Research on novel matching topology and characteristics of rotary ultrasonic machining system with inductive contactless power transmitter

The rotary ultrasonic vibration machining (RUM) system composed of ultrasonic transducers, machining tools, and inductive contactless power transmitter (ICPT) plays an important role in precision and efficient ultrasonic machining of difficult-to-machine materials. Due to the influence of leakage inductance, self-inductance of ICPT, the capacitive piezoelectric vibrator, and the machining load, the matching of the RUM system is essential for efficient and reliable power transmission. A new matching topology of dual capacitance series–parallel on the primary side of ICPT is proposed in this paper, with which the RUM system can realize ideal bilateral resonance and simplify the matching structure. The model of the bilateral resonance of the RUM system with a new matching topology is established, and then, the matching capacitance calculation method is proposed. The transmission and load characteristics of the RUM system with the new matching topology are studied. The results indicate that the transmission efficiency and power output vary with the self-inductance and mutual inductance of the ICPT. When the self-inductance of the primary side is equal to that of the secondary side of ICPT, the system exhibits a balanced comprehensive transmission performance. These results are of great significance for the engineering application of the RUM.