Grinding wheel abrasion monitoring and compensating system and method for casting grinding machine
By combining the laser ranging module and the main control module, the wear of the grinding wheel is monitored in real time and automatically compensated, which solves the problem of casting accuracy and consistency caused by the wear of the resin grinding wheel, and realizes the automated continuous production of the casting grinding machine.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-02-09
- Publication Date
- 2026-03-27
AI Technical Summary
In existing technologies, resin grinding wheels wear out quickly, resulting in poor grinding accuracy and consistency of castings. Furthermore, automated continuous production cannot be achieved, requiring frequent machine shutdowns to manually measure the grinding wheel diameter and reset the grinding program.
A laser ranging module is used to monitor grinding wheel wear in real time. The wear amount is calculated and automatically compensated by the main control module. Combined with the human-machine interaction module and the process compensation output module, automated monitoring and compensation are achieved.
It enables real-time monitoring and automatic compensation of grinding wheel wear, ensuring consistent dimensional accuracy and surface quality of castings, supporting automated continuous production, and reducing manual intervention.
Smart Images
Figure CN121733434A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a monitoring and compensation system and method, specifically to a grinding wheel wear monitoring and compensation system and method for a casting grinding machine. Background Technology
[0002] In the field of casting grinding, traditionally, low-wear steel stone wheels or electroplated wheels are commonly used. However, for castings made of special materials (such as high-performance alloys and thin-walled parts), it is necessary to use resin wheels that are more flexible and less likely to cause workpiece burns. The main disadvantage of resin wheels is their rapid wear rate. During automated grinding, the rapid reduction in wheel diameter can lead to changes in the machining reference, severely affecting the grinding accuracy and consistency of the casting, such as causing excessive or insufficient grinding.
[0003] Currently, operators must frequently stop the machine to manually measure the grinding wheel diameter and reset the Z-axis reference point of the grinding program. This is not only inefficient and reliant on manual experience, but also makes it impossible to achieve fully automated continuous production. Summary of the Invention
[0004] The purpose of this invention is to solve the technical problems of existing grinding wheel measurement, which requires frequent machine shutdowns for manual measurement, resulting in low efficiency and the inability to achieve automated continuous production. The invention provides a grinding wheel wear monitoring and compensation system and method for casting grinding machines.
[0005] To solve the above-mentioned technical problems, the technical solution provided by the present invention is as follows: A grinding wheel wear monitoring and compensation system for a casting grinding machine includes a laser ranging module, a main control module, and a human-machine interaction module that are electrically connected in sequence. The laser ranging module is installed on the casting grinding machine at a position corresponding to the position of the grinding wheel, and monitors the real-time distance between itself and the surface of the grinding wheel. The main control module pre-stores the initial distance and wear threshold input through the human-computer interaction module; The laser ranging module transmits the real-time distance to the main control module, which then obtains the wear amount of the grinding wheel based on the initial distance and the real-time distance, and transmits the wear amount to the human-computer interaction module for display. It also includes a process compensation output module connected to the main control module; when the wear amount is greater than or equal to the wear threshold, the main control module obtains the grinding compensation amount based on the wear threshold and the wear amount, and sends the compensation amount to the casting grinding machine through the process compensation output module.
[0006] Furthermore, the laser ranging module includes a laser ranging sensor and a universal bracket for mounting the laser ranging sensor. The base of the universal bracket is mounted on the casting grinding machine at a position corresponding to the position of the grinding wheel via a Z-axis electric telescopic component. The laser rangefinder and the Z-axis electric telescopic component are both connected to the main control module.
[0007] Furthermore, a protective cover is provided at the laser emission port of the laser ranging sensor.
[0008] Furthermore, the main control module is a PLC controller or an industrial computer; it is used to store the initial distance and wear threshold input through the human-machine interaction module, and to obtain the wear amount of the grinding wheel based on the initial distance and the real-time distance.
[0009] Furthermore, the process compensation output module is an analog output unit or a digital I / O unit.
[0010] A method for monitoring and compensating for grinding wheel wear in a casting grinding machine, comprising the following steps: S1. Adjust the universal bracket so that the laser from the laser rangefinder sensor is perpendicularly irradiated onto the outer circle of the grinding wheel; S2. The distance between the laser emission port of the laser rangefinder and the outer surface of the grinding wheel is detected by the laser rangefinder and transmitted to the human-machine interaction module through the main control module. S3. Preset the wear threshold and use the distance obtained in step S2 as the initial distance; at the same time, input the initial distance and wear threshold into the main control module through the human-computer interaction module; S4. The laser rangefinder detects the real-time distance between the laser emission port of the laser rangefinder and the outer surface of the grinding wheel, and transmits the real-time distance to the main control module. S5. The main control module calculates the wear of the grinding wheel based on the preset initial distance and real-time distance, and transmits the wear to the human-computer interaction module for display. At the same time, the main control module compares the wear amount with the wear threshold; If the wear amount is greater than or equal to the wear threshold, the main control module calculates the grinding compensation amount based on the wear threshold and the wear amount, and sends the compensation amount to the casting grinding machine through the process compensation output module; the casting grinding machine controls the grinding feed axis to perform compensated feed according to the compensation amount; If the wear amount is less than the wear threshold, then continue to step S4.
[0011] Furthermore, step S4 specifically includes: S41. Set multiple data acquisition reference lines on the outer circle of the grinding wheel that correspond to the encoder angle values of the grinding wheel drive motor; S42. Set multiple evenly distributed data acquisition points along the axis of the grinding wheel on each data acquisition reference line of the grinding wheel, and the distance between two adjacent data acquisition points is denoted as L. S43. Within the same rotation cycle of the grinding wheel, the real-time distance between the laser emission port and the data acquisition points on different data acquisition reference lines on the outer circle of the grinding wheel is detected sequentially by the laser range sensor. S44. Control the Z-axis electric telescopic component to move a distance L through the main control module, and repeat step S43 until the real-time distance measurement of multiple data acquisition points within multiple different data acquisition reference lines is completed. S45. The main control module calculates the average real-time distance of all data acquisition points within the same data acquisition reference line, and uses this average as the real-time distance between the laser emission port and each data acquisition reference line of the grinding wheel; and transmits the real-time distance to the main control module.
[0012] Furthermore, in step S5, the formula for calculating the wear amount is: ΔD = D1 - D0; In the formula, ΔD is the wear amount, D0 is the initial distance denoted as , and D1 is the real-time distance.
[0013] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. The grinding wheel wear monitoring and compensation system and method for casting grinding machines provided by this invention, by setting up a laser ranging module, a main control module, and a process compensation output module, allows the laser ranging module to monitor the real-time distance between the laser emission port and the grinding wheel surface. The main control module obtains the wear amount of the grinding wheel based on the initial distance and the real-time distance. When the wear amount is greater than or equal to the wear threshold, the main control module obtains the grinding compensation amount based on the wear threshold and the wear amount, and sends the compensation amount to the casting grinding machine through the process compensation output module. Compared with existing grinding wheel measurement methods, no manual intervention is required for measurement, which can ensure automated continuous production. At the same time, it can compensate for the wear of the grinding wheel in a timely manner, ensuring that the dimensional accuracy and surface quality of each processed casting are highly consistent.
[0014] 2. The grinding wheel wear monitoring and compensation system and method for casting grinding machines provided by the present invention, by setting multiple data acquisition reference lines on the outer circle of the grinding wheel corresponding to the encoder angle values of the grinding wheel drive motor, and setting multiple evenly distributed data acquisition points along the grinding wheel axis on each data acquisition reference line of the grinding wheel, can ensure the accuracy of the laser range sensor measurement by measuring the real-time distance between each data acquisition point on the same data acquisition reference line and the laser emission port in multiple rotation cycles of the grinding wheel and calculating the average value. Attached Figure Description
[0015] Figure 1 This is a structural block diagram of an embodiment of the present invention; Figure 2 This is a schematic diagram of the casting grinding machine in an embodiment of the present invention.
[0016] Explanation of reference numerals in the attached drawings: 1-base, 2-Z-axis linear slide rail, 3-dual-station workpiece exchange table, 4-X-axis swing arm, 5-Y-axis swing arm, 6-turntable, 7-workpiece fixing fixture, 8-clamping mechanism, 9-servo motor, 10-grinding wheel drive motor, 11-grinding wheel, 12-grinding head drive motor, 13-grinding head, 14-drive rod, 15-laser rangefinder sensor. Detailed Implementation
[0017] The technical solutions of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0018] like Figure 1 As shown, a grinding wheel wear monitoring and compensation system for a casting grinding machine includes a laser ranging module, a main control module, and a human-machine interaction module that are electrically connected in sequence. The laser ranging module is installed on the casting grinding machine at a position corresponding to the position of the grinding wheel, and monitors the real-time distance between the laser ranging module and the surface of the grinding wheel. The main control module pre-stores the initial distance and wear threshold input through the human-machine interface module; the main control module is a PLC controller or an industrial computer. The laser ranging module transmits the real-time distance to the main control module, which then obtains the wear amount of the grinding wheel based on the initial distance and the real-time distance, and transmits the wear amount to the human-computer interaction module for display. It also includes a process compensation output module connected to the main control module; the process compensation output module is an analog output unit or a digital I / O unit; when the wear amount is greater than or equal to the wear threshold, the main control module obtains the grinding compensation amount based on the wear threshold and the wear amount, and sends the compensation amount to the casting grinding machine through the process compensation output module.
[0019] The laser ranging module includes a laser ranging sensor and a universal bracket for mounting the laser ranging sensor. The base of the universal bracket is mounted on the casting grinding machine at a position corresponding to the grinding wheel position via a Z-axis electric telescopic component. Both the laser ranging sensor and the Z-axis electric telescopic component are connected to the main control module.
[0020] To prevent the splashes generated by the grinding wheel during the grinding process from affecting the laser rangefinder, a protective cover is installed at the laser emission port of the laser rangefinder.
[0021] The monitoring and compensation method of the grinding wheel wear monitoring system for casting grinding machines of the present invention is as follows: 1) Adjust the universal bracket so that the laser from the laser rangefinder sensor is perpendicularly illuminating the outer circle of the grinding wheel; 2) The distance between the laser emission port of the laser rangefinder and the outer surface of the grinding wheel is detected by the laser rangefinder and transmitted to the human-machine interaction module through the main control module; 3) Set a wear threshold and use the distance obtained in step 2) as the initial distance; at the same time, input the initial distance and wear threshold into the main control module through the human-computer interaction module; 4) The laser rangefinder detects the real-time distance between the laser emission port of the laser rangefinder and the outer surface of the grinding wheel, and transmits the real-time distance to the main control module; specifically: 41) Set multiple data acquisition reference lines on the outer circle of the grinding wheel that correspond to the encoder angle values of the grinding wheel drive motor; 42) Set multiple evenly distributed data acquisition points along the axis of the grinding wheel on each data acquisition reference line of the grinding wheel, and denot the distance between two adjacent data acquisition points as L; 43) During the same rotation cycle of the grinding wheel, the real-time distance between the laser emission port and the data acquisition points on different data acquisition reference lines on the outer circle of the grinding wheel is detected sequentially by the laser range sensor. 44) Control the Z-axis electric telescopic component to move a distance L through the main control module, and repeat step S43 until the real-time distance measurement of multiple data acquisition points within multiple different data acquisition reference lines is completed. 45) The main control module calculates the average real-time distance of all data acquisition points within the same data acquisition reference line, and uses this average as the real-time distance between the laser emission port and each data acquisition reference line of the grinding wheel; and transmits the real-time distance to the main control module. 5) The main control module calculates the wear of the grinding wheel based on the preset initial distance and real-time distance, and transmits the wear amount to the human-computer interaction module for display; The formula for calculating wear is: ΔD = D1 - D0; where ΔD is the wear amount, D0 is the initial distance, and D1 is the real-time distance.
[0022] At the same time, the main control module compares the wear amount with the wear threshold; If the wear amount is greater than or equal to the wear threshold, the main control module calculates the grinding compensation amount based on the wear threshold and the wear amount, and sends the compensation amount to the casting grinding machine through the process compensation output module; the casting grinding machine controls the grinding feed axis to perform compensated feed according to the compensation amount; where the compensation amount is the difference between the wear amount and the wear threshold. If the wear amount is less than the wear threshold, then continue to step 4.
[0023] In other embodiments of the present invention, when some grinding wheels are relatively rough, laser irradiation on the outer surface of the grinding wheel can easily cause a large measurement error in the distance, resulting in excessive grinding feed during the compensation feed of the casting grinding machine; a limit threshold can be set in the main control module, and if the wear amount exceeds the limit threshold, the main control module will issue an alarm through the human-machine interaction module; to avoid excessive grinding wheel load during the grinding process.
[0024] In this embodiment, as Figure 2 As shown, the casting grinding machine includes a base 1, a Z-axis linear slide rail 2 and a dual-station exchange table mounted on the top of the base 1; an X-axis swing arm 4 is mounted on the slide of the Z-axis linear slide rail 2, a Y-axis swing arm 5 is mounted at the end of the X-axis swing arm 4, a turntable 6 is mounted at the end of the Y-axis swing arm 5, and a workpiece fixing fixture 7 is mounted on the mounting base of the turntable 6; a reduction motor for driving the X-axis swing arm 4 and the Y-axis swing arm 5 to swing is mounted on the slide of the Z-axis linear slide rail 2 and at the end of the X-axis swing arm 4; a clamping mechanism 8 is mounted on the top of the Y-axis swing arm 5, and the clamping rod of the clamping mechanism 8 cooperates with the workpiece fixing fixture 7 to fix the workpiece; a servo motor 9 is mounted on the base of the Z-axis linear slide rail 2, a grinding wheel drive motor 10 is mounted on the housing of the servo motor 9, and a grinding wheel 11 is mounted on the output shaft of the grinding wheel drive motor 10; A grinding head drive motor 12 is rotatably mounted on the housing of the grinding wheel drive motor 10. A grinding head 13 is provided on the output shaft of the grinding head drive motor 12. A drive rod 14 is provided between the side of the grinding head drive motor 12 and the output shaft of the servo motor 9. The two ends of the drive rod 14 are rotatably connected to the side of the grinding head drive motor 12 and the output shaft of the servo motor 9, respectively. The base 1 of the universal bracket is mounted on the base of the Z-axis linear slide rail 2 via the Z-axis electric telescopic component, and the laser range sensor 15 is mounted on the universal bracket; the laser emitted by the laser range sensor 15 is perpendicularly irradiated on the outer surface of the grinding wheel 11.
[0025] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions within the technical scope disclosed in the present invention should be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.
Claims
1. A grinding wheel wear monitoring and compensation system for a casting grinding machine, characterized in that: It includes a laser ranging module, a main control module, and a human-machine interaction module that are electrically connected in sequence; The laser ranging module is installed on the casting grinding machine at a position corresponding to the position of the grinding wheel, and monitors the real-time distance between itself and the surface of the grinding wheel. The main control module pre-stores the initial distance and wear threshold input through the human-computer interaction module; The laser ranging module transmits the real-time distance to the main control module, which then obtains the wear amount of the grinding wheel based on the initial distance and the real-time distance, and transmits the wear amount to the human-computer interaction module for display. It also includes a process compensation output module connected to the main control module; when the wear amount is greater than or equal to the wear threshold, the main control module obtains the grinding compensation amount based on the wear threshold and the wear amount, and sends the compensation amount to the casting grinding machine through the process compensation output module.
2. The grinding wheel wear monitoring and compensation system for a casting grinding machine according to claim 1, characterized in that: The laser ranging module includes a laser ranging sensor and a universal bracket for mounting the laser ranging sensor. The base of the universal bracket is mounted on the casting grinding machine at a position corresponding to the position of the grinding wheel via a Z-axis electric telescopic component. The laser rangefinder and the Z-axis electric telescopic component are both connected to the main control module.
3. The grinding wheel wear monitoring and compensation system for a casting grinding machine according to claim 2, characterized in that: The laser rangefinder sensor has a protective cover at its laser emission port.
4. The grinding wheel wear monitoring and compensation system for a casting grinding machine according to claim 1, characterized in that: The main control module is a PLC controller or an industrial computer; it is used to store the initial distance and wear threshold input through the human-machine interaction module, and to obtain the wear amount of the grinding wheel based on the initial distance and the real-time distance.
5. The grinding wheel wear monitoring and compensation system for a casting grinding machine according to claim 1, characterized in that: The process compensation output module is an analog output unit or a digital I / O unit.
6. A monitoring and compensation method for a grinding wheel wear monitoring and compensation system for a casting grinding machine based on any one of claims 1-5, characterized in that, Includes the following steps: S1. Adjust the universal bracket so that the laser from the laser rangefinder sensor is perpendicularly irradiated onto the outer circle of the grinding wheel; S2. The distance between the laser emission port of the laser rangefinder and the outer surface of the grinding wheel is detected by the laser rangefinder and transmitted to the human-machine interaction module through the main control module. S3. Preset the wear threshold and use the distance obtained in step S2 as the initial distance; at the same time, input the initial distance and wear threshold into the main control module through the human-computer interaction module; S4. The laser rangefinder detects the real-time distance between the laser emission port of the laser rangefinder and the outer surface of the grinding wheel, and transmits the real-time distance to the main control module. S5. The main control module calculates the wear of the grinding wheel based on the preset initial distance and real-time distance, and transmits the wear to the human-computer interaction module for display. At the same time, the main control module compares the wear amount with the wear threshold; If the wear amount is greater than or equal to the wear threshold, the main control module calculates the grinding compensation amount based on the wear threshold and the wear amount, and sends the compensation amount to the casting grinding machine through the process compensation output module; the casting grinding machine controls the grinding feed axis to perform compensated feed according to the compensation amount; If the wear amount is less than the wear threshold, then continue to step S4.
7. The method for monitoring and compensating grinding wheel wear in a casting grinding machine according to claim 6, characterized in that, Step S4 is as follows: S41. Set multiple data acquisition reference lines on the outer circle of the grinding wheel that correspond to the encoder angle values of the grinding wheel drive motor; S42. Set multiple evenly distributed data acquisition points along the axis of the grinding wheel on each data acquisition reference line of the grinding wheel, and the distance between two adjacent data acquisition points is denoted as L. S43. Within the same rotation cycle of the grinding wheel, the real-time distance between the laser emission port and the data acquisition points on different data acquisition reference lines on the outer circle of the grinding wheel is detected sequentially by the laser range sensor. S44. Control the Z-axis electric telescopic component to move a distance L through the main control module, and repeat step S43 until the real-time distance measurement of multiple data acquisition points within multiple different data acquisition reference lines is completed. S45. The main control module calculates the average real-time distance of all data acquisition points within the same data acquisition reference line, and uses this average as the real-time distance between the laser emission port and each data acquisition reference line of the grinding wheel; and transmits the real-time distance to the main control module.
8. The method for monitoring and compensating grinding wheel wear in a casting grinding machine according to claim 6, characterized in that: In step S5, the formula for calculating the wear amount is: ΔD = D1 - D0; In the formula, ΔD is the wear amount, D0 is the initial distance denoted as , and D1 is the real-time distance.