Grinding wheel abrasion automatic detection and replacement system

Abstract

The invention relates to the technical field of machining automation, in particular to a grinding wheel abrasion automatic detection and replacement system. Comprising a grinding wheel device, a wear detection module, a control unit, a replacement execution mechanism and a power supply module, the abrasion detection module is connected with the grinding wheel device and used for detecting the abrasion state of the grinding wheel in real time. The control unit receives a signal of the wear detection module, analyzes the wear condition of the grinding wheel and controls the action of the replacement execution mechanism; the replacement execution mechanism automatically executes the dismounting and mounting operation of the grinding wheel according to the instruction of the control unit; the power supply module provides power support for the whole system. The abrasion state of the grinding wheel can be automatically monitored, and the grinding wheel can be automatically disassembled and assembled when the abrasion loss reaches the preset threshold value, so that the machining precision and efficiency are ensured, meanwhile, manual intervention is reduced, and production safety is improved.

Description

Technical Field

[0001] The invention relates to the technical field of mechanical processing automation, and in particular to an automatic detection and replacement system for grinding wheel wear. Background Art

[0002] In modern industrial production, grinding wheels, as important grinding tools, play a key role in cutting and grinding operations. With the development of automation technology, there is a growing demand for real-time monitoring of the wear status of grinding wheels and automatic replacement. Traditional methods of replacing grinding wheels rely on manual inspection and replacement, which is not only inefficient but also easily affected by the operator's experience level, resulting in inaccurate replacement timing, thus affecting processing accuracy and production efficiency. In addition, manual replacement of grinding wheels also has certain safety hazards, and improper operation may cause equipment damage or personal injury.

[0003] With the development of automation technology, some automatic detection and replacement equipment for grinding wheels have appeared on the market. However, these devices usually have the following defects: first, the detection module is easily affected by cutting fluid and grinding dust, resulting in reduced detection accuracy; second, the design of the replacement mechanism is often complex, with high requirements for installation space and operating environment, limiting its application scope; third, the control unit is not intelligent enough to achieve real-time analysis and prediction of wear status, resulting in inaccurate timing of grinding wheel replacement; finally, these systems often lack user-friendly interactive interfaces, making it difficult for operators to quickly grasp the system status and perform necessary maintenance. Summary of the invention

[0004] The present invention proposes an automatic detection and replacement system for grinding wheel wear, which can automatically monitor the wear state of the grinding wheel and automatically remove and install the grinding wheel when the wear reaches a preset threshold, thereby ensuring processing accuracy and efficiency, while reducing manual intervention and improving production safety.

[0005] The technical solution adopted by the present invention is: a grinding wheel wear automatic detection and replacement system, including a grinding wheel device, a wear detection module, a control unit, a replacement actuator, and a power module. The grinding wheel device is used to perform cutting and grinding operations; the wear detection module is connected to the grinding wheel device, and is used to detect the wear state of the grinding wheel in real time; the control unit receives the signal of the wear detection module, analyzes the grinding wheel wear, and controls the action of the replacement actuator; the replacement actuator automatically performs the disassembly and installation operations of the grinding wheel according to the instructions of the control unit; the power module provides power support for the entire system.

[0006] As a further improvement of the present invention, the wear detection module package is composed of a plurality of non-contact wear sensors, which are fixed near the grinding wheel to measure the changes in the surface morphology and cutting force of the grinding wheel, and convert the measurement data into electrical signals and output them to the control unit.

[0007] As a further improvement of the present invention, the non-contact wear sensor includes a laser displacement sensor, an optical imaging sensor, and an ultrasonic sensor.

[0008] As a further improvement of the present invention, the control unit is composed of a microprocessor, a memory, an input-output interface, and a software program. The microprocessor is responsible for processing the signal transmitted by the wear detection module and judging the degree of wear of the grinding wheel according to the built-in algorithm; the memory is used to protect the wear data and the control program; the input-output interface is used to receive external instructions and output system status; the software program contains an instruction set for controlling the grinding wheel replacement process.

[0009] As a further improvement of the present invention, the microprocessor has a built-in wear judgment algorithm, which calculates the current wear of the grinding wheel based on the received sensor data, combined with a preset wear threshold and wear rate model, and updates the wear status in real time. When it is detected that the wear exceeds the preset threshold, the microprocessor triggers the replacement of the actuator to ensure timely replacement of the grinding wheel, thereby maintaining processing accuracy and efficiency.

[0010] As a further improvement of the present invention, the memory is a solid-state storage device with fast reading and writing capabilities to ensure real-time recording and rapid retrieval of wear data; the input and output interface is designed as a high-speed communication interface to ensure rapid and accurate data transmission between the control unit and the wear detection module and the replacement actuator.

[0011] As a further improvement of the present invention, the software program includes multiple modular functions, specifically an automatic calibration program, a fault diagnosis program and a user interaction interface. The automatic calibration program ensures the accuracy of the wear detection module and compensates for any possible measurement deviation through regular calibration; the fault diagnosis program can detect abnormal conditions inside the system and provide corresponding maintenance prompts to reduce unexpected downtime; the user interaction interface provides an intuitive operating platform for the operator, through which the grinding wheel replacement process can be manually controlled, the system status can be viewed, and the system settings and maintenance can be performed.

[0012] As a further improvement of the present invention, the replacement actuator is composed of an electric motor, a gear box, a drive shaft, and a clamping device. The electric motor is responsible for providing power, the gear box transmits the power of the electric motor to the drive shaft, and the drive shaft drives the clamping device to disassemble and install the grinding wheel. The precise clamping structure design of the clamping device can firmly grasp the grinding wheel and keep the grinding wheel stable during the replacement process, avoiding damage to the grinding wheel due to vibration and improper operation.

[0013] A method for using a grinding wheel wear automatic detection and replacement system comprises the following steps:

[0014] Step 1: First, start the system and perform initialization settings to ensure that all modules are working properly;

[0015] Step 2: Then, the grinding wheel device starts to perform cutting and grinding operations, and the wear detection module monitors the wear state of the grinding wheel in real time;

[0016] Step 3: The control unit analyzes the wear condition of the grinding wheel according to the data provided by the wear detection module;

[0017] Step 4: When the wear reaches the preset threshold, the control unit issues a command to start the replacement actuator to automatically remove and install the grinding wheel;

[0018] Step 5: Finally, after the system completes the replacement, it automatically returns to the standby state and prepares for the next wear detection and replacement operation.

[0019] The beneficial effects of the present invention are as follows: (1) Improving production efficiency and processing accuracy: by real-time monitoring of the wear state of the grinding wheel and automatically replacing it when the wear reaches a preset threshold, the continuity of the processing process and the optimal use state of the grinding wheel are ensured, thereby improving production efficiency and processing accuracy.

[0020] (2) Enhanced production safety: Reduced manual intervention, lowered the risk of direct contact between operators and high-speed rotating grinding wheels, effectively prevented equipment damage or personal injury caused by improper operation, and improved production safety.

[0021] (3) Optimizing resource utilization and reducing costs: By precisely controlling the timing of grinding wheel replacement, the service life of the grinding wheel is extended, reducing resource waste caused by premature replacement or excessive use. At the same time, it reduces production interruptions caused by downtime for grinding wheel replacement, further reducing production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a system block diagram of a grinding wheel wear automatic detection and replacement system of the present invention;

[0023] Figure 2The present invention is a flow chart of a grinding wheel wear automatic detection and replacement system. DETAILED DESCRIPTION

[0024] In order to make the technical problems, technical solutions and beneficial effects to be solved by the present application more clearly understood, the present application is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the embodiments described herein are only used to explain the present application and are not used to limit the present application.

[0025] The present invention provides a grinding wheel wear automatic detection and replacement system, comprising a grinding wheel device, a wear detection module, a control unit, a replacement actuator, and a power module. The grinding wheel device is used to perform cutting and grinding operations; the wear detection module is connected to the grinding wheel device and is used to detect the wear state of the grinding wheel in real time; the control unit receives a signal from the wear detection module, analyzes the wear of the grinding wheel, and controls the action of the replacement actuator; the replacement actuator automatically performs the disassembly and installation operations of the grinding wheel according to the instructions of the control unit; and the power module provides power support for the entire system.

[0026] The wear detection module package in the present invention is composed of multiple non-contact wear sensors. The non-contact wear sensors are fixed near the grinding wheel and are used to measure the changes in the surface morphology and cutting force of the grinding wheel, and convert the measured data into electrical signals and output them to the control unit. The non-contact wear sensors include laser displacement sensors, optical imaging sensors, and ultrasonic sensors.

[0027] The control unit in the present invention is composed of a microprocessor, a memory, an input / output interface, and a software program. The microprocessor is responsible for processing the signal transmitted by the wear detection module and judging the degree of wear of the grinding wheel according to the built-in algorithm; the memory is used to protect the wear data and the control program; the input / output interface is used to receive external instructions and output the system status; the software program includes an instruction set for controlling the grinding wheel replacement process.

[0028] The microprocessor has a built-in wear determination algorithm. The wear determination algorithm calculates the current wear of the grinding wheel based on the received sensor data, combined with the preset wear threshold and wear rate model, and updates the wear status in real time. When the wear is detected to exceed the preset threshold, the microprocessor will trigger the replacement actuator to ensure timely replacement of the grinding wheel, thereby maintaining processing accuracy and efficiency.

[0029] The memory is a solid-state storage device with fast reading and writing capabilities to ensure real-time recording and rapid retrieval of wear data; the input and output interfaces are designed as high-speed communication interfaces to ensure rapid and accurate data transmission between the control unit and the wear detection module and replacement actuator.

[0030] The software program includes multiple modular functions, namely automatic calibration program, fault diagnosis program and user interaction interface. The automatic calibration program ensures the accuracy of the wear detection module and compensates for any possible measurement deviation through regular calibration; the fault diagnosis program can detect abnormal conditions within the system and provide corresponding maintenance prompts to reduce unexpected downtime; the user interaction interface provides operators with an intuitive operating platform, through which they can manually control the grinding wheel replacement process, view the system status, and perform system settings and maintenance.

[0031] The replacement actuator in the present invention is composed of an electric motor, a gear box, a drive shaft, and a clamping device. The electric motor is responsible for providing power, the gear box transmits the power of the electric motor to the drive shaft, and the drive shaft drives the clamping device to disassemble and install the grinding wheel. The precise clamping structure design of the clamping device can firmly grasp the grinding wheel and keep the grinding wheel stable during the replacement process, avoiding damage to the grinding wheel due to vibration and improper operation.

[0032] A method for using a grinding wheel wear automatic detection and replacement system comprises the following steps: first, starting the system and performing initialization settings to ensure that all modules work normally; then, the grinding wheel device starts to perform cutting and grinding operations, and the wear detection module monitors the wear state of the grinding wheel in real time; a control unit analyzes the wear state of the grinding wheel based on data provided by the wear detection module; when the wear amount reaches a preset threshold, the control unit issues an instruction to start a replacement actuator to automatically disassemble and install the grinding wheel; finally, after the system completes the replacement, it automatically returns to a standby state to prepare for the next wear detection and replacement operation.

[0033] Embodiment 1:

[0034] In this embodiment, the grinding wheel wear automatic detection and replacement system is applied in a typical manufacturing environment, such as a production line for automotive parts. The system is installed next to a CNC grinding machine to monitor and maintain the wear status of the grinding wheel to ensure the consistency of processing quality and maximize production efficiency.

[0035] First, after the grinding wheel device is started, it will start cutting and grinding according to the pre-set program. During the operation, the wear detection module monitors the wear state of the grinding wheel in real time through non-contact wear sensors. These sensors can accurately measure the changes in the surface morphology of the grinding wheel and the changes in the cutting force, and convert these data into electrical signals and transmit them to the control unit in real time.

[0036] After the control unit receives the signal from the wear detection module, the microprocessor will analyze the data using the built-in wear determination algorithm. The algorithm combines the preset wear threshold and wear rate model to calculate the current wear of the grinding wheel and update the wear status in real time. When the wear exceeds the preset threshold, the control unit will trigger the replacement actuator to ensure timely replacement of the grinding wheel.

[0037] The replacement actuator consists of an electric motor, a gearbox, a drive shaft and a clamping device. The electric motor provides power, the gearbox transmits the power to the drive shaft, and the drive shaft drives the clamping device to remove and install the grinding wheel. The precise clamping structure design of the clamping device can firmly grasp the grinding wheel and keep the grinding wheel stable during the replacement process to avoid damage to the grinding wheel caused by vibration and improper operation.

[0038] After the grinding wheel is replaced, the system automatically returns to standby mode to prepare for the next wear detection and replacement operation. The entire process does not require manual intervention, which greatly reduces the workload of operators, and due to the timeliness of wear detection and replacement, significantly improves production efficiency and processing quality.

[0039] Through this embodiment, it can be seen that the effectiveness and practicality of the automatic detection and replacement system for grinding wheel wear of the present invention in practical applications not only improves production efficiency, but also ensures the stability of processing quality, providing an efficient and reliable solution for the manufacturing industry.

[0040] Embodiment 2:

[0041] In this embodiment, the grinding wheel wear automatic detection and replacement system of the present invention is applied to a precision machining field, such as the production of aerospace parts. The system is integrated into a high-precision CNC grinding machine to ensure that the wear state of the grinding wheel is accurately monitored and maintained in a timely manner under extreme machining conditions.

[0042] During precision grinding operations, the wear detection module continuously monitors the wear status of the grinding wheel through non-contact wear sensors. These sensors can not only detect small changes in the surface morphology of the grinding wheel, but also monitor subtle changes in cutting forces, ensuring accurate wear data even in the most demanding machining environments.

[0043] After the control unit receives the signal from the wear detection module, the microprocessor will quickly analyze the data and use the built-in wear determination algorithm to calculate the current wear of the grinding wheel. When the wear exceeds the preset threshold, the control unit will automatically issue a command to start the replacement actuator and perform the removal and installation of the grinding wheel. The entire process is fully automated and does not require human intervention, ensuring the continuity and stability of the processing process.

[0044] The design of the replacement actuator takes into account the needs of precision machining. The precise coordination of the electric motor, gearbox, drive shaft and clamping device ensures the accuracy and stability during the grinding wheel replacement process. The precise clamping structure design of the clamping device can firmly grasp the grinding wheel and keep the grinding wheel stable during the replacement process to avoid damage to the grinding wheel caused by vibration and improper operation.

[0045] After the grinding wheel is replaced, the system automatically returns to standby mode to prepare for the next wear detection and replacement operation. The automation of the entire process not only reduces the workload of operators, but also significantly improves production efficiency and processing quality due to the timeliness of wear detection and replacement.

[0046] This embodiment further proves the effectiveness and practicality of the grinding wheel wear automatic detection and replacement system of the present invention in the field of precision machining, and provides an efficient and reliable solution for high-precision manufacturing industries such as aerospace.

[0047] In summary, the automatic detection and replacement system for grinding wheel wear of the present invention has significant technical advantages and application value. The design of the system fully considers the actual needs in different industrial environments, and can provide stable and reliable wear monitoring and timely grinding wheel replacement services for both mass-produced automotive parts and high-precision aerospace parts. Through the use of non-contact wear sensors, the system can accurately monitor the wear state of the grinding wheel to ensure the consistency of processing quality and maximize production efficiency.

[0048] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features thereof may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A grinding wheel wear automatic detection and replacement system, characterized in that: It includes a grinding wheel device, a wear detection module, a control unit, a replacement actuator, and a power module. The grinding wheel device is used to perform cutting and grinding operations; the wear detection module is connected to the grinding wheel device and is used to detect the wear status of the grinding wheel in real time; the control unit receives the signal of the wear detection module, analyzes the wear status of the grinding wheel, and controls the action of the replacement actuator; the replacement actuator automatically performs the removal and installation operations of the grinding wheel according to the instructions of the control unit; the power module provides power support for the entire system.

2. The automatic detection and replacement system for grinding wheel wear according to claim 1, characterized in that: The wear detection module package is composed of a plurality of non-contact wear sensors, which are fixed near the grinding wheel and used to measure the changes in the surface morphology and cutting force of the grinding wheel, and convert the measured data into electrical signals and output them to the control unit.

3. The automatic detection and replacement system for grinding wheel wear according to claim 2, characterized in that: The non-contact wear sensor includes a laser displacement sensor, an optical imaging sensor, and an ultrasonic sensor.

4. The automatic detection and replacement system for grinding wheel wear according to claim 1, characterized in that: The control unit is composed of a microprocessor, a memory, an input / output interface, and a software program. The microprocessor is responsible for processing the signal transmitted by the wear detection module and determining the degree of wear of the grinding wheel according to the built-in algorithm; the memory is used to protect the wear data and the control program; the input / output interface is used to receive external instructions and output the system status; the software program contains an instruction set for controlling the grinding wheel replacement process.

5. The automatic detection and replacement system for grinding wheel wear according to claim 4, characterized in that: The microprocessor has a built-in wear determination algorithm, which calculates the current wear of the grinding wheel based on the received sensor data, combined with a preset wear threshold and wear rate model, and updates the wear status in real time. When it is detected that the wear exceeds the preset threshold, the microprocessor triggers the replacement actuator to ensure timely replacement of the grinding wheel, thereby maintaining processing accuracy and efficiency.

6. The automatic detection and replacement system for grinding wheel wear according to claim 4, characterized in that: The memory is a solid-state storage device with fast reading and writing capabilities to ensure real-time recording and rapid retrieval of wear data; the input and output interface is designed as a high-speed communication interface to ensure rapid and accurate data transmission between the control unit and the wear detection module and the replacement actuator.

7. The automatic detection and replacement system for grinding wheel wear according to claim 4, characterized in that: The software program includes multiple modular functions, specifically an automatic calibration program, a fault diagnosis program and a user interaction interface. The automatic calibration program ensures the accuracy of the wear detection module and compensates for any possible measurement deviations through regular calibration; the fault diagnosis program can detect abnormal conditions within the system and provide corresponding maintenance prompts to reduce unexpected downtime; the user interaction interface provides an intuitive operating platform for operators, through which they can manually control the grinding wheel replacement process, view the system status, and perform system settings and maintenance.

8. The automatic detection and replacement system for grinding wheel wear according to claim 1, characterized in that: The replacement actuator is composed of an electric motor, a gear box, a drive shaft, and a clamping device. The electric motor is responsible for providing power. The gear box transmits the power of the electric motor to the drive shaft. The drive shaft drives the clamping device to remove and install the grinding wheel. The precise clamping structure design of the clamping device can firmly grasp the grinding wheel and keep the grinding wheel stable during the replacement process to avoid damage to the grinding wheel due to vibration and improper operation.

9. A method for using a grinding wheel wear automatic detection and replacement system, characterized in that: The following steps are involved: Step 1: First, start the system and perform initialization settings to ensure that all modules are working properly; Step 2: Then, the grinding wheel device starts to perform cutting and grinding operations, and the wear detection module monitors the wear state of the grinding wheel in real time; Step 3: The control unit analyzes the wear condition of the grinding wheel according to the data provided by the wear detection module; Step 4: When the wear reaches the preset threshold, the control unit issues a command to start the replacement actuator to automatically remove and install the grinding wheel; Step 5: Finally, after the system completes the replacement, it automatically returns to the standby state and prepares for the next wear detection and replacement operation.

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