SEALED LAMINATED STRUCTURE, SYSTEM AND METHOD FOR ELECTROLYTIC PROCESSING THE SAME
Generally stated, provided is a sealed laminated metal structure. This laminated metal structure has a metal layer, where the metal layer has a first surface and an opposite second surface. A material is laminated on each of the first and second surfaces of the metal layer. Typically, the laminated metal structure is removed from a larger laminated sheet of metal. The laminated metal structure is subjected to alternating current electrolytic deburring and cleaning to remove any burrs along the perimeter edge. After deburring and cleaning, a sealer, which is a phosphate compound, is deposited on the perimeter edge of the laminated metal structure where the metal is exposed using alternating current.
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The invention generally relates to a sealed laminated structure along with the system and method for electrolytically processing a laminated structure to deburr and seal the laminated structure.
BACKGROUND OF THE INVENTIONElectrical generators may be used in power plants, cogeneration plants, vehicles, or in other articles of manufacture that convert energy into electrical energy. These electrical generators may contain thin sheets of metal, which are laminated with a thin coating on each side of the thin metal sheet and are generally called “laminations”. The laminations are used in the core of the electrical generator and other electrical equipment to reduce parasitic eddy currents within the generator. Generally, the laminations are cut or stamped from a larger sheet of thin metal that has been previously coated with the thin coatings on each side of the metal prior to cutting or stamping. However, such cutting or stamping from a larger sheet may result in the formation of burrs along the cut edges of each lamination.
Typically, the burrs along the edges of the laminations are removed using time-consuming, imprecise, costly and difficult processes. Processes typically used to deburr along the edges of the lamination include sanding, grinding and other similar mechanical deburring processes. The difficulty in these processes is exasperated by the thinness of the metal sheets and the coatings on the surfaces of the metal. However, these processes not only remove the burrs, these processes may also remove the coating layers on the thin metal. As a result, the laminations prepared by mechanical processes may have insulation damage, which may result in eddy currents in the generator and generator core failure.
Further, the coatings placed on the thin metal may on occasion be applied to a surface of the thin metal that may have metal particles, which may have been missed in the cleaning process prior to coating of the metal. In that situation, the coating will be thin in the area of the metal particle or the metal particle may extend through the surface of the coating. When these metal particles are present on the surface of the lamination, the lamination may be prone to electrical shorting where the metal particles are present.
SUMMARY OF THE INVENTIONGenerally stated, provided is a sealed laminated metal structure. This laminated metal structure has a metal layer, where the metal layer has a first surface and an opposite second surface. A material is laminated on each of the first and second surfaces of the metal layer. Typically, the laminated metal structure is removed from a larger laminated sheet of metal. The laminated metal structure has a perimeter edge with metal of the metal layer exposed along at least a portion the perimeter edge. The laminated metal structure is subjected to alternating current electrolytic deburring and cleaning to remove any burrs along the perimeter edge. After deburring and cleaning, a sealer, which is a phosphate compound, is deposited on the perimeter edge of the laminated metal structure where the metal is exposed.
In addition, provided is a system having an electrolytic deburring and cleaning tool for cleaning a workpiece, and an electrolytic sealing tool for depositing a sealer on the workpiece. The electrolytic deburring and cleaning tool has a first electrode, a second electrode, a first electrolyte supply configured to supply a first electrolyte between the first electrode and the workpiece, a second electrolyte supply configured to supply a second electrolyte between the second electrode and the workpiece, and a power supply configured to supply alternating current to the first and second electrodes. The first electrolyte and the second electrolyte are electrically insulated from one another, and the workpiece makes the electrical connection between the first electrode and the second electrode through the first electrolyte and the second electrolyte, respectively. The electrolytic sealing tool has a first electrode, a second electrode, a first electrolyte supply configured to supply a first sealer electrolyte between the first electrode and the workpiece, a second electrolyte supply configured to supply a second sealer electrolyte between the second electrode and the workpiece, and a power supply configured to supply alternating current to the first and second electrodes. The first sealer electrolyte and the second sealer electrolyte are electrically insulated from one another, and the first and second sealer electrolyte each contain a component capable of being deposited on the workpiece to seal deburred and cleaned sections of the workpiece. The workpiece makes the electrical connection between the first electrode and the second electrode through the first sealer electrolyte and the second sealer electrolyte, respectively.
Also provided is a method of processing a workpiece. The method includes electrolytically deburring and cleaning the workpiece using alternating current to form a deburred and cleaned workpiece, by contacting the workpiece simultaneously with a first electrolyte and a second electrolyte, wherein the first electrolyte and the second electrolyte are electrically insulated from one another. An alternating current is supplied between a first electrode and a second electrode, where the first electrode is in communication with the first electrolyte, and the second electrode is in communication with the second electrolyte. The method further includes electrolytically sealing the deburred and cleaned workpiece by contacting the deburred and cleaned workpiece simultaneously with a first sealing electrolyte and a second sealing electrolyte, where the first sealing electrolyte and the second sealing electrolyte are electrically insulated from one another. An alternating current is supplied between a first electrode and a second electrode, where the first electrode is in communication with the first sealing electrolyte, and the second electrode is in communication with the second sealing electrolyte.
To gain a better understanding of the invention, attention is directed to the Figures of the present specification.
Referring to
Layers 14 and 16 may each independently be a single layer, shown in
Metal layer 12 may be made from a variety of metals. Generally, metal layer 12 may be made from a metal that is selected for the particular purpose in which the metal structure 10 is intended to be used. For example, in electric motors, such as for stator laminations, the metal is generally “electric steel”. Electric steels may be grain oriented (“GO”) or non-grain oriented (“NGO”) steels. An example of electric steels is silicon iron steels.
Generally, laminations are prepared from large sheets having a metal layer 12 which have been laminated or coated with insulation layers 14 and 16. Individual laminations are removed from the large sheets by mechanical cutting, laser cutting, plasma cutting, stamping, punching or other suitable methods. Stamping or punching is typically used since the individual laminations are thin and can be easily stamped or punched out of the larger sheet. However, cutting, punching or stamping will leave perimeter edge 17 with bare metal of metal layer 12 exposed. In addition, burrs will generally be present along perimeter edge 17. Burrs are raised edges or small pieces of metal that remain attached to the cut lamination due to the cutting process.
Attention is directed to
Once lamination 100 is removed from a larger laminated sheet, lamination 100 is then subjected to a deburring process and sealing process. To accomplish the deburring and sealing, a system having an electrolytic deburring tool and an electrolytic sealing tool is used. Electrolytic deburring and electrolytic sealing using the system of the electrolytic deburring tool and the electrolytic sealing tool is described below will result in the sealed laminate structure shown in
To remove burrs 21 from lamination or workpiece 100, workpiece 100 is subjected to electrolytic deburring process using electrolytic deburring tool 200 shown in
Power supply 216 generates an alternating current (AC) at a particular frequency, current, and voltage. For example, the frequency of the AC may be less than approximately 1000 Hertz, 750 Hertz, 500 Hertz or 0.1 Hertz. Generally, the frequency may be selected at any frequency within the range of about 0.1 Hertz to about 1000 Hertz. At greater frequencies, the AC may cause the effective resistance of conductive material in the electrolytic deburring tool 201 to increase. In certain embodiments, the current and/or voltage of the AC generated by the power supply 216 may be adjustable. In further embodiment (not shown), the AC from the power supply 216 may be passed through a transformer (not shown), which may be used to change the voltage and/or current of the AC. For example, the transformer may step down the voltage supplied by the power supply 216. In other embodiments, the transformer may be omitted or included in the power supply 216. In addition to the power supply, a power supply controller may be used to adjust the frequency, voltage and current generated by the power supply. The voltage wave generated by power supply 216 may be rectangular or sinusoidal.
Connected to power supply 216 is first power wire 220 and second power wire 222. First and second power wires 220 and 222 supply the AC to first electrode 224 and second electrode 226, respectively. When the AC flows toward first or second electrodes 224 or 226, the electrode function as a transient cathode. When AC flows away from first or second electrodes 224 or 226, the electrode function as a transient anode. Thus, as the AC alternately flows toward and away from first and second electrodes 224 and 226, the electrodes alternately function as the transient cathode and the transient anode. In other words, first electrode 224 functions as the transient cathode for approximately half of the time and as the transient anode for the other half of the time. Similarly, second electrode 226 functions as the transient cathode for approximately half of the time and as the transient anode the other half of the time. Further, when first electrode 224 functions as the transient cathode, second electrode 226 functions as the transient anode. Similarly, when first electrode 224 functions as the transient anode, second electrode 226 functions as the transient cathode. First and second electrodes 224 and 226 may be made from bi-polar and stable electrode materials such as, but not limited to, graphite, lead, titanium, niobium, iridium, platinum, ruthenium, or combinations thereof. The combination of these materials may be in the form of an alloy or in the form of a coating. In addition, first and second electrodes 224 and 226 may be inert. In other words, first and second electrodes 224 and 226 may not dissolve when the electrodes function as the transient anode.
Tank 210 may be a single tank divided into first cell 213 first and second cell 214, divided by divider 212. Alternatively, tank 210 may be two separate tanks, where one tank forms first cell 213 and a second tank forms second cell 214. In any event, whether a single tank or multiple tanks, tank 210 may be made from non-conductive materials such as, but not limited to, plastic, glass, fiberglass, rubber and the like, to help prevent current leakage through grounding connections. As described in more detail below, first and second electrolytes 232 and 234 carry the current to or from electrodes 224 and 226, respectively. Examples of materials that may be used as first and second electrolytes 232 and 234 include, but are not limited to, sodium nitrate, sodium chloride, or a combination (mixture) thereof. In certain embodiments, first and second electrolytes 232 and 234 may be the same. In other embodiments, the first and second electrolytes 232 and 234 may be different from one another.
Coupled to first cell 213 is first electrolyte system 228. As described in detail below, the first electrolyte system 228 includes various components to store, transfer, filter, and control a flow rate or pressure of the first electrolyte 232. Examples of such components include pumps, motors, filters, piping, valves, sensors, and so forth. First electrolyte supply 236 (e.g., conduit) is coupled to the discharge of first electrolyte system 228 to carry first electrolyte 232 to first cell 213. A first electrolyte nozzle (not shown) may optionally be coupled to an end of the first electrolyte supply 236. The first electrolyte nozzle may be configured to focus the flow of the first electrolyte 232 to a particular location in first cell 213. Both first electrolyte supply 236 and the first electrolyte nozzle, if present, may be made from non-conductive materials similar to that used for the tank 210, such as, but not limited to, plastic, rubber or fiberglass. A first electrolyte return 238 (e.g., conduit) may be coupled to an outlet of first cell 213 of tank 210. First electrolyte return 238 carries first electrolyte 232 from tank 210 to the first electrolyte system 228. First electrolyte return 238 may also be made from non-conductive materials similar to that used for the first electrolyte supply 236. As shown in
A second electrolyte system 230 may be coupled to second cell 214. Examples of components that may be included in second electrolyte system 230 include, but are not limited to, pumps, motors, filters, piping, valves, sensors, and so forth. The configuration of second electrolyte system 230 may be similar to that of the first electrolyte system 228. Specifically, second electrolyte 234 flows from second electrolyte system 230 through second electrolyte supply 240 (e.g., conduit) and then optionally to a second electrolyte nozzle (not shown). Second electrolyte 234 then flows from second cell 214 through a second electrolyte return 242 (e.g., conduit) may be coupled to an outlet of second cell 214. Second electrolyte return 242 carries second electrolyte 234 from tank 210 to the second electrolyte system 230. As with the first electrolyte system 228, the various components of second electrolyte system 230 and the components coupled to second electrolyte system 230, including conduits 240 and 242 may be made from non-conductive materials such as, but not limited to, plastic, rubber or fiberglass. As shown in
Deburring tool 201 may further have workpiece holder 250, which is adapted to hold the workpiece (lamination) 100 in place before, during and after deburring. Workpiece holder 250 is generally made from a material that is non-conductive. Workpiece holder 250 may hold workpiece 100 in place by using a vacuum, a permanent magnet or electromagnetic components. Other similar methods may be used so long as the method of holding the workpiece 100 to workpiece holder 250 does not interfere with the deburring process.
Connected to workpiece holder 250 is machine connector 252, which is connected to a means to lower workpiece (lamination) 100 into electrolyte 232, 234 for deburring. For example, machine connector 252 may be directly or indirectly connected to a motor, a mechanical lever or other similar mechanisms that can effectively lower workpiece (lamination) 100 into and out of electrolyte 232, 234.
Deburring tool 200 may have additional components, such as a controller for controlling deburring tool. The controller (not shown) may be configured to receive and send various signals to control deburring tool 200. For example, the controller may generate a first electrolyte control signal that is sent to the first electrolyte system 228. The first electrolyte control signal may include various instructions for controlling the components of the first electrolyte system 228. Similarly, the controller may generate a second electrolyte control signal that is sent to the second electrolyte system 230. In addition, the first electrolyte system 228 may generate a first electrolyte sensor signal that is sent to the controller for processing. The first electrolyte sensor signal may convey information regarding various sensors included in the first electrolyte system 228. Similarly, second electrolyte system 230 may generate a second electrolyte sensor signal that is sent to the controller for processing. For example, but not limited to, the controller may send signals and receive signals to control the speed of a pump, or the concentration of the electrolytes 232 and 234 in the first and second electrolyte systems 228 and 230. Additionally, the controller may control the frequency, current and/or voltage of the power from the AC power supply 216.
Turing to the electrolyte systems in more detail, attention is directed to
Generally, to operate each electrolyte system 228 and 230, a controller (not shown) sends control signals to one or more of the following components: return tank pump 284, storage tank pump 292, storage tank control valve 296, and storage tank bypass control valve 298. Similarly, a return sensor signal may include signals from the return tank level sensor 282, first electrolyte flow sensor 299, and/or tank level sensor 252 and/or 253 (
Once burrs 21 are removed from lamination or workpiece 100, workpiece 100 is subjected to electrolytic deposition/conversion process where a phosphate compound is deposited to the bare metal exposed after deburring (deposition) or the phosphate compound reacts with the bare metal of lamination (workpiece) 100 (conversion). To accomplish electrolytic deposition/conversion, electrolytic sealing tool 300, shown in
Power supply 316 generates an alternating current (AC) at a particular frequency, current, and voltage, similar to power supply 216 of the deburring tool. For example, the frequency of the AC may be less than approximately 1000 Hertz, 750 Hertz, 500 Hertz or 0.1 Hertz. Generally, the frequency may be selected at any frequency within the range of about 0.1 Hertz to about 1000 Hertz. At greater frequencies, the AC may cause the effective resistance of conductive material in the electrolytic sealing tool 300 to increase. In certain embodiments, the current and/or voltage of the AC generated by the power supply 316 may be adjustable. As with power supply 216, the AC from the power supply 316 may be passed through a transformer (not shown), which may be used to change the voltage and/or current of the AC. The transformer is an optional component of the electrolytic sealing tool. In addition to the power supply, a power supply controller may be used to adjust the frequency, voltage and current generated by the power supply. The voltage wave may be rectangular or sinusoidal.
Connected to power supply 316 is first power wire 320 and second power wire 322. First and second power wires 320 and 322 supply the AC to first electrode 324 and second electrode 326, respectively. When the AC flows toward first or second electrodes 324 or 326, the electrodes function as a transient cathode. When AC flows away from first or second electrodes 324 or 326, the electrodes function as a transient anode. Thus, as the AC alternately flows toward and away from first and second electrodes 324 and 326, the electrodes alternately function as the transient cathode and the transient anode. When first electrode 324 functions as the transient cathode, second electrode 326 functions as the transient anode. Similarly, when first electrode 324 functions as the transient anode, second electrode 326 functions as the transient cathode. First and second electrodes 324 and 326 may be made from bi-polar and stable electrode materials such as, but not limited to, graphite, lead, titanium, niobium, or combinations thereof as alloys or coatings. In addition, first and second electrodes 324 and 326 may be inert.
Tank 310 may be a single tank divided into first section 313 and second section 314 divided by divider 312. Alternatively tank 310 may be two separate tanks, where one tank forms first section 313 and a second tank forms second section 314. In any event, tank 310 may be made from non-conductive materials such as, but not limited to, plastic, glass rubber, fiberglass and the like, to help prevent current leakage through grounding connections. First section 313 of tank 310 contains first deposition electrolyte 332, and second section 314 contains second deposition electrolyte 334. As described in more detail below, first and second electrolytes 332 and 334 carry the current to or from electrodes 324 and 326, respectively. Examples of materials that may be used as first and second deposition electrolytes 332 and 334 include, but are not limited to, a composition containing a metal oxide, such as zinc oxide or manganese oxide, a combination (mixture) thereof, phosphoric acid, sodium hydroxide and sodium salt, such as sodium nitrate or sodium chloride. Other compositions are useable will be apparent to those skilled in the art, but generally will contain a source of phosphate in the electrolyte. In certain embodiments, first and second deposition electrolytes 332 and 334 may be the same. In other embodiments, the first and second deposition electrolytes 332 and 334 may be different from one another.
Coupled to first section 313 of tank 310 is first deposition electrolyte system 328. In a similar fashion, second section 314 of tank 310 is coupled to second deposition electrolyte system 328. Each deposition electrolyte system 328, 330 includes various components to store, transfer, filter, and control a flow rate or pressure of deposition electrolyte 332, 334. Examples of such components include pumps, motors, filters, piping, valves, sensors, and so forth. An exemplary deposition electrolytes system is shown in
Electrolytic sealing tool 301 may further have workpiece holder 350, which is adapted to hold the workpiece (lamination) 100 in place before, during and after electrolytic sealing process. Workpiece holder 350 is generally made from a material that is non-conductive and may hold workpiece 100 in place by using a vacuum, a permanent magnet or electromagnetic components. Other similar methods may be used so long as the method of holding the workpiece 100 to workpiece holder does not interfere with the electrolytic sealing process.
Connected to workpiece holder 350 is machine connector 352, which is connected to a means to lower workpiece (lamination) 100 into the deposition electrolyte for sealing. For example, machine connector 352 may be directly or indirectly connected to a motor, a mechanical lever or other similar mechanisms that can effectively lower workpiece (lamination) 100 into and out of the deposition electrolytes.
Electrolytic sealing tool 300 may have additional components, such as a controller for controlling the electrolytic sealing tool. The controller (not shown) may be configured to receive and send various signals to control electrolytic sealing tool 300. For example, the controller may generate control signals that are sent to the deposition electrolyte systems 328, 330. The controller may also be adapted to receive signals from the deposition electrolyte systems 328, 330. For example, the controller may send signals and receive signals to control the speed of a pump or the concentration of the electrolytes 332 and 334 in the first and second electrolyte systems 328 and 330. Additionally, the controller may control the frequency, current and/or voltage of the power from the AC power supply 316.
Deburring tool 200 and electrolytic sealing tool 300 may be separate and distinct tools. Alternatively, deburring tool 200 and electrolytic sealing tool 300 may be a single tool. When a single tool, to switch from the deburring tool to the electrolytic sealing tool, the electrolyte on needs to be changed, which may be time consuming. For that reason, typically two separate tools are used.
To process a workpiece to be deburred and sealed, workpiece 100 is first subjected to electrolytic deburring using an electrolytic deburring tool 200, as exemplified in
Show in
An electrical connection is made between first and second electrolytes 232, 234, by metal layer 12 of workpiece 100. First electrolyte 232 serves to carry the AC between the workpiece 100 and first electrode 224. Similarly, second electrolyte 234 serves to carry the AC between workpiece 100 and the second electrode. Depending on the direction of the current, which is continuously changing, the current either flows away from workpiece 100 towards each electrode 224, 226 or from each electrode towards 224, 226, towards workpiece 100. It is also noted that the current will flow in the opposite direction to or from workpiece, in an alternative manner, at each portion of workpiece depending on the if the portion of workpiece 100 is contact with the first or second electrolyte 232, 234. Two different processes occur, depending if the electrode is the transient cathode or transient electrode. To gain a better understanding of this, attention is directed to
In the next cycle of the AC, first and second electrode 224, 226 reverse polarity such that first electrode 224 acts as the transient anode, and second electrode 226 acts as the transient cathode. Thus, the electrolytic deburring depicted in
Once workpiece 100 is deburred and cleaned, workpiece 100 is then optionally rinsed and dried. Workpiece 100 is then electrolytically sealed using an electrolytic sealing tool 300, as exemplified in
Electrolytic sealing seals the perimeter edge of workpiece 100, where metal layer 12 is exposed along perimeter edge 17, by depositing sealer 18 on the exposed metal along perimeter edge 17, of the deburred lamination or work piece 199, as is shown in
To gain an understanding of the electrolytic sealing process show in
An electrical connection is made between first and second electrolytes 332, 334, by metal layer 12 of deburred workpiece 199. First electrolyte 332 serves to carry the AC between the workpiece 100 and first electrode 324. Similarly, second electrolyte 334 serves to carry the AC between deburred workpiece 199 and the second electrode 326. Depending on the direction of the current, which is continuously changing, the current either flows away from deburred workpiece 199 towards each electrode 324, 326 or from each electrode 324, 326, towards deburred workpiece 199. It is also noted that the current will flow in the opposite direction to or from deburred workpiece 199, in an alternative manner, at each portion of deburred workpiece 199 depending on the if the portion of deburred workpiece 199 is contact with the first or second electrolyte 332, 334. Two different processes occur, depending if the electrode is the transient cathode or transient electrode. One process is cathodic phosphating, which occurs when deburred workpiece 199 acts as a transient cathode, in the presence of the transient anode electrode. The other process is anodic phosphating, which occurs when deburred workpiece 199 acts as the transient anode, in the presence of the transient cathode electrode. In both cathodic phospating and anodic phosphating, phosphates are deposited on the exposed metal 12 of deburred lamination 199, which results in a sealed deburred workpiece. Alternatively, the phosphate may react with the metal of metal layer 12 to form a metal phosphate on the metal layer in a process called conversion.
In each of the electrolytic deburring/cleaning process and the electrolytic sealing process, the workpiece 100, 199 is contacted with the electrolytes of each process such that the workpiece 100, 199 is in a horizontal/planner configuration, as is shown in
The electrodes used in each of the sides (cells) of the tank may be shaped to a shape that is similar to the workpiece being processed or may have a general shape of a flat plate, such as a rectangle or a square. Also, each of the electrodes may be provided with a supply hole which 250, 350, 251 and 351 in
To gain a better understanding of the configuration of each tank, attention is directed to
As shown in
In a further embodiment, each tank used in the deburring and cleaning process and/or the electrolytic sealing process may have more that two cells. Attention is directed to
Although the present invention has been described with reference to various embodiments, those skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. As such, it is intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it is the appended claims, including all equivalents thereof, which are intended to define the scope of the invention.
Claims
1. A sealed laminated metal structure comprising:
- a lamination comprising a metal layer, the metal layer having a first surface and an opposite second surface, a material laminated on each of the first and second surfaces of the metal layer, wherein the lamination is removed from a larger laminated sheet of metal, the lamination having a perimeter edge with metal of the metal layer exposed along at least a portion the perimeter edge, and the lamination being subjected to alternating current electrolytic deburring and cleaning to remove any burrs along the perimeter edge, and
- a sealer comprising a phosphate compound deposited on the perimeter edge of the lamination where the metal is exposed.
2. The sealed laminated structure according to claim 1, wherein the material laminated to each of the first surface and the second surface of the metal layer comprises an insulation coating, and the sealer is further applied to laminated metal structure where any metal of the first or second surface is exposed through the insulation coating as a result of the alternating current electrolytic deburring and cleaning.
3. The sealed laminate structure according to claim 1, wherein the sealer comprises a metal phosphate.
4. The sealed laminate structure according to claim 3, wherein the metal phosphate comprises zinc phosphate or manganese phosphate.
5. The sealed laminate structure according to claim 1, wherein the sealer is applied by an alternating current electrolytic deposition and/or alternating current electrolytic conversion.
6. The sealed laminate structure according to claim 2, wherein the sealer comprises zinc phosphate or manganese phosphate and the sealer is applied by an alternating current electrolytic deposition.
7. A system comprising:
- an electrolytic deburring and cleaning tool for cleaning a workpiece comprising: a first electrode, a second electrode, a first electrolyte supply configured to supply a first electrolyte between the first electrode and the workpiece, a second electrolyte supply configured to supply a second electrolyte between the second electrode and the workpiece, and a power supply configured to supply alternating current to the first and second electrodes, wherein the first electrolyte and the second electrolyte are electrically insulated from one another, and the workpiece makes the electrical connection between the first electrode and the second electrode through the first electrolyte and the second electrolyte respectively; and
- an electrolytic sealing tool for depositing a sealer on the workpiece which has been processed with the electrolytic deburring and cleaning tool, comprising: a first electrode, a second electrode, a first electrolyte supply configured to supply a first sealer electrolyte between the first electrode and the workpiece, a second electrolyte supply configured to supply a second sealer electrolyte between the second electrode and the workpiece, and a power supply configured to supply alternating current to the first and second electrodes, wherein the first sealer electrolyte and the second sealer electrolyte are electrically insulated from one another, the first and second sealer electrolyte each contain a component capable of being deposited on the workpiece to seal deburred and cleaned sections of the workpiece, and the workpiece makes the electrical connection between the first electrode and the second electrode through the first sealer electrolyte and the second sealer electrolyte, respectively.
8. The system according to claim 7, wherein each of the electrolytic deburring and cleaning tool and the electrolytic sealing tool comprises a workpiece holder for inserting the workpiece into the electrolytes and removing the workpiece from the electrolytes.
9. The system according to claim 7, wherein each of the first and second electrodes of both the deburring and cleaning tool and the sealing tool alternatively functions as a transient cathode and a transient anode as the alternating current flow toward and away from the first and second electrode of each tool, respectively.
10. The system according to claim 7, wherein each of the deburring and cleaning tool and the sealing tool comprises a first cell and a second cell, the first cell of each tool comprising a first container, the first electrode positioned in the first container and the first electrolyte contained within the first container; and the second cell of each tool comprising a second container, the second electrode positioned in the second tank and the second electrolyte contained within the second container such that the second electrolyte is in communication with the second electrode, wherein the first cell is electrically isolated from the second cell.
11. The system according to claim 10, wherein each cell further comprises an inlet, an outlet, a pump, a filter and a storage tank, wherein the electrolyte is circulated between the container and the storage tank by the pump and the electrolyte is filtered by the filter before the electrolyte is returned to the container of each cell.
12. The system according to claim 7, wherein the deburring and cleaning tool comprises more than two cells, and each additional cell comprise an additional container, an additional electrode, and an additional electrolyte supply and each addition cell is electrically separated from the other cells.
13. The system according to claim 7, wherein the sealing tool comprises more than two cells, and each additional cell comprise an additional container, an additional electrode, and an additional electrolyte supply and each addition cell is electrically separated from the other cells.
14. The system according to claim 12, wherein there are an even number of additional cells and the cells are arranged in an alternating pattern such that when the electrode in a given cell is a transient anode, the electrode in the adjacent cells is a transient cathode, and when the electrode of a given cell is a transient cathode, the electrode in the adjacent cell is a transient anode.
15. The system according to claim 13, wherein there are an even number of additional cells and the cells are arranged in an alternating pattern such that when the electrode in a given cell is a transient anode, the electrode in the adjacent cells is a transient cathode, and when the electrode of a given cell is a transient cathode, the electrode in the adjacent cell is a transient anode.
16. The system according to claim 7, wherein the first and second electrolyte is electrically insulated from each other by a separator which is an electrical insulator.
17. The system according to claim 7, wherein each of the first and second electrodes of each of the electrolytic deburring and cleaning tool and the electrolytic sealing tool are each independently a bi-polar stable material.
18. A method of processing a workpiece comprising:
- electrolytically deburring and cleaning the workpiece using alternating current to form a deburred and cleaned workpiece comprising: contacting the workpiece simultaneously with a first electrolyte and a second electrolyte, wherein the first electrolyte and the second electrolyte are electrically insulated from one another, supplying alternating current to a first electrode and a second electrode, where the first electrode is in communication with the first electrolyte, and the second electrode is in communication with the second electrolyte, and electrolytically sealing the deburred and cleaned work workpiece comprising: contacting the deburred and cleaned workpiece simultaneously with a first sealing electrolyte and a second sealing electrolyte, wherein the first sealing electrolyte and the second sealing electrolyte are electrically insulated from one another, supplying alternating current to a first electrode and a second electrode, where the first electrode is in communication with the first sealing electrolyte, and the second electrode is in communication with the second sealing electrolyte.
19. The method according to claim 18, wherein the workpiece, in each of the electrolytically deburring and cleaning and the electrolytically sealing, is contacted with electrolyte such that there is a gap between the workpiece and each electrode, and the electrolyte is positioned in the gap.
20. The method according to claim 19, wherein the gap for the electrolytically deburring and cleaning is between about 0.01 to about 0.05 inches and the gap for the electrolytically sealing is between about 0.05 to about 2.0 inches.
21. The method according to claim 18, wherein the sealing electrolyte is a composition comprising zinc oxide, phosphoric acid, sodium hydroxide and sodium nitrate.
Type: Application
Filed: Aug 10, 2012
Publication Date: Feb 13, 2014
Applicant: GENERAL ELECTRIC COMPANY (Schenectady, NY)
Inventors: Yuefeng Luo (Mechanicville, NY), William Edward Adis (Scotia, NY), Michael Lewis Jones (Scotia, NY)
Application Number: 13/572,055
International Classification: C25D 5/02 (20060101); C25D 5/34 (20060101); C25D 17/10 (20060101); C25F 7/00 (20060101); C25D 7/06 (20060101); C25D 17/02 (20060101);