame portion of the frame element 2 to the opposing frame portion of the frame element 2 and the guide 3b.

(19) A Y carriage 5 of a Y linear axis (second linear axis), which can be moved in the Y direction by means of a drive (not shown), is held on the underside of the X carriage 4. For example, the X direction is orthogonal to the Y direction and the undersides of the transverse beams 4a and 4b of the X carriage 4 have respective guides (not shown) extending in the Y direction on which the Y carriage 5 of the Y linear axis is guided.

(20) The Y carriage 5 is guided moveable in the Y-direction on the guides on the underside of the frame element 4 of the X-carriage by means of the Y linear axis (see FIG. 1D) and has a monolithically formed frame element which is formed, e.g., from a fibre reinforced plastic, in particular from a carbon fibre reinforced plastic.

(21) In this preferred embodiment, the X and the Y carriages are each formed from a fibre reinforced plastic or each comprise a respective frame element made of a fibre reinforced plastic. In further embodiments, it is, of course, possible to form one or both of these carriages or their frame elements from another material, e.g., preferably aluminum for reasons of weight.

(22) A turret element 6, which extends in a Z-direction extending, for example, orthogonally to the X and Y directions of the X and Y linear axes, is held centrally on the Y carriage 5 of the Y linear axis.

(23) A rotary direct drive (not shown) is arranged on the Y carriage 5 of the Y linear axis and is configured to drive the tower element 6 to rotate about a rotational axis (second rotational axis, preferably controllable over at least 360°), which is parallel to the Z direction.

(24) A Z carriage 8 of a Z linear axis (third linear axis), which can be moved in the Z direction by means of a further linear drive, is arranged in the interior of the exemplary hollow-shaped turret element 6.

(25) At the lower end of the Z carriage 8, a spindle device with a machining element 12 (e.g., a machining head, e.g., a milling head) is arranged; see, e.g., FIG. 1D. The machining element 12 or the spindle device includes a tool spindle 13 with a tool holder 14 on which a milling tool 15 for machining a workpiece is held, for example. A spindle drive for driving the spindle is arranged in the spindle housing of the spindle 13. The spindle device and its exemplary structure will be described below with reference to FIGS. 2 and 3.

(26) In preferred embodiments of the invention, a piezoelectric actuator (as an electrical load) or a similar vibration drive (electrical load) may additionally be provided in order to additionally drive a vibration movement in the tool, in which the tool vibrates in the direction of the spindle axis. This is particularly advantageous in the machining of composite components and surfaces of fibre composite materials, since ragged edge formation or fraying on the machined surface can be avoided.

(27) The machining element 12 or the spindle device is arranged or held on the lower end of the Z carriage 8 which projects into the turret element 6 rotatable about the Z axis with the rotary direct drive on the Y carriage 5 and is held moveable in the Z direction on the turret element 6.

(28) A further rotary direct drive 11 configured to rotate the machining element 12 with the spindle 13 rotationally about a rotation axis (second rotation axis, optionally formed as a pivot axis, preferably controllable over at least 180°), which is oriented, for example, perpendicularly to the Z direction, is provided at the lower end of the Z carriage 8, for example.

(29) Attached to one side of the machining element 12A is, for example, a measuring means 17, which may comprise, for example, a laser measuring system for measuring the surface of the workpiece or for determining a position of the machine tool 1 relative to the workpiece and/or other non-contact measuring systems for examining the surface of the workpiece (for example, an optical system with a camera and/or an ultrasonic measuring system). Such a measuring means (or parts of such a measuring means) may also be arranged on the inner side of the frame 2. Moreover, in further embodiments, such a measuring means may also be provided as part of the spindle device as an electrical load of the spindle device.

(30) Moreover, in further embodiments, the machine tool 1 preferably comprises a laser tool measuring system or a laser tool measuring means which may be arranged either on the machining element 2 and/or on the inner side of the frame 2 in order to measure a tool 15 held on the spindle 13 or the position thereof by means of a laser. An optional laser tool measuring device 24 is arranged on the inner side of the frame 2 in FIG. 1D, for example. This opens up, for example, the possibility of measuring the tool length and diameter of the tool 15 held on the spindle 13 by means of the tool laser of the tool measuring device 24, which is attached to the frame in the interior of the machine.

(31) A cable guide (not shown) extending from the Y carriage 5 may be connected to the machining element 12 and then provides the electrical power supply for the spindle drive, the direct drive 11, the piezoelectric drive and/or the measuring means 17 or other electrical loads. In addition, control signals may be transmitted to the spindle drive and the direct drive 11 via the cable guide 16 and sensor signals may be read out from the measuring means 17.

(32) Further cable guides (e.g., for actuator signals, sensor signals or the electrical power supply) are preferably led in cable ducts, which, in preferred embodiments, are formed on or in the monolithic frame element 2.

(33) In FIGS. 1A and 1D, for example, an interface opening 19 is formed externally at a corner of the frame member 2 as an end of cable guide ducts formed on the frame member 2, which lead directly or indirectly to one or more of the carriages and the drives on the carriage of the axes.

(34) Herein, the machine tool 1 also preferably provides external connections arranged on the frame element 2, e.g. the already mentioned control interface 19, for connecting a power connection for electrical power supply and/or for connecting a communication connection for actuator and/or sensor signal transmission from/to an external control device, and/or also a suction connection 20 for an external suction device (optionally preferably via a connection of internal suction ducts at or in the frame element 2 to the suction openings 18).

(35) FIG. 2 shows, by way of example, a schematic perspective view of a spindle device 100 according to an embodiment of the present invention.

(36) The spindle device 100 according to this embodiment includes a spindle housing 110. On the spindle side on the spindle housing 110, a tool holder 14, which can be driven rotationally about the spindle axis, is arranged on the spindle 13, which is adapted to hold a tool (see tool 15 in FIGS. 1A to 1D).

(37) In this embodiment, the tool holder 14 is, for example, formed such that the receiving element of the tool holder 14, which is non-rotatably connected to the spindle 13 or the spindle rotor described later, is configured to hold a tool, e.g. a milling or drilling tool, directly (i.e., in particular, without a replaceable tool interface).

(38) In particular, this advantageously allows designing the spindle device 100 particularly compact so that the spindle device 100 is excellently suitable for a mobile machine tool.

(39) However, the present invention is not limited to spindle devices with a direct tool holder according to FIGS. 2 and 3, but rather other preferred and exemplary embodiments may be provided in which the tool holder of the spindle device is configured to hold a replaceable tool interface, i.e., particularly preferably a replaceable hollow shank taper tool interface or also a replaceable steep taper tool interface.

(40) In the embodiment according to FIGS. 2 and 3, the spindle housing 110 of the spindle device 100 additionally comprises, for example, a pneumatic or hydraulic port 111 as well as a fastening element 112 with which the spindle device 110 can be attached or fastened to the machining element 12 or the tool head.

(41) Furthermore, connections 113 for connecting one or more cable guides for sensor signals and actuator signals (e.g., for the spindle drive) and optionally also for power cables for the electrical power supply of the spindle drive and/or the electrical load of the spindle device 100 (such as a measuring means and/or a vibration unit or a coil unit) are provided at the fastening element 112.

(42) FIG. 3 shows, by way of example, a schematic sectional view of the spindle device 100 according to an embodiment of the present invention.

(43) Inside the spindle housing 110 of the spindle device 100, the spindle device 100 includes a spindle drive which has a spindle rotor 130 rotatably supported in a spindle stator 120.

(44) When the spindle of the spindle device 100 is driven, the spindle rotor 130 is rotationally driven, in preferred embodiments based on an electric motor by means of electromagnetic induction. In further embodiments, however, the spindle rotor 130 may also be driven indirectly via a gear unit (not shown) in a mechanical manner.

(45) At one end of the spindle rotor 130, the tool holder 14 rotatably mounted on a bearing element 190 is arranged, which in this embodiment is configured as a one-piece tool holder element which includes a labyrinth coupling 14 at a central portion. The labyrinth coupling advantageously allows for a vibration of the tool holder 14 in the axial direction of the spindle device 100 or in the spindle axis direction.

(46) In addition, the tool holder 14 includes, by way of example, a pin portion 14b arranged in the interior of the spindle housing 110 (optionally with a thread). A receiving portion 14c of the tool holder 14 protrudes outwardly from the spindle housing 110 and is configured, for example, for the direct reception of a tool (i.e., without an replaceable hollow shank taper interface or a replaceable steep taper interface).

(47) However, the invention is not limited to one-piece tool holder elements, and in further embodiments, the tool holder 14 may also be formed in several pieces or in several parts.

(48) Furthermore, the spindle device 100 comprises, by way of example, a vibration unit 160 for driving a vibration (or oscillation) of the tool holder 14.

(49) For example, the vibrating unit 160 comprises, in this embodiment, four piezoelectric actuators 161, 162, 163 and 164 arranged successively in the axial direction or piezoelectric actuators of a piezoelectric drive, each of which is arranged circumferentially on the pin portion 14b of the tool holder 14.

(50) For example, in this embodiment, an oscillator unit is provided, which can drive a vibration in the axial direction. However, the invention is not limited to such axial oscillator units. Rather, in other embodiments, it is alternatively or additionally possible to drive a vibration of the tool holder in one or more radial directions of the spindle device (e.g., by means of one or more radial oscillator units) and/or to drive a vibration of the tool holder in the rotational direction of the spindle (e.g., by means of a rotational oscillator unit).

(51) The piezoelectric actuators 161, 162, 163 and 164 of the vibration unit 160 are, for example, fastened to the tool holder 14 by means of a spacer disc 182 and a fastening element 181 (e.g. formed as a nut element).

(52) Respective electrical contact plates, via which the piezoelectric actuators 161, 162, 163 and 164 are each electrically connected to electrical line contacts 151 and 152, are, for example, arranged between the piezoelectric actuators 161, 162, 163 and 164.

(53) In the interior of the spindle rotor 130, the spindle device 100 includes an axially arranged hollow shank element 150, which is led through the spindle rotor 130 from one end to the other end of the spindle rotor 130 along the rotational axis of the spindle rotor 130 or along the spindle axis of the spindle device 100 and is connected, for example, non-rotatably to the spindle rotor 130.

(54) The electrical line contacts 151 and 152 or the electrical lines thereof (such as single-pole cables or a multi-pole cable) are led, by way of example, along the rotational axis of the spindle rotor 130 or along the spindle axis of the spindle device 100 through the hollow shank element 150 to the side of the spindle rotor 130 facing away from the tool holder 14.

(55) Furthermore, a coil unit 140 is arranged on the side of the spindle rotor 130 facing away from the tool holder 14, which comprises, for example, a fixed transmitter coil 142, which is connected to the spindle housing 110 or attached to the spindle housing 110, and a rotatably mounted receiver coil 141,

(56) A thin gap or air gap not shown in FIG. 3 is provided between the transmitter coil 142 and the receiver coil 141 in such a way that a electrical or electromagnetic non-contact energy transfer from the transmitter coil 142 to the (possibly rotating) receiver coil 141 is made possible, in particular for the electrical power supply to the vibration unit 160 as a possible embodiment of an electrical load.

(57) Herein, the electrical line contacts 151 and 152 are electrically connected to the receiver coil 141 on the side of the spindle rotor 130 facing away from the tool holder 14 (connection not shown in FIG. 3)

(58) In particularly preferred embodiments, preferably both the transmitter coil 142 and the receiver coil 141 are each formed as a full-circumference coil.

(59) When the spindle is driven, i.e., when the spindle rotor 130 rotates, the receiver coil 141 of the coil unit 140, the vibrating unit 160 with electrical lines 151 and 152 and the hollow shank element 150, as well as the tool holder 14, co-rotate at the same speed with the spindle rotor 130, whereby the non-contact energy transfer from the transmitter coil 142 (which is connected to an external energy source, preferably to a radio-frequency AC source) to the receiver coil 141 is made possible, and thus the vibration unit 160 may be driven or supplied with electrical energy.

(60) The vibration unit 160 is configured to drive a vibration of the tool holder 14 in the axial direction of the spindle device 100, in particular a vibration with a frequency in the ultrasonic range.

(61) Via the exemplary labyrinth coupling 14a, the tool holder 14 is connected to the spindle rotor 130 in a decoupled manner such that the tool holder 14 rotates with the spindle rotor 130 in a rotationally fixed way relative to the spindle rotor 130 but vibrates or oscillates in the axial direction in a manner decoupled from the spindle rotor 130.

(62) In summary, the present invention and the embodiments thereof advantageously allow to provide a spindle device which allows for a simple and compact design and furthermore allows for simple and efficient tool changing, preferably without deteriorating the efficiency of the energy transfer between the coils.