Design of Compensation Network and Parameter Optimization for Rotary Ultrasonic Machining Under Varying Loads

In rotary ultrasonic machining (RUM), the yutilization of contactless energy transfer (CET) theory addresses the limitations imposed by traditional contact power supply systems on rotational speed, however, it also introduces the challenge of inadequate transmission performance. Specifically, impedance variations of oscillator pose challenges for the CET system (CETS). These challenges include maintaining high transmission efficiency and desirable impedance characteristics, which can impact the performance of system and the quality of workpiece. To address the issue, this article proposes the implementation of a bilateral compensation network using an LC–CL structure to against the low output power and poor anti-interference capabilities of series–series (SS) topology. Additionally, a variable loads parameter optimization (VLPO) model, based on the fluctuations of equivalent dynamic component parameters during actual machining, is proposed. This model integrates an efficiency evaluation function aimed at achieving higher transmission efficiency and reducing fluctuations, as well as evaluation functions for the quality factor, admittance circle radius, and bandwidth to enhance impedance characteristics. Through the implementation of VLPO, the system impedance characteristics of LC–CL are significantly improved in comparison to SS and carrying capacity is effectively enhanced. The effectiveness of this scheme is validated through the construction of CETS experimental platform.