EMISSION DISINTEGRATION

RELATED APPLICATIONS

[0001] This application claims the full Paris Convention benefit of and priority to U.S. Provisional Application Serial No. 61/461 ,854, filed January 24, 201 1 , the contents of which is incorporated herein by reference, as if fully set forth herein.

BACKGROUND

1. Field

[0002] This disclosure relates to devices and methods for selectively positioning a forceless electrical emission device within a hole or guide.

DESCRIPTION

[0003] Electric discharge machining, or EDM, is an established method and apparatus utilized for machining metal. It operates through the utilization of an electrical discharge to remove metal from the workpiece. In the EDM process, an electrode is brought into close proximity to the workpiece. High voltage is applied in pulses at high frequency. The process occurs in the presence of a dielectric fluid. This creates sparking at generally the closest position between the workpiece and the electrode. Particles are removed from the workpiece when sparking is quenched. The duration of the spark (on-time) and the recovery time (off-time) are controlled so that the workpiece and electrode temperatures are not raised to the temperature of bulk melting. Therefore, erosion is essentially limited to a vaporization process wherein boluses of material are liberated from a workpiece.

[0004] According to some exemplary implementations, devices, systems, and methods of the present disclosure are directed to a forceless electrical emission disintegration method and device. The device provides the electrodes, a dielectric, dielectric containment, and fluid removal . The device may be connected by a flexible umbilical to support equipment, which may include one or more of plasma power system, plasma controller, dielectric fluid pressurizing system, dielectric fluid delivery system, dielectric fluid drain system, dielectric fluid cleaning and deionization system as indicated in U.S. Application Serial No. 12/603,507.

[0005] According to some exemplary implementations, devices, systems, and methods include a flushing system for hand held forceless electrical emission disintegration method and device. The flushing system may include a temporarily sealable hood surrounding the distal end of a positioning collar surrounding an erosion electrode. The erosion electrode is used in combination with said hand held device to remove material from a workpiece. Material liberated during erosion or cutting on a workpiece is dubbed "FOD" or foreign object debris.

[0006] According to some exemplary implementations, devices, systems, and methods of the present disclosure are directed at a closed loop flushing system for a hand-held device. The flushing system including a fluid inlet and outlet in fluid communication with a sealable hood surrounding the distal end of an erosion electrode, open until pressed / sealed into contact with a workpiece. In some instance the fluid inlet provides pressurized fluid to said workpiece for cooling and / or flushing. In some instances the fluid outlet is evacuated to remove said fluid and any debris therein. .

[0007] According to some exemplary implementations, disclosed is a method and device to position the erosion electrode of a forceless electrical emission disintegration device by attaching a collar to a base; the erosion base having a ground and an erosion electrode extended through said collar. The collar having a distal end with an extended latching guide and, positioning said distal end in a pre-cut in a workpiece.

[0008] According to some exemplary implementations, disclosed is a forceless electrical emission disintegration device and method to position the erosion electrode of a forceless electrical emission disintegration device by attaching a collar to a base; the erosion base having a ground and an erosion electrode extended through said collar. The collar having a distal end with an extended latching guide and, positioning said distal end in a pre-cut in a workpiece and applying pressure to seal the distal end against the workpiece.

[0009] According to some exemplary implementations, disclosed is a device and method to position an erosion electrode of a forceless electrical emission disintegration device by attaching a collar to a base; the erosion base having a ground and an erosion electrode extended through said collar. The collar having a distal end with an extended latching guide and, positioning said distal end in a pre-cut in a workpiece and applying sufficient pressure to seal the distal end against the workpiece and generally contain dielectric flushing fluid added to the workpiece through the collar and applying electrical power to erode a section of the workpiece bordered by said latching guide. In some instances a hood is placed around the base or collar to provide additional seal against the workpiece for the containment of dielectric flushing fluid during erosion. In some aspects a pilot hole may be eroded which will provide a hole, guide or channel in a portion of said workpiece.

[0010] According to some exemplary implementations, disclosed is a device and method to position an erosion electrode wherein moving a centered pin device with a hood supporting a removable bushing and a slideable pin along a workpiece surface causes the slideable pin to drop into a pre-cut in said workpiece. After sad pin has dropped then removing said bushing and said pin from said hood thereby revealing a busing guide formed in said hood and then mating a fitted collar with an erosion electrode into said bushing guide whereby the shaped fitted collar urges the distal end of said erosion electrode into said pre-cut. In some instances the method and device include sealing the hood against the workpiece. . In some instances the method and device include a ground electrode placed within the tubular erosion electrode.

DRAWINGS

[001 1 ] The above-mentioned features and objects of the present disclosure will become more apparent with reference to the following description taken in conjunction with the accompanying drawings wherein like reference numerals denote like elements and in which:

[0012] Figure 1 shows a cut away view of a forceless electrical emission and disintegration device.

[0013] Figure 2 shows a positioning collar for a forceless electrical emission and disintegration device.

[0014] Figures 3, 4, and 5 show a forceless electrical emission device with a positioning collar used to generate a specifically positioned removal of material from a workpiece.

[0015] Figures 6A through 6F show a positioning system to form an aligned hole.

[0016] All descriptions and callouts in the Figures are hereby incorporated by this reference as if fully set forth herein.

FURTHER DESCRIPTION

[0017] According to exemplary implementations, a positioning method and device to place the erosion electrode of a forceless electrical emission disintegration device in a specific position within a hole, gap, cut, or guide is disclosed herein. As shown in the figure 1 , a hand-held device 10 may be positioned to remove a fastener 1000 which extends through a workpiece 2000 such as one or more frames. As further shown in figure 1 , fastener 1000 and fastener collar 1002 secure one the fastener to a workpiece. As will be clear to those skilled in the art, any variety of fasteners and associated components may be the object upon which some exemplary implementations of the disclosed device and method may operate.

[0018] The base 20 may be configured to be held in the hand of the workman. Various configurations may be provided to provide hand-held operation of the device 10. According to some exemplary implementations, the base 20 may carry a switch 30 to activate components of the hand-held device 10, as disclosed herein. [0019] According to some exemplary implementations, mounted on a distal end of the base 25 is a hood 40. The hood may be removable. If removable the hood 40 needs to be sealed against leakage of fluid through its mounting with the distal end of the base 25. In some instances the hood 40 may be mounted around a collar 50, the collar being interposed between the distal end of the base 25 and the hood 40. To seal the hood- collar 27 or hood-base interface "0" rings 42 or other seal may be utilized. The hood 40 defines a workspace 300, within which erosion activity may occur. The hood 40 may be configured to seal against a portion of a workpiece 2000, such as a frame, thereby enclosing and/or defining the workspace such that the workspace includes access to at least a portion of a fastener 1000, a collar 1002, or a portion of the workpiece 2000. According to some exemplary implementations, as the hood 40 engages the workpiece 2000, the hood 40 may be configured to enclose the workspace so as to substantially isolate it from the environment outside the workspace. During erosion, substances within the workspace may be contained except through controlled inlets and outlets, as disclosed herein. For example, at least a portion of the hood 40 may be of a flexible or deformable material which may form a seal 45 that adaptably interfaces with the surface 2002 of the workpiece to create a seal at the interface 49. There may be provided a collar structure 60 for stabilizing the hand-held device 10 against a workpiece, such as at the surface 2002. Inlet 70 and outlet 75 channels may be provided for passage of dielectric fluid there through.

[0020] Those of ordinary skill in the art will recognize that the coolant fluid may in some instances be the dielectric fluid. In other cases, a dielectric fluid and a coolant fluid may be provided in sequence. For example, a coolant fluid may be provided after an erosion process has been completed. According to some exemplary implementations, the dielectric outlet 75 may evacuate the dielectric fluid generally from the workspace defined by the hood 40, wherein turbulence within the workspace provides opportunities for the dielectric fluid and other debris to be removed through the dielectric outlet 75. [0021] According to some exemplary implementations, hand-held forceless electrical emission disintegration device 10 may include an erosion base which has at least a ground electrode 80 and an erosion electrode 88. The erosion electrode 88 may be configured to controllably approach a portion of a workpiece to be eroded, such as a fastener 1000, the distal end of the erosion electrode 0) disintegrates a channel 90 conforming to the electrode shape in the fastener. The erosion electrode may be mechanically driven up and down within the base 20 via a controlled drive mechanism 500. Drive mechanisms are more fully detailed in U.S. Application Serial No. 12/603,507, filed 10/21 /2009, and PCT application PCT/US10/55316, filed November 2, 2010 and are hereby incorporated as if fully set forth herein.

[0022] The collar 50 may be removable from the distal end of the base 25. The collar 50 may be attached in a variety of well known variations and those of ordinary skill in the art will recognize the attachment means may depend on the intended usage or workpiece. The collar 50 is shown in figure 1 being attached at the base-collar interface 52. A variety of electrode shapes, geometries, and morphologies may be provided for the erosion electrode 88. Electrode morphologies may be selected according to desired usage (i.e. erosion results and application specific variables).

[0023] Illustrated in Figure 2 is a collar positioning device 100. The device 100 modifies a collar 50 such as that shown in Figure 1 at the distal end 102 of the collar 50. Near the outer edge of the distal end of the collar is a first annular wall 104. Closer to the center of the distal end is a second longer annular wall 106 forming a latching catch which is of a size and shape to correspond to a pre-selected opening. The erosion electrode 88 is shown protruding form the center of the device 100. A recess 1 10 is established between the first and second annular walls 104/ and can latch therein. The recess 1 10 may be used to contain a sealing material (not shown in Figure 2) to at least partially seal the collar 50 against a workpiece. The inlet 75 for fluid is shown between the second annular wall and the erosion electrode 88.

[0024] According to other exemplary implementations, aspects of which are shown in Figures 3, 4, and 5, the erosion electrode 88 is a hollow tubular structure. In some instances aspects of one exemplary implementation may fit properly into another exemplary implementation. The hollow tubular structure of an erosion electrode 88 may be symmetrical about an axis and configured to travel longitudinally along the axis, thereby eroding a ring-shaped portion of the workpiece.

[0025] According to some exemplary implementations, the dielectric inlet 70 and dielectric outlet 75 are provided in fluid communication with the workspace defined by at least one of the collar 50 and the hood 40. According to some exemplary implementations, dielectric fluid may be provided to the workspace or the gap between the erosion electrode 88 and the workpiece by a variety of structures and methods. For example, the dielectric inlet 70 may provide targeted, high-velocity flow of the dielectric fluid directed to the spark gap 95 between the erosion electrode 88 and the workpiece. A dielectric outlet 75 provides a pathway to remove the dielectric flushing fluid from the workpiece and to also remove any erosion debris. The distal end of the erosion electrode 89 is surrounded by the second annular wall 106 of the collar 50. The diameter "d1 " of the second annular wall 106 is less than the diameter of a target hole 2010 in the workpiece 2000. The target hole may represent a pre-cut in a material. Workpiece 2000 is indicated as a layered workpiece wherein the top layer 2004 with the pre-cut 2010 is above a bottom layer 2006 without pre-cut. In the aerospace industry the bottom layer could represent a titanium support or frame and the top layer 2004 may represent a composite, aluminum or other material comprising a skin layer. The diameter "d2" of the pre-cut is larger than the diameter "d1 " of the second annular wall such that the second annular wall can removably mate with the pre-cut 2010.

[0026] Illustrated in Figures 3, 4, and 5 is a bifurcated first annular wall 104 wherein a guide channel 105 for a seal 108 is formed in the first annular wall. The seal being an "O" ring or other malleable material. The dielectric flushing fluid 300 enters the device 10 via the inlet 70 and travels to the workspace. The used dielectric flushing fluid 302 leaves the workspace via outlet 75.

[0027] The device 100 (see figure 2) maintains clearance between the first layer 2004 of the workpiece 2000 and the erosion electrode 88. The positioning collar also urges the erosion electrode 88 towards the center of the pre-cut 2010 in the first layer 2004 thereby useful for aligning a hole or erosion to be made in the second layer 2006. Figure 5 illustrates an erosion through a portion of the second layer 2006 resulting in a plug 2012 being disassociated from the second layer 2006 forming a guide hole aligned with pre-cut 2010. In instances wherein the a layer or frame requires holes or guides eroded in positions corresponding to pre-cuts or cut outs in a top layer or a guide said positioning collar device is removably placed within said pre-cut or cut out to orient, position or otherwise place the forceless electrical emission disintegration device in a proper location to form a hole, guide or cut-out be erosion.

[0028] Aspects of a centered pin device and system 400 of positioning method are disclosed wherein a modified hood 40 acts as a guide for a removable bushing 402, in some instances said bushing has an extended upper portion 403 or grab points (not shown) for gripping to allow removal or placement. A movable pin 404 is slideable located in a pin guide 405 in a preselected position, preferably centered, in said bushing. Said hood 40 provides a hollow center having an annular wall forming a bushing guide 409. The outer wall 410 of the bushing 402 is configured to removably mate with said busing guide 409.

[0029] The pin 404 is used as a locator to identify a pre-cut hole 2010. Shown in figures 6A-F is a workpiece 2000 with a two layer structure. The first layer 2004 of the workpiece 2000 having a preformed pre-cut hole 2010 and a second layer 2006. As the device 400 is moved along the surface of the workpiece the pin 404 will slide down the pin guide 405 and drop into the pre-cut hole 2010. Once said hood 40 is centered around the pin extended into the pre-cut hole 2010 the bushing 402 and pin 404 can be lifted out of the bushing guide 409. Said hood is kept in place via pressure, adhesive, suction, friction and/or vacuum.

[0030] A hand-held forceless electrical emission disintegration device 10 having a base 20 with a distal end 25 is affixed to a fitted collar 450 with an annular wall 452 of a size and shape configured to removably mate with said busing guide 409. A tubular erosion electrode 88 (and may also have a ground electrode within said erosion electrode) extends from said device 10. The fitted collar 450 in cooperation with the bushing guide urges the erosion electrode 88 towards the center of the pre-cut 2010 thereby useful for aligning a hole or erosion to be made in the second layer 2006.

[0031] The erosion electrode 88 may be configured to controllably approach a portion of the second layer 2006 through the pre-cut hole 2004 in the first layer, the distal end of the erosion electrode 89 disintegrates a hole 2015 in the second layer conforming to the electrode shape and aligned with he pre-cut hole 2004. The erosion electrode may be mechanically driven up and down within the base 20 via a controlled drive mechanism 500. Drive mechanisms, closed loop flushing and power supplies are more fully detailed in U .S. Application Serial No. 12/603,507, filed 10/21 /2009, and PCT application PCT/US10/55316, filed November 2, 2010 and are hereby incorporated as if fully set forth herein which describes a dielectric inlet configured to provide a dielectric fluid to the gap between the erosion electrode and the workpiece. The dielectric inlet may provide dielectric fluid along at least a portion of the erosion electrode 88 such that the dielectric fluid is delivered directly to the location of plasma events occurring at the end of the erosion electrode. For example, where the erosion electrode is a hollow tubular structure, the dielectric inlet may provide the dielectric fluid within the hollow tubular structure, such that the dielectric fluid is drawn through the spark gap to reach a dielectric outlet located outside the hollow tubular structure. Where the erosion electrode is disposed within a hollow tubular structure, the dielectric inlet may likewise provide the dielectric fluid within the hollow tubular structure to the spark gap. High voltage is applied in pulses at high frequency. The process occurs in the presence of a dielectric fluid. This creates sparking at generally the closest position between the workpiece and the electrode. Particles are transported from the workpiece with fluid flow.

[0032] While the method and apparatus have been described in terms of what are presently considered to be the most practical and preferred embodiments, it is to be understood that the disclosure need not be limited to the disclosed embodiments. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures. The present disclosure includes any and all embodiments of the following claims.

[0033] It should also be understood that a variety of changes may be made without departing from the essence of the invention. Such changes are also implicitly included in the description. They still fall within the scope of this invention. It should be understood that this disclosure is intended to yield a patent covering numerous aspects of the invention both independently and as an overall system and in both method and apparatus modes.

[0034] Further, each of the various elements of the invention and claims may also be achieved in a variety of manners. This disclosure should be understood to encompass each such variation, be it a variation of an embodiment of any apparatus embodiment, a method or process embodiment, or even merely a variation of any element of these.

[0035] Particularly, it should be understood that as the disclosure relates to elements of the invention, the words for each element may be expressed by equivalent apparatus terms or method terms - even if only the function or result is the same.

[0036] Such equivalent, broader, or even more generic terms should be considered to be encompassed in the description of each element or action. Such terms can be substituted where desired to make explicit the implicitly broad coverage to which this invention is entitled.

[0037] It should be understood that all actions may be expressed as a means for taking that action or as an element which causes that action.

[0038] Similarly, each physical element disclosed should be understood to encompass a disclosure of the action which that physical element facilitates.

[0039] Any patents, publications, or other references mentioned in this application for patent are hereby incorporated by reference. In addition, as to each term used it should be understood that unless its utilization in this application is inconsistent with such interpretation, common dictionary definitions should be understood as incorporated for each term and all definitions, alternative terms, and synonyms such as contained in at least one of a standard technical dictionary recognized by artisans and the Random House Webster's Unabridged Dictionary, latest edition are hereby incorporated by reference.

[0040] Finally, all referenced listed in the Information Disclosure Statement or other information statement filed with the application are hereby appended and hereby incorporated by reference; however, as to each of the above, to the extent that such information or statements incorporated by reference might be considered inconsistent with the patenting of this/these invention(s), such statements are expressly not to be considered as made by the applicant(s).

[0041] In this regard it should be understood that for practical reasons and so as to avoid adding potentially hundreds of claims, the applicant has presented claims with initial dependencies only.

[0042] Support should be understood to exist to the degree required under new matter laws - including but not limited to United States Patent Law 35 USC 132 or other such laws ~ to permit the addition of any of the various dependencies or other elements presented under one independent claim or concept as dependencies or elements under any other independent claim or concept.

[0043] To the extent that insubstantial substitutes are made, to the extent that the applicant did not in fact draft any claim so as to literally encompass any particular embodiment, and to the extent otherwise applicable, the applicant should not be understood to have in any way intended to or actually relinquished such coverage as the applicant simply may not have been able to anticipate all eventualities; one skilled in the art, should not be reasonably expected to have drafted a claim that would have literally encompassed such alternative embodiments.

[0044] Further, the use of the transitional phrase "comprising" is used to maintain the "open-end" claims herein, according to traditional claim interpretation. Thus, unless the context requires otherwise, it should be understood that the term "compromise" or variations such as "comprises" or "comprising", are intended to imply the inclusion of a stated element or step or group of elements or steps but not the exclusion of any other element or step or group of elements or steps.

[0045] Such terms should be interpreted in their most expansive forms so as to afford the applicant the broadest coverage legally permissible.