Grinding device with automatic detection function and grinding method

Abstract

The application provides a grinding device with automatic detection function and a grinding method, and relates to the field of grinding devices.The grinding device comprises a synchronous gear disc set, four electric grinding rods, a ball limiting groove and a micro telescopic unit.The micro telescopic unit comprises a tubular hollow metal shell and a counterweight, two electromagnet blocks are arranged in the hollow metal shell, and a spring dynamometer is arranged between the two electromagnet blocks.The micro telescopic unit is fixedly connected with the tail end of the electric grinding rod.The grinding device further comprises a lifting column module corresponding to each micro telescopic unit, the lifting column module comprises a lifting column with adjustable height, an electromagnet ball is arranged at the bottom of the lifting column, the size of the electromagnet ball is adapted to the ball limiting groove, and the top of the lifting column is fixedly connected with the position where the center of gravity of the micro telescopic unit is located.

Description

Technical Field

[0001] This invention relates to the field of grinding equipment, and more specifically to a grinding device and grinding method with automatic detection function. Background Technology

[0002] In the field of precision manufacturing, grinding is a critical process with extremely high requirements for the dimensional and shape accuracy of workpieces. Traditional grinding often relies on the experience and skills of operators, resulting in problems such as unstable machining accuracy and low efficiency. Therefore, developing grinding devices with automatic detection functions has become crucial to solving these problems. In traditional grinding processes, operators need to frequently stop the machine to inspect the workpiece's dimensions and shape, and then manually adjust the grinding parameters based on the inspection results. This method is not only inefficient but also prone to introducing human error, leading to unstable machining accuracy. To overcome the shortcomings of existing technologies, grinding devices with automatic detection functions have emerged. This type of device is expected to integrate advanced sensor technology, automated control systems, and computer control technology to achieve real-time detection and automatic adjustment of workpiece dimensions and shape.

[0003] To further achieve the high precision requirements of grinding, the following measures can usually be taken:

[0004] (1) Select high-precision grinding equipment:

[0005] Choose grinding equipment with high-precision positioning and control systems, such as CNC grinding machines and coordinate grinding machines. These machines typically employ advanced servo drive systems and closed-loop control systems, enabling high-precision positioning and feeding. However, the purchase and maintenance costs are too high.

[0006] (2) Optimize grinding parameters:

[0007] Based on the material, shape, and size requirements of the workpiece, appropriate grinding parameters, such as grinding speed, feed rate, and depth of cut, are selected. By optimizing these parameters, better grinding results and higher machining accuracy can be achieved. However, the control of these specific parameters largely depends on complex electronic control systems.

[0008] (3) Adopting advanced grinding technology:

[0009] Advanced technologies such as high-speed grinding, ultra-precision grinding, and creep-feed grinding can significantly improve the efficiency and accuracy of grinding processes. However, from an engineering practice perspective, switching between various grinding modes remains overly complex.

[0010] (4) Strengthen process monitoring and testing:

[0011] During the grinding process, sensors and inspection instruments are used to monitor and detect the workpiece's dimensions, shape, and surface roughness in real time. Once an anomaly is detected, adjustments and corrections are made immediately to ensure machining quality. However, how to effectively achieve online fine-tuning remains a bottleneck problem in the industry.

[0012] In summary, grinding is a critical process that demands extremely high precision in workpiece dimensions and shape. To achieve this high precision, it is necessary to select high-precision grinding equipment, optimize grinding parameters, adopt advanced grinding technologies, and strengthen process monitoring and inspection. Summary of the Invention

[0013] To address the aforementioned problems, the present invention aims to provide a grinding device with automatic detection function, enabling online detection, real-time control, and standard calibration in grinding processes. This device contributes to the upgrading of automation technology in my country's grinding processes. Based on mechanical transmission technology, it employs synchronous gear sets, electric grinding rods, and micro-telescopic units to achieve a novel high-precision grinding process.

[0014] The present invention adopts the following technical solution:

[0015] A grinding device with automatic detection function includes a synchronous gear disk assembly (1) and four electric grinding rods (2). The synchronous gear disk assembly (1) includes a hollow large gear disk. Four ball bearing grooves pointing towards the center of the hollow large gear disk are formed on the disk surface in a centrally symmetrical manner, with the center of the hollow large gear disk as the center. The length of the ball bearing grooves is not greater than the radius of the hollow large gear disk. Each electric grinding rod (2) is connected to a micro-telescopic unit (4). The micro-telescopic unit (4) includes a tubular hollow metal shell and a counterweight (4a). Two electromagnet blocks (4b) are disposed inside the hollow metal shell, and a spring balance (4c) is disposed between the two electromagnet blocks (4b). One is fixed to a tubular hollow metal shell and named the fixed block, and the other is named the moving block. The moving block can slide inside the tubular hollow metal shell based on the electromagnetic force between it and the fixed block. The moving block is fixedly connected to the tail end of the electric grinding rod (2). The grinding device also includes a lifting column module (3) corresponding to each micro-telescopic unit. Each lifting column module (3) includes a lifting column (3b) with adjustable column height. An electromagnet ball (3a) is set at the bottom of the lifting column. The size of the electromagnet ball (3a) is adapted to the ball limiting groove so that the electromagnet ball (3a) is limited in the ball limiting groove and can only roll along the ball limiting groove. The top of the lifting column (3b) is fixedly connected to the position of the center of gravity of the micro-telescopic unit (4).

[0016] Preferably, the synchronous gear disk assembly (1) further includes an electric pinion (1a), which is connected to the hollow large gear disk via teeth, so as to drive the hollow large gear disk to rotate; the hollow large gear disk is annular. The electric grinding rod (2) includes an electric rotating shaft and sandpaper wrapped around the electric rotating shaft.

[0017] Preferably, the device further includes a test lifting block, which is a quadrangular prism with a square cross-section. The center point of the square coincides with the center point of the hollow large gear disk in a direction perpendicular to the hollow large gear disk. The side length of the square is equal to the length of the electric grinding rod. The test lifting block can move in a direction perpendicular to the hollow large gear disk.

[0018] Preferably, the device also includes a measurement and control module for controlling the power supply of the electromagnet ball (3a) and the electromagnet block (4b), controlling the height of the lifting column (3b), the lifting and lowering of the test lifting block, the rotation speed of the electric shaft of the electric pinion (1a) and the electric grinding rod (2), and collecting the detection signal of the spring balance (4c).

[0019] The present invention also provides a method for grinding using a grinding device with an automatic detection function as described in claim 5, comprising the following steps:

[0020] S1 electric grinding bar position initialization:

[0021] Based on the workpiece to be ground, the positions of the four electric grinding rods relative to the workpiece are set.

[0022] The electromagnet ball (3a) is de-energized so that the electromagnet ball (3a) can move in the ball limit groove. By adjusting the height of the lifting column and the position of the micro-telescopic unit (4), the four electric grinding rods are adjusted to the appropriate positions.

[0023] The electromagnet ball (3a) is energized to lock the electromagnet ball (3a) from moving in the ball limit groove;

[0024] S2 calibration:

[0025] The measurement and control module is used to control the test lifting block to rise above the hollow large gear disk, and to control the power supply of the moving block and the fixed block in the four micro telescopic units (4) to the preset value, so that the moving block pushes the electric grinding rod to stick to the test lifting block;

[0026] Collect the detection signals of each spring force gauge (4c) as pressure signals, and determine whether the difference between the pressure signals fed back by the two relative micro-telescopic units (4) exceeds the preset calibration threshold. If it does not exceed the threshold, the calibration is completed. If it does exceed the threshold, adjust the energization of the moving block and the stationary block in the micro-telescopic unit (4) and the position of the electric grinding rod so that the difference in pressure signals is less than the calibration threshold. Record the energization of the electromagnet block in each micro-telescopic unit (4).

[0027] S3 grinding:

[0028] Stop energizing the moving block and the stationary block, and replace the test lifting block with the workpiece to be ground;

[0029] According to the energization status recorded in S2, the electromagnet blocks in each micro-telescopic unit (4) are re-energized to control the rotation speed of the electric shaft of the electric grinding rod (2) to grind the workpiece to be ground.

[0030] Set the working threshold; collect and judge in real time whether the detection signal of the spring force gauge (4c) fed back by the two micro-telescopic units (4) exceeds the preset working threshold. If it exceeds the threshold, adjust the energization of the moving block and the fixed block in the micro-telescopic unit (4) through the measurement and control module to make the pressure the same.

[0031] Four electric grinding rods are synchronously connected to a synchronous gear disk assembly via micro-telescopic units, enabling synchronized and precise grinding of rods with different diameters. Ultimately, the four electric grinding rods maintain synchronization to achieve different grinding working diameters.

[0032] The electric grinding rods achieve grinding operations with different height differences under the action of the corresponding lifting columns. Therefore, various height combinations can be selected, such as: ① grinding with 4 electric grinding rods at the same height, ② 2+2 electric grinding rods with two sets of height grinding, that is, one set is responsible for rough grinding and the other set is responsible for fine grinding, ③ 1+1+2 electric grinding rods with three sets of height grinding, that is, the first two sets are responsible for rough grinding and semi-fine grinding respectively, and the last set is responsible for fine grinding, etc.

[0033] The test lifting block is responsible for detecting the symmetry of the relative positions of the four electric grinding bars, providing data reference for calibration and fine-tuning. When the four electric grinding bars are connected end-to-end or in pairs, the grinding device can be calibrated by visually observing the fit or clamping degree between the test lifting block and the electric grinding bars.

[0034] In this invention, the grinding rod moves from top to bottom or bottom to top, and the grinding device adjusts to the corresponding grinding diameter based on its diameter. The main body of the electric grinding rod is an electric rotating shaft, wrapped with sandpaper of different roughness to adapt to different grinding methods. The fine grinding process, performed after rough or semi-fine grinding, generally uses a set of opposing grinding rods for synchronous processing. The asymmetry problem most likely to occur during bilateral grinding is addressed by the micro-telescopic unit, which detects and analyzes the internal pressure difference between the two grinding rods and then adjusts the overall length of the micro-telescopic unit by adjusting the magnetic force between the internal electromagnet blocks, thus minimizing the asymmetry in grinding force. Compared with existing technologies, this invention also has the following advantages:

[0035] 1. Promote the automation upgrade of high-precision grinding processes;

[0036] 2. The overall structure is integrated, saving space and costs;

[0037] 3. Online detection and real-time calibration;

[0038] 4. Capable of quickly adjusting to and responding to the grinding requirements of blank materials of different diameters;

[0039] 5. The process of rough grinding, semi-fine grinding and fine grinding has been fully considered. Attached Figure Description

[0040] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the accompanying drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Some specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings in an exemplary and non-limiting manner. The same reference numerals in the drawings indicate the same or similar parts or components. Those skilled in the art should understand that these drawings are not necessarily drawn to scale. In the drawings:

[0041] Figure 1 Overall schematic diagram of a grinding device with automatic detection function

[0042] Figure 2 Schematic diagram of the rising column structure

[0043] Figure 3 Different grinding modes

[0044] Figure 4 Micro-expansion unit structure diagram

[0045] Figure 5 Schematic diagram of test lifting block calibration

[0046] In the diagram: 1. Synchronous gear disk assembly; 2. Electric grinding rods, a total of 4, named Electric Grinding Rod 1 2a, Electric Grinding Rod 2b, Electric Grinding Rod 3 2c, Electric Grinding Rod 4 2d respectively; 3. Lifting column module; 4. Micro telescopic unit; 5. Test lifting block, etc. Detailed Implementation

[0047] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0048] The present invention will be further described below with reference to specific embodiments.

[0049] Reference Figure 1 A grinding device with automatic detection function includes 1. a synchronous gear set, 2. an electric grinding rod, 3. a lifting column, 4. a micro-telescopic unit, and a control power supply. Regarding the synchronous gear set, a small electric gear drives a large hollow gear to rotate; the overall design is a ring-shaped hollow structure, supported and suspended by a support column, with the material to be ground entering from the y-direction. In this paper, the y-direction refers to the direction perpendicular to the surface of the large hollow gear, and the z-direction and x-direction are mutually perpendicular and form a plane parallel to the surface of the large hollow gear.

[0050] The four electric grinding rods are synchronously connected to the synchronous gear disk group through lifting columns fixed on the micro-telescopic unit, so as to realize synchronous and precise grinding of rods of different diameters; the four electric grinding rods achieve grinding operations with different height differences in the y direction under the action of the corresponding lifting columns; the micro-telescopic unit is responsible for online pressure detection, correction and fine adjustment of the force changes of the electric grinding rods.

[0051] Reference Figure 2 Regarding the lifting column structure, on one hand, it moves in the xoz plane under the drive of the synchronous gear disk assembly to accommodate grinding rods of different diameters. The electromagnet balls at the bottom of the lifting column move within the ball-limiting grooves of the hollow large gear disk and can generate magnetic force under the control of the power supply. When movement is needed, the magnetic force disappears; when movement is not required or grinding is not in operation, the electromagnet balls and the ball-limiting grooves generate a magnetic attraction fixing force. On the other hand, the lifting column achieves changes in the height of the electric grinding rod in the y-direction.

[0052] Reference Figure 3By changing the height of the electric grinding rods, multiple grinding modes can be achieved. For example: 1: Electric grinding rod 1 (2a), electric grinding rod 2 (2b), electric grinding rod 3 (2c), and electric grinding rod 4 (2d) are all the same height, and all four sides are ground simultaneously; 2: Electric grinding rod 1 (2a) and electric grinding rod 3 (2c) are at the same height, and electric grinding rod 2 (2b) and electric grinding rod 4 (2d) are at the same height. In this mode, the two sets of grinding rods use sandpaper with different roughness to achieve rough grinding and fine grinding; 3: Electric grinding rod 2 (2b) and electric grinding rod 4 (2d) are at the same height but different from the height of electric grinding rod 1 (2a) and electric grinding rod 3 (2c). In this mode, the three sets of grinding rods use sandpaper with different roughness to achieve rough grinding, semi-fine grinding, and fine grinding.

[0053] Reference Figure 4 While the synchronous gear set can ensure the precise symmetry of grinding operations for electric grinding rods 2a, 2b, 2c, and 2d to a certain extent, considering factors such as abrasive paper wear on the electric grinding rods and the asymmetry of the grinding rods themselves, a micro-telescopic unit is introduced to achieve online grinding detection. The micro-telescopic unit is designed as a hollow metal rod, consisting of a metal shell, a counterweight 4a, two built-in electromagnets 4b, and a spring balance 4c. The spring balance detects the pressure exerted by the electric grinding rods on the built-in electromagnets and transmits the information synchronously to the backend control power supply. Analysis shows that if the pressure values ​​of the two symmetrical grinding rods deviate too much, feedback is sent to the built-in electromagnets, which use current to generate magnetic force (repulsion / attraction) for fine-tuning. The top of the lifting column 3b is fixedly connected to the center of gravity of the micro-telescopic unit 4. When the lower ball bearing of the lifting column is fixed, the position of the center of gravity is conducive to supporting the micro-telescopic unit 4. Since the micro-telescopic unit 4 is also connected to the grinding rod, and the center of gravity of the micro-telescopic unit will change due to the slight adjustment of the position of the built-in electromagnet block 4b, a counterweight block 4a is designed to reduce the overall center of gravity movement of the micro-telescopic unit 4.

[0054] Reference Figure 5 The device can be calibrated using a test lifting block. The symmetry of the relative positions of the four electric grinding rods and their fit with the test lifting block are tested using a test lifting block. For example, (1) the fit between the electric grinding rods and the lifting block can be observed, and (2) whether slippage occurs when only two symmetrical electric grinding rods are clamped to the lifting block. The observed data provides a reference for the calibration and fine-tuning of the grinding device.

[0055] The following provides a method for grinding using the aforementioned grinding apparatus with automatic detection function, comprising the following steps:

[0056] S1 Electric Grinding Rod Position Initialization: Based on the workpiece to be ground, set the positions of the four electric grinding rods relative to the workpiece; control the electromagnet ball 3a to be de-energized, so that the electromagnet ball 3a can move in the ball limit groove; adjust the height of the lifting column and the position of the micro-telescopic unit 4 to adjust the four electric grinding rods to their proper positions; control the electromagnet ball 3a to be energized, and lock the electromagnet ball 3a so that it cannot move in the ball limit groove.

[0057] S2 Calibration: The measurement and control module controls the test lifting block to rise above the hollow large gear disk, and controls the power supply of the moving block and fixed block in the four micro-telescopic units 4 to the preset value, so that the moving block pushes the electric grinding rod to stick to the test lifting block; the detection signal of each spring force gauge 4c is collected as a pressure signal, and it is determined whether the difference between the pressure signals fed back by the two opposite micro-telescopic units 4 exceeds the preset calibration threshold. If it does not exceed the threshold, the calibration is completed; if it does exceed the threshold, the power supply of the moving block and fixed block in the micro-telescopic unit 4 and the position of the electric grinding rod are adjusted so that the difference in pressure signals is less than the calibration threshold, and the power supply of the electromagnet block in each micro-telescopic unit 4 is recorded.

[0058] S3 Grinding: Stop energizing the moving block and stationary block, and replace the test lifting block with the workpiece to be ground; re-energize the electromagnet blocks in each micro-telescopic unit 4 according to the energizing magnitude recorded in S2, and control the rotation speed of the electric shaft of the electric grinding rod 2 to grind the workpiece; set the working threshold; collect and judge in real time whether the detection signals of the spring force gauges 4c fed back by the two opposite micro-telescopic units 4 exceed the preset working threshold. If they exceed the threshold, adjust the energizing magnitude of the moving block and stationary block in the micro-telescopic unit 4 through the measurement and control module to make the pressure magnitude the same.

[0059] The key to this invention lies in its comprehensive addressing of common problems in the grinding process, namely the requirements for symmetry, synchronization, and online detection, thereby ensuring the precision of grinding results and the efficiency of engineering processing to a great extent. Finally, from an application perspective, compared with existing grinding devices, this invention offers greater flexibility in the selection of functional modes, making it suitable for processing large batches of diverse materials to be ground.

[0060] The above description is only a part of the specific embodiments of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the protection scope of the present invention.

Claims

1. A grinding device with automatic detection function, characterized in that, Includes a synchronous gear set (1) and four electric grinding rods (2). The synchronous gear disk assembly (1) includes a hollow large gear disk. With the center of the hollow large gear disk as the center, four ball bearing grooves pointing towards the center of the hollow large gear disk are formed on the disk surface in a centrally symmetrical manner. The length of the ball bearing grooves is not greater than the radius of the hollow large gear disk. Each of the electric grinding rods (2) is connected to a micro-telescopic unit (4); the micro-telescopic unit (4) includes a tubular hollow metal shell and a counterweight (4a), two electromagnet blocks (4b) are provided inside the hollow metal shell, and a spring balance (4c) is provided between the two electromagnet blocks (4b); one of the two electromagnet blocks is fixed to the tubular hollow metal shell and named the fixed block, and the other electromagnet block is named the moving block. The moving block can slide inside the tubular hollow metal shell based on the electromagnetic force between it and the fixed block; the moving block is fixedly connected to the tail end of the electric grinding rod (2); The grinding device also includes a lifting column module (3) corresponding to each micro-telescopic unit. Each lifting column module (3) includes a lifting column (3b) with adjustable column height. An electromagnet ball (3a) is provided at the bottom of the lifting column. The size of the electromagnet ball (3a) is adapted to the ball limiting groove, so that the electromagnet ball (3a) is limited in the ball limiting groove and can only roll along the ball limiting groove. The top of the lifting column (3b) is fixedly connected to the position of the center of gravity of the micro-telescopic unit (4).

2. A grinding device with automatic detection function as described in claim 1, characterized in that, The synchronous gear disk assembly (1) also includes an electric pinion (1a), which is connected to the hollow large gear disk by teeth so that the electric pinion can drive the hollow large gear disk to rotate; the hollow large gear disk is ring-shaped.

3. A grinding device with automatic detection function as described in claim 2, characterized in that, The electric grinding rod (2) includes an electric shaft and sandpaper wrapped around the electric shaft.

4. A grinding device with automatic detection function as described in claim 3, characterized in that, It also includes a test lifting block, which is a quadrangular prism with a square cross-section. The center point of the square coincides with the center point of the hollow large gear disk in a direction perpendicular to the hollow large gear disk. The side length of the square is equal to the length of the electric grinding rod. The test lifting block can move in a direction perpendicular to the hollow large gear disk.

5. A grinding device with automatic detection function as described in claim 4, characterized in that, It also includes a measurement and control module, which is used to control the power supply of the electromagnet ball (3a) and electromagnet block (4b), control the height of the lifting column (3b), the lifting and lowering of the test lifting block, the rotation speed of the electric shaft of the electric pinion (1a) and the electric grinding rod (2), and collect the detection signal of the spring balance (4c).

6. A method for grinding using a grinding apparatus with automatic detection function as described in claim 5: characterized in that, Includes the following steps: S1 electric grinding bar position initialization: Based on the workpiece to be ground, the positions of the four electric grinding rods relative to the workpiece are set. The electromagnet ball (3a) is de-energized so that the electromagnet ball (3a) can move in the ball limit groove. By adjusting the height of the lifting column and the position of the micro-telescopic unit (4), the four electric grinding rods are adjusted to the appropriate positions. The electromagnet ball (3a) is energized to lock the electromagnet ball (3a) from moving in the ball limit groove; S2 calibration: The measurement and control module is used to control the test lifting block to rise above the hollow large gear disk, and to control the power supply of the moving block and the fixed block in the four micro telescopic units (4) to the preset value, so that the moving block pushes the electric grinding rod to stick to the test lifting block; Collect the detection signals of each spring force gauge (4c) as pressure signals, and determine whether the difference between the pressure signals fed back by the two relative micro-extension units (4) exceeds the preset calibration threshold. If it does not exceed the threshold, the calibration is completed. If the pressure signal difference exceeds the calibration threshold, adjust the energization of the moving block and stationary block in the micro-telescopic unit (4) and the position of the electric grinding rod to make the pressure signal difference less than the calibration threshold, and record the energization of the electromagnet block in each micro-telescopic unit (4). S3 grinding: Stop energizing the moving block and the stationary block, and replace the test lifting block with the workpiece to be ground; According to the energization status recorded in S2, the electromagnet blocks in each micro-telescopic unit (4) are re-energized to control the rotation speed of the electric shaft of the electric grinding rod (2) to grind the workpiece to be ground. Set the working threshold; collect and judge in real time whether the detection signal of the spring force gauge (4c) fed back by the two micro-telescopic units (4) exceeds the preset working threshold. If it exceeds the threshold, adjust the energization of the moving block and the fixed block in the micro-telescopic unit (4) through the measurement and control module to make the pressure the same.

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