A torus secondary enveloping worm grinder

Abstract

The present application relates to the technical field of robot grinding machine, especially to a torus secondary envelope worm grinding machine, comprising: a marble casting structure bed, a work shaft direct drive mechanism and a grinding wheel driving mechanism, the output end of the grinding wheel driving mechanism is installed with a grinding wheel, and one side of the work shaft direct drive mechanism is installed with a grinding wheel dressing mechanism; the present application adopts a marble bed matched with a linear motor, a torque motor direct drive and a grating ruler closed loop control, greatly improves the equipment stability and positioning accuracy, simultaneously breaks through the limitation of "B axis rotation center and actual torus center fixed connection" of market equipment, constructs a virtual torus center system through real-time linkage of X axis, Z axis and B axis, only needs to input torus size parameters on the numerical control controller interface, the system can automatically solve the compensation displacement, dynamically simulates the torus center of any size, does not need to replace hardware components, realizes the rapid change processing of full specification torus workpieces.

Description

Technical Field

[0001] This invention relates to the field of robotic grinding technology, specifically to a toroidal double-envelope worm gear grinding machine. Background Technology

[0002] The toroidal double-envelope worm gear is a core component of precision transmission systems, and its machining quality directly determines the transmission accuracy. The toroidal double-envelope worm gear grinding machine is the core processing equipment for this type of workpiece.

[0003] According to the prior art, the multi-axis linkage CNC worm grinding machine disclosed in the announcement number (CN216882096U) has achieved CNC grinding of worms. However, most of the similar grinding machines on the market adopt a design that fixes the actual toroidal center to the rotation center of the working axis. When processing workpieces with different toroidal speed ratios, it is necessary to replace special equipment or make complicated adjustments to hardware components. The efficiency of change-of-type grinding is extremely low. Moreover, the dressing operation after the grinding wheel wears out completely depends on manual intervention and cannot achieve automated control of the grinding process.

[0004] In addition, the existing worm gear grinding machine beds are mostly made of cast iron, which has poor shock absorption, low thermal expansion and corrosion resistance, resulting in insufficient equipment operation stability. At the same time, existing equipment usually does not have automatic workpiece datum finding and automatic grinding allowance detection mechanisms, requiring manual calibration and zeroing, which further reduces machining accuracy and production efficiency, and cannot meet the machining requirements of high-end precision worm gears. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a toroidal double-envelope worm gear grinding machine, which solves the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a toroidal double-envelope worm gear grinding machine, comprising:

[0007] The bed has a marble casting structure, with an X-axis linear drive mechanism for lateral compensation of the virtual toroidal center installed on one side of the top of the bed, and a Z-axis linear drive mechanism for longitudinal compensation of the virtual toroidal center installed on the other side of the top of the bed.

[0008] A working axis direct drive mechanism is installed in the middle of the bed. A workpiece detection mechanism that provides virtual toroidal center parameter correction data is installed on the top of the bed and is located at the front end of the working axis direct drive mechanism. A B-axis direct drive mechanism is installed on the top of the bed and on one side of the working axis direct drive mechanism.

[0009] A grinding wheel drive mechanism is installed on the top of the B-axis direct drive mechanism, a grinding wheel is installed at the output end of the grinding wheel drive mechanism, and a grinding wheel dressing mechanism is installed on one side of the working shaft direct drive mechanism.

[0010] A controller mounting box is installed on one side of the bed. A CNC controller is installed inside the controller mounting box. The CNC controller is electrically connected to the X-axis linear drive mechanism, the Z-axis linear drive mechanism, the working axis direct drive mechanism, the workpiece inspection mechanism, the B-axis direct drive mechanism, the grinding wheel drive mechanism, and the grinding wheel dressing mechanism.

[0011] Preferably, a tailstock clamping mechanism is provided on the other side of the direct drive mechanism of the working shaft, and a debris collection mechanism is also provided on the top of the bed;

[0012] The physical rotation center of the B-axis direct drive mechanism is separated from the actual toroidal center of the worm. The CNC controller calculates the compensation displacement of the X-axis and Z-axis in real time according to the input toroidal parameters. The CNC controller drives the X-axis linear drive mechanism and the Z-axis linear drive mechanism to perform high-precision position compensation, so that the motion trajectory of the grinding wheel is equivalent to rotating around the "virtual toroidal center", which is suitable for machining toroidal surfaces of worms of different sizes.

[0013] Preferably, the X-axis linear drive mechanism includes an X-axis linear guide rail mounted on one side of the top of the bed, an X-axis linear module slidably mounted on the X-axis linear guide rail, and an X-axis linear grating ruler mounted on the side of the X-axis linear module.

[0014] Preferably, the Z-axis linear drive mechanism includes a Z-axis linear guide rail fixedly installed on the other side of the top of the bed, a Z-axis linear module slidably installed on the Z-axis linear guide rail, a Z-axis motion table installed on the sliding table of the Z-axis linear module, and a Z-axis linear grating ruler installed on the side of the Z-axis linear module.

[0015] Preferably, the working axis direct drive mechanism includes a mounting base fixedly installed on the top of one end of the Z-axis motion table, a working axis torque direct drive motor is installed on one side of the top of the mounting base, a first angle encoder is installed at the end of the working axis torque direct drive motor, and a workpiece chuck is installed at the output end of the working axis torque direct drive motor.

[0016] The working axis torque direct drive motor and the CNC controller control the adjustment of the virtual toroidal center, and adjust the workpiece rotation speed and phase in real time according to the toroidal parameters to ensure the accuracy of the envelope motion between the grinding wheel and the workpiece.

[0017] Preferably, the workpiece inspection mechanism includes a mounting rail fixedly installed at the top center of the Z-axis motion table, a first cylinder mounting seat is installed on the top of the mounting rail, a first drive cylinder is installed on the top of the first cylinder mounting seat, and a radial position sensor is installed at the output end of the first drive cylinder in conjunction with the fixed seat.

[0018] Preferably, a second cylinder mounting seat is provided on one side of the mounting rail, a second drive cylinder is mounted on the top of the second cylinder mounting seat, and an axial position sensor is mounted on the output end of the second drive cylinder in conjunction with the fixed seat.

[0019] Preferably, the B-axis direct drive mechanism includes a B-axis motor mounting base fixedly installed on the top of the X-axis linear module sliding table, a B-axis torque direct drive motor is installed inside the B-axis motor mounting base, and a second angle encoder is installed at the end of the B-axis torque direct drive motor;

[0020] The physical rotation center of the B-axis torque direct drive motor does not coincide with the actual toroidal center of the worm gear.

[0021] Preferably, the grinding wheel drive mechanism includes a mounting bracket fixedly installed on the output end of the B-axis torque direct drive motor. An A-axis direct drive motor is mounted on one side of the mounting bracket. A grinding wheel frequency conversion motor is mounted on the output end of the A-axis direct drive motor in conjunction with the motor frame. A grinding wheel transmission chain box is connected to the output end of the grinding wheel transmission chain box. A grinding machine is connected to the driven end of the grinding wheel transmission chain box. The output end of the grinding machine is fixedly connected to the grinding wheel. The second cylinder mounting seat is fixedly connected to one side of the protective cover of the grinding machine.

[0022] Preferably, the grinding wheel dressing mechanism is a grinding wheel dresser, which is fixedly connected to one side of the mounting base.

[0023] Preferably, the tailstock clamping mechanism includes a sliding guide rail fixedly installed on the top of the Z-axis motion table, a pin sliding seat slidably installed on the sliding guide rail, a lead screw nut installed inside the pin sliding seat, a lead screw threadedly connected inside the lead screw nut, a hand crank installed at the end of the lead screw, a pin cylinder installed on the top of the pin sliding seat, a pin installed at the output end of the pin cylinder, and the pin coaxially arranged with the workpiece jaws.

[0024] Preferably, the chip collection mechanism includes a sloping groove formed on the top of the bed, the sloping groove being located below the grinding position of the grinding wheel and the workpiece, and a chip outlet being formed at the end of the sloping groove.

[0025] Preferably, it also includes a protective cover installed outside the mounting frame, with transparent observation windows installed on both sides of the protective cover, and a coolant nozzle provided inside the protective cover. The outlet end of the coolant nozzle passes through the protective cover of the grinding wheel and is positioned opposite the grinding wheel. The inlet end of the coolant nozzle is connected to a soft coolant supply pipe.

[0026] Compared with the prior art, the beneficial effects of the present invention are:

[0027] This invention provides a toroidal double-envelope worm gear grinding machine:

[0028] 1) This invention breaks through the limitation of "the B-axis rotation center is fixedly connected to the actual toroidal center" in commercial equipment. By real-time linkage of the X-axis, Z-axis and B-axis, a virtual toroidal center system is constructed. Only the toroidal dimension parameters need to be input in the CNC controller interface, and the system can automatically calculate and compensate for the displacement, dynamically simulating the toroidal center of any size. No hardware components need to be replaced, realizing rapid changeover processing of toroidal workpieces of all specifications.

[0029] 2) The bed, constructed from marble castings, significantly improves the machine's vibration damping performance, thermal expansion coefficient, and corrosion resistance compared to existing technologies and traditional cast iron beds, providing a stable foundation for precision grinding. Combined with the linear modules and linear grating rulers of the X-axis and Z-axis linear drive mechanisms, and the torque direct drive motor structure of the working axis and B-axis direct drive mechanisms, it eliminates the traditional reducer and ball screw transmission methods, effectively eliminating gear backlash, belt slippage, and transmission backlash. This enables rapid acceleration and deceleration adjustment with high positioning accuracy, effectively solving the core defects of traditional grinding machines, such as poor operational stability, slow dynamic response, and insufficient machining accuracy, from a hardware perspective.

[0030] 2) This invention controls multi-axis linkage through a CNC controller. Only the workpiece toroidal parameters need to be input into the system to automatically complete the motion trajectory calculation and adaptation. It can achieve the change-of-type grinding of workpieces with different toroidal speed ratios without changing any hardware components, which completely solves the problems of cumbersome change-of-type grinding and low efficiency of traditional special-purpose grinding machines. At the same time, relying on the radial position sensor and axial position sensor of the workpiece detection mechanism, the workpiece can automatically find the reference and automatically detect the grinding allowance, replacing the manual calibration and zeroing operation. With the help of the grinding wheel dresser, the grinding wheel dressing is automatically completed according to the cutting state. No manual intervention is required throughout the process, which greatly improves the automation control level and production efficiency of the grinding process.

[0031] 3) This invention, through the coaxial clamping design of the tailstock clamping mechanism, ensures that the ejector pin and the workpiece chuck are concentrically clamped, further enhancing the workpiece clamping stability and preventing workpiece displacement during grinding. Combined with the sloping groove and chip outlet of the chip collection mechanism, grinding chips are automatically collected and discharged. The protective cover and observation window ensure processing safety, and the coolant nozzles provide real-time cooling and lubrication to the grinding area. This effectively solves the problems of difficult grinding chip cleaning, lack of processing protection, and inadequate cooling, comprehensively improving the safety of the grinding machine, continuous processing capability, and service life, and better adapting to the large-scale processing needs of high-end precision toroidal double-envelope worm gears. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the structure of the present invention;

[0033] Figure 2 This is a schematic diagram of the bed structure of the present invention;

[0034] Figure 3This is a schematic diagram of the working shaft direct drive mechanism of the present invention;

[0035] Figure 4 This is a schematic diagram of the grinding wheel drive mechanism of the present invention;

[0036] Figure 5 This is one of the schematic diagrams of the grinding wheel drive mechanism of the present invention;

[0037] Figure 6 This is a schematic diagram of the debris collection mechanism of the present invention;

[0038] Figure 7 This is a schematic diagram of the structure of Embodiment 2 of the present invention.

[0039] In the diagram: 100, Bed; 200, X-axis linear drive mechanism; 201, X-axis linear guide; 202, X-axis linear module; 203, X-axis linear grating ruler; 300, Z-axis linear drive mechanism; 301, Z-axis linear guide; 302, Z-axis linear module; 304, Z-axis motion table; 305, Z-axis linear grating ruler; 400, Working axis direct drive mechanism; 401, Mounting base; 402, Working axis torque direct drive motor; 403, First angle encoder; 404, Workpiece chuck; 500, Workpiece inspection mechanism; 501, Mounting rail; 502, First cylinder mounting base; 503, First drive cylinder; 504, Radial position sensor; 505, Second cylinder mounting base; 506, Second drive cylinder; 507, Axial position sensor; 600, B-axis direct drive mechanism; 601, B-axis motor. Machine mounting base; 602, B-axis torque direct drive motor; 603, second angle encoder; 700, grinding wheel drive mechanism; 701, mounting bracket; 702, A-axis direct drive motor; 703, grinding wheel frequency converter motor; 704, grinding wheel drive chain box; 705, grinding machine; 706, grinding wheel; 800, grinding wheel dressing mechanism; 801, grinding wheel dresser; 900, controller mounting box; 901, CNC control. Device; 1000, Tailstock clamping mechanism; 1001, Sliding guide rail; 1002, Ejector pin sliding seat; 1003, Lead screw nut; 1004, Lead screw; 1005, Hand crank; 1006, Ejector pin cylinder; 1008, Ejector pin; 1100, Debris collection mechanism; 1101, Sloping groove; 1102, Chip outlet; 1200, Protective cover; 1201, Observation window; 1202, Coolant nozzle. Detailed Implementation

[0040] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. 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.

[0041] The terms "first," "second," etc., used in the specification and claims of this application are used to distinguish similar objects and not to describe a specific order or sequence. It should be understood that such use of data can be interchanged where appropriate so that embodiments of this application can be implemented in orders other than those illustrated or described herein, and the objects distinguished by "first," "second," etc., are generally of the same class and the number of objects is not limited; for example, a first object can be one or more. Furthermore, in the specification and claims, "and / or" indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship.

[0042] In the description of this invention, it should be understood that the terms "center", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0043] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "configuration" should be interpreted broadly. For example, they can refer to a fixed connection or configuration, a detachable connection or configuration, or an integral connection or configuration. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0044] Example 1

[0045] like Figure 1-6 As shown, the present invention proposes a toroidal double-envelope worm gear grinding machine, comprising:

[0046] The bed 100 has a marble casting structure. An X-axis linear drive mechanism 200 for lateral compensation of the virtual toroidal center is installed on one side of the top of the bed 100, and a Z-axis linear drive mechanism 300 for longitudinal compensation of the virtual toroidal center is installed on the other side of the top of the bed 100.

[0047] A working axis direct drive mechanism 400 is installed in the middle of the bed 100. A workpiece detection mechanism 500 is installed on the top of the bed 100 and provides virtual toroidal center parameter correction data at the front end of the working axis direct drive mechanism 400. A B-axis direct drive mechanism 600 is installed on the top of the bed 100 and on one side of the working axis direct drive mechanism 400.

[0048] A grinding wheel drive mechanism 700 is installed on the top of the B-axis direct drive mechanism 600, a grinding wheel 706 is installed at the output end of the grinding wheel drive mechanism 700, and a grinding wheel dressing mechanism 800 is installed on one side of the working axis direct drive mechanism 400.

[0049] A controller mounting box 900 is installed on one side of the bed 100. A CNC controller 901 is installed inside the controller mounting box 900. The CNC controller 901 is electrically connected to the X-axis linear drive mechanism 200, the Z-axis linear drive mechanism 300, the work axis direct drive mechanism 400, the workpiece inspection mechanism 500, the B-axis direct drive mechanism 600, the grinding wheel drive mechanism 700, and the grinding wheel dressing mechanism 800.

[0050] On the other side of the working shaft direct drive mechanism 400, there is a tailstock clamping mechanism 1000, and on the top of the bed 100, there is a debris collection mechanism 1100.

[0051] The physical rotation center of the B-axis direct drive mechanism 600 is separated from the actual toroidal center of the worm. The CNC controller 901 calculates the compensation displacement of the X-axis and Z-axis in real time according to the input toroidal parameters. The CNC controller 901 drives the X-axis linear drive mechanism 200 and the Z-axis linear drive mechanism 300 to perform high-precision position compensation, so that the motion trajectory of the grinding wheel 706 is equivalent to rotating around the "virtual toroidal center", which is suitable for machining the toroidal surface of worms of different sizes.

[0052] Specifically, during operation, the marble casting bed 100 serves as a support platform providing high rigidity and low vibration. The working axis direct drive mechanism 400 completes the clamping and rotation drive of the workpiece, and the tailstock clamping mechanism 1000 clamps the workpiece coaxially from the other side to ensure stable workpiece clamping. When the equipment is started, the CNC controller 901 issues a running command. The X-axis linear drive mechanism 200 and the Z-axis linear drive mechanism 300 cooperate to complete the lateral and longitudinal precise compensation displacement required for the virtual toroidal center. The workpiece detection mechanism 500 collects the reference position and grinding allowance data of the workpiece in real time and transmits them to the CNC controller 901 (as the basis for correcting the virtual toroidal center parameters). The B-axis direct drive mechanism 600 drives the grinding wheel drive mechanism 700 to achieve swing angle adjustment, which, in coordination with the X / Z axis compensation motion, makes the motion trajectory of the grinding wheel 706 equivalent to rotate around the virtual toroidal center, conforming to the workpiece to complete the toroidal secondary envelope grinding.

[0053] The grinding wheel dressing mechanism 800 automatically dresses the grinding wheel 706 according to the grinding state, and the chip collection mechanism 1100 collects the chips generated during grinding simultaneously. Under the unified control of the CNC controller 901, all structures cooperate in an orderly manner. By simply modifying the toroidal parameters through the interface, automatic toroidal surface change of different sizes can be achieved. The entire process of automatic change, automatic detection, automatic grinding and automatic dressing can be completed without manual intervention, eliminating the problems of cumbersome change of traditional special machines and low efficiency of manual calibration, and realizing high-precision and highly automated worm gear grinding.

[0054] In this embodiment: the X-axis linear drive mechanism 200 includes an X-axis linear guide rail 201 mounted on one side of the top of the bed 100, an X-axis linear module 202 slidably mounted on the X-axis linear guide rail 201, and an X-axis linear grating ruler 203 mounted on the side of the X-axis linear module 202.

[0055] Specifically, when the X-axis linear drive mechanism 200 is working, as the lateral compensation execution unit of the virtual toroidal center, the X-axis linear guide 201 provides stable linear guidance support for the X-axis linear module 202, avoiding deviation and shaking during the movement. The X-axis linear module 202 receives instructions from the CNC controller 901 to execute lateral compensation feed motion, realizing precise adjustment of the lateral position of the virtual toroidal center. The X-axis linear grating ruler 203 collects the displacement data of the X-axis linear module 202 in real time and synchronously feeds the signal back to the CNC controller 901 to form closed-loop control. The CNC controller 901 corrects the motion deviation in real time according to the feedback data, eliminates the gap error of the traditional transmission structure, and provides high-precision data support of ±0.001mm level for the lateral position calibration of the virtual toroidal center.

[0056] During the grinding process, the X-axis linear guide 201 continuously ensures the smoothness of the movement, the X-axis linear module 202 and the Z-axis linear drive mechanism 300 work together to complete the composite compensation displacement of the virtual toroidal center, and the X-axis linear grating ruler 203 monitors the displacement accuracy throughout the process, providing reliable power and positioning guarantees for the transverse precision grinding of toroidal worm gears of different sizes.

[0057] In this embodiment: the Z-axis linear drive mechanism 300 includes a Z-axis linear guide rail 301 fixedly installed on the other side of the top of the bed 100, a Z-axis linear module 302 slidably installed on the Z-axis linear guide rail 301, a Z-axis motion table 304 installed on the sliding table of the Z-axis linear module 302, and a Z-axis linear grating ruler 305 installed on the side of the Z-axis linear module 302.

[0058] Specifically, when the Z-axis linear drive mechanism 300 is working, as the longitudinal compensation execution unit of the virtual toroidal center, the Z-axis linear guide rail 301 can provide longitudinal linear motion guidance for the Z-axis linear module 302, ensuring accurate and unbiased motion direction. The Z-axis linear module 302 receives instructions from the CNC controller 901 to drive the Z-axis motion table 304 to complete longitudinal compensation feed, driving the upper working axis direct drive mechanism 400 and the workpiece detection mechanism 500 to move synchronously. The Z-axis linear grating ruler 305 detects the motion displacement and position information of the Z-axis linear module 302 in real time and transmits the data back to the CNC controller 901 in real time. The CNC controller 901 quickly adjusts the motion speed and displacement according to the feedback signal, providing ±0.001mm-level high-precision data support for the longitudinal position calibration of the virtual toroidal center.

[0059] Similarly, during the grinding process, the Z-axis linear guide 301 ensures smooth movement, the Z-axis linear module 302 provides backlash-free direct drive force, the Z-axis motion table 304 bears the load and operates stably, and the Z-axis linear grating ruler 305 performs closed-loop calibration accuracy. Together with the X-axis, it completes the dynamic adjustment of the virtual toroidal center, adapting to worm gear grinding processes of different lengths and toroidal parameters.

[0060] In this embodiment: the working axis direct drive mechanism 400 includes a mounting base 401 fixedly installed on the top of one end of the Z-axis motion table 304, a working axis torque direct drive motor 402 is installed on one side of the top of the mounting base 401, a first angle encoder 403 is installed at the end of the working axis torque direct drive motor 402, and a workpiece chuck 404 is installed at the output end of the working axis torque direct drive motor 402;

[0061] The working axis torque direct drive motor 402 and the CNC controller 901 control and link the virtual toroidal center adjustment, and adjust the workpiece rotation speed and phase in real time according to the toroidal parameters to ensure the envelope motion accuracy of the grinding wheel 706 and the workpiece.

[0062] Specifically, when the working axis direct drive mechanism 400 is working, the working axis torque direct drive motor 402 receives instructions from the CNC controller 901 to directly drive the workpiece to rotate, without the need for a reduction mechanism to transmit power, thus avoiding transmission gaps and torque fluctuations. The first angle encoder 403 collects the rotation angle and speed data of the working axis torque direct drive motor 402 in real time and feeds the signal back to the CNC controller 901 to achieve full closed-loop precise control of the rotation angle. The workpiece chuck 404, driven by the working axis torque direct drive motor 402, securely clamps the workpiece and, together with the tailstock clamping mechanism 1000, achieves coaxial fixation of the workpiece.

[0063] During the grinding process, the direct drive motor 402 of the working axis torque smoothly drives the workpiece to rotate with its low speed and high torque characteristics. The first angle encoder 403 accurately calibrates the rotation angle and matches it in real time with the dynamic adjustment of the virtual toroidal center. The workpiece chuck 404 keeps the workpiece firmly clamped, ensuring the workpiece rotation accuracy and running stability, providing precise workpiece rotation matching for grinding wheel grinding, and improving the machining accuracy of the worm gear tooth surface.

[0064] In this embodiment: the workpiece inspection mechanism 500 includes a mounting rail 501 fixedly installed in the middle of the top of the Z-axis motion table 304. A first cylinder mounting seat 502 is installed on the top of the mounting rail 501. A first drive cylinder 503 is installed on the top of the first cylinder mounting seat 502. A radial position sensor 504 is installed at the output end of the first drive cylinder 503 in conjunction with the fixed seat.

[0065] A second cylinder mounting seat 505 is provided on one side of the mounting rail 501. A second drive cylinder 506 is mounted on the top of the second cylinder mounting seat 505. An axial position sensor 507 is mounted on the output end of the second drive cylinder 506 in conjunction with a fixed seat.

[0066] Specifically, before the grinding operation, the first drive cylinder 503 drives the radial position sensor 504 to move radially toward the workpiece via the first cylinder mounting base 502, and the second drive cylinder 506 drives the axial position sensor 507 to move axially toward the end of the workpiece via the second cylinder mounting base 505. The radial position sensor 504 detects the radial reference position and radial grinding allowance of the workpiece in real time, and the axial position sensor 507 accurately collects the axial reference position and axial grinding allowance of the workpiece. The two sets of sensors transmit the detection data synchronously to the CNC controller 901. The CNC controller 901 automatically corrects the virtual toroidal center parameters according to the detection results, completes the workpiece zeroing calibration, and calculates the optimal grinding parameters. After the detection is completed, the first drive cylinder 503 and the second drive cylinder 506 drive the sensors to reset, avoiding interference with the grinding operation. Then, the workpiece detection mechanism 500 replaces the traditional method of manually finding the reference and manually measuring the allowance, realizing the automation of detection and the accuracy of data, and providing reliable data support for the dynamic adjustment of the virtual toroidal center and high-precision grinding.

[0067] In this embodiment: the B-axis direct drive mechanism 600 includes a B-axis motor mounting base 601 fixedly installed on the top of the sliding table of the X-axis linear module 202. A B-axis torque direct drive motor 602 is installed inside the B-axis motor mounting base 601, and a second angle encoder 603 is installed at the end of the B-axis torque direct drive motor 602.

[0068] The physical rotation center of the B-axis torque direct drive motor 602 does not coincide with the actual toroidal center of the worm gear.

[0069] Specifically, when the B-axis direct drive mechanism 600 is working, the B-axis torque direct drive motor 602 receives instructions from the CNC controller 901 to directly drive the grinding wheel drive mechanism 700 to complete the swing angle motion. There is no reduction gear transmission, which realizes rapid start and stop and high dynamic response. The second angle encoder 603 collects the swing angle and motion speed data of the B-axis torque direct drive motor 602 in real time and feeds the signal back to the CNC controller 901 to form a closed loop control. It forms a real-time linkage with the X-axis linear drive mechanism 200 and the Z-axis linear drive mechanism 300. Through the displacement calculation and compensation control of the CNC controller 901, a virtual toroidal circle center motion system is jointly constructed.

[0070] During the machining process, the swing angle motion of the B-axis torque direct drive motor 602 is precisely coordinated with the X / Z axis compensation motion, and the second angle encoder 603 accurately calibrates the swing angle accuracy, realizing adaptive swing angle grinding of worm gears with different toroidal speed ratios. The changeover can be completed without hardware replacement, improving the equipment's versatility and grinding adaptability.

[0071] In this embodiment: the grinding wheel drive mechanism 700 includes a mounting bracket 701 fixedly installed on the output end of the B-axis torque direct drive motor 602. The A-axis direct drive motor 702 is installed on one side of the mounting bracket 701. The output end of the A-axis direct drive motor 702 is fitted with a grinding wheel frequency conversion motor 703. The output end of the grinding wheel frequency conversion motor 703 is connected to a grinding wheel transmission chain box 704. The driven end of the grinding wheel transmission chain box 704 is connected to a grinding wheel machine 705. The output end of the grinding wheel machine 705 is fixedly connected to the grinding wheel 706. The second cylinder mounting seat 505 is fixedly connected to one side of the protective cover of the grinding wheel machine 705.

[0072] The grinding wheel dressing mechanism 800 is a grinding wheel dresser 801, which is fixedly connected to one side of the mounting base 401.

[0073] Specifically, when the grinding wheel drive mechanism 700 and the grinding wheel dressing mechanism 800 are working, the mounting bracket 701 can swing synchronously with the B-axis. Under the coordinated control of the virtual toroidal center system, the A-axis direct drive motor 702 drives the grinding wheel assembly to complete the angle fine adjustment. The grinding wheel frequency conversion motor 703 adjusts the speed according to the grinding stage requirements. The power is smoothly transmitted to the grinding machine 705 through the grinding wheel transmission chain box 704 via the drive chain. The grinding machine 705 drives the grinding wheel 706 to rotate at high speed to complete the worm grinding.

[0074] When the grinding wheel 706 wears during the grinding process, the Z-axis linear drive mechanism 300 can drive the grinding wheel dresser 801 to move towards the grinding wheel 706. The grinding wheel dresser 801 receives instructions from the CNC controller 901 and automatically dresses the outer circumferential surface of the grinding wheel 706 to restore the accuracy of the grinding wheel tooth profile. No manual intervention is required throughout the process, ensuring the accuracy of the grinding tooth surface and the continuity of the machining.

[0075] In this embodiment: the tailstock clamping mechanism 1000 includes a sliding guide rail 1001 fixedly installed on the top of the Z-axis motion table 304, a pin sliding seat 1002 slidably installed on the sliding guide rail 1001, a lead screw nut 1003 installed inside the pin sliding seat 1002, a lead screw 1004 threadedly connected inside the lead screw nut 1003, a hand crank 1005 installed at the end of the lead screw 1004, a pin cylinder 1006 installed on the top of the pin sliding seat 1002, a pin 1008 installed at the output end of the pin cylinder 1006, and the pin 1008 is coaxially arranged with the workpiece chuck 404.

[0076] Specifically, the operator turns the hand crank 1005 to drive the lead screw 1004 to rotate. The lead screw 1004 is threadedly engaged with the lead screw nut 1003, which drives the ejector pin sliding seat 1002 to move along the sliding guide rail 1001 and adjust it to the workpiece matching position. The ejector pin cylinder 1006 receives the instruction from the CNC controller 901 and drives the ejector pin 1008 to extend towards the workpiece chuck 404, pressing the workpiece between the ejector pin 1008 and the workpiece chuck 404, ensuring that the workpiece and the working axis torque direct drive motor 402 are coaxially set.

[0077] During the grinding process, the ejector pin 1008 maintains a constant clamping force to prevent radial runout and axial displacement of the workpiece, providing a stable workpiece base for precise adjustment of the virtual toroidal center. The sliding guide rail 1001 ensures smooth movement of the ejector pin sliding seat 1002. The lead screw 1004 and lead screw nut 1003 achieve precise position adjustment, improving the stability of the workpiece during grinding and ensuring the machining accuracy and consistency of the worm gear teeth.

[0078] In this embodiment: the chip collection mechanism 1100 includes a sloping groove 1101 opened on the top of the bed 100. The sloping groove 1101 is located below the grinding position of the grinding wheel 706 and the workpiece. The end of the sloping groove 1101 is provided with a chip outlet 1102.

[0079] Specifically, the slope groove 1101 is located on the top of the bed 100 and directly below the grinding position of the grinding wheel 706 and the workpiece. Metal chips generated during grinding fall directly into the slope groove 1101 under the action of gravity. The inclined slope of the slope groove 1101 guides the chips to slide towards the chip outlet 1102 at the end, avoiding the accumulation of chips in the grinding area, motion guide rail or around the sensor, preventing chips from scratching the precision motion structure required for virtual toroidal center adjustment such as the X-axis linear guide rail 201 and Z-axis linear guide rail 301, and keeping the equipment worktable clean.

[0080] Example 2

[0081] Please refer to the detailed information. Figure 7The technical feature that distinguishes this embodiment from embodiment 1 is that it also includes a protective cover 1200 installed on the outside of the mounting frame 701. Both sides of the protective cover 1200 are equipped with transparent observation windows 1201. The inside of the protective cover 1200 is provided with a coolant nozzle 1202. The outlet end of the coolant nozzle 1202 passes through the protective cover 1200 of the grinding wheel 705 and is positioned opposite to the grinding wheel 706. The inlet end of the coolant nozzle 1202 is connected to a soft coolant supply pipe.

[0082] Specifically, the protective cover 1200 isolates the high-speed moving structures such as the grinding wheel 706 and grinding machine 705 from the external environment, preventing grinding debris and coolant from splashing and ensuring operator safety. The observation windows 1201 on both sides of the protective cover 1200 are made of transparent material, allowing operators to observe the grinding process and the running status of the grinding wheel 706 in real time without opening the protective cover 1200. The coolant nozzle 1202 is located inside the protective cover 1200, with the outlet end passing through the grinding machine 705. The protective cover 1200 is aligned with the grinding contact position between the grinding wheel 706 and the workpiece, and the inlet end is connected to an external cooling system through a coolant supply pipe. During the grinding process, the coolant nozzle 1202 continuously sprays coolant to cool and lubricate the grinding wheel 706 and the workpiece, reducing grinding wheel wear and workpiece thermal deformation. This provides an environmental guarantee for the long-term stable operation of the virtual toroidal center system, allowing the equipment to continuously and stably process worm gears of different toroidal dimensions for extended periods.

[0083] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element. Furthermore, it should be noted that the scope of the methods and apparatuses in the embodiments of this application is not limited to performing functions in the order shown or discussed, but may also include performing functions substantially simultaneously or in the reverse order, depending on the functions involved. For example, the described methods may be performed in a different order than described, and various steps may be added, omitted, or combined. Additionally, features described with reference to certain examples may be combined in other examples.

[0084] The embodiments of this application have been described above with reference to the accompanying drawings. However, this application is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of this application without departing from the spirit and scope of the claims, and all of these forms are within the protection scope of this application.

Claims

1. A toroidal double-envelope worm gear grinding machine, characterized in that, include: A marble casting structure bed (100), with an X-axis linear drive mechanism (200) for lateral compensation of the virtual toroidal center installed on one side of the top of the bed (100), and a Z-axis linear drive mechanism (300) for longitudinal compensation of the virtual toroidal center installed on the other side of the top of the bed (100). A working axis direct drive mechanism (400) is installed in the middle of the bed (100). A workpiece detection mechanism (500) that provides virtual toroidal center parameter correction data is installed on the top of the bed (100) at the front end of the working axis direct drive mechanism (400). A B-axis direct drive mechanism (600) is installed on the top of the bed (100) and on one side of the working axis direct drive mechanism (400). A grinding wheel drive mechanism (700) is installed on the top of the B-axis direct drive mechanism (600), a grinding wheel (706) is installed at the output end of the grinding wheel drive mechanism (700), and a grinding wheel dressing mechanism (800) is installed on one side of the working shaft direct drive mechanism (400). A controller mounting box (900) is installed on one side of the bed (100). A CNC controller (901) is installed inside the controller mounting box (900). The CNC controller (901) is electrically connected to the X-axis linear drive mechanism (200), the Z-axis linear drive mechanism (300), the work axis direct drive mechanism (400), the workpiece inspection mechanism (500), the B-axis direct drive mechanism (600), the grinding wheel drive mechanism (700), and the grinding wheel dressing mechanism (800). The other side of the working shaft direct drive mechanism (400) is provided with a tailstock clamping mechanism (1000), and the top of the bed (100) is also provided with a debris collection mechanism (1100). The physical rotation center of the B-axis direct drive mechanism (600) is separated from the actual toroidal center of the worm. The CNC controller (901) calculates the compensation displacement of the X-axis and Z-axis in real time according to the input toroidal parameters. The CNC controller (901) drives the X-axis linear drive mechanism (200) and the Z-axis linear drive mechanism (300) to perform high-precision position compensation, so that the motion trajectory of the grinding wheel (706) is equivalent to rotating around the "virtual toroidal center", which is suitable for machining the toroidal surface of worms of different sizes.

2. The toroidal double-envelope worm gear grinding machine according to claim 1, characterized in that, The X-axis linear drive mechanism (200) includes an X-axis linear guide (201) mounted on one side of the top of the bed (100), an X-axis linear module (202) slidably mounted on the X-axis linear guide (201), and an X-axis linear grating ruler (203) mounted on the side of the X-axis linear module (202).

3. The toroidal double-envelope worm gear grinding machine according to claim 1, characterized in that, The Z-axis linear drive mechanism (300) includes a Z-axis linear guide rail (301) fixedly installed on the other side of the top of the bed (100), a Z-axis linear module (302) is slidably installed on the Z-axis linear guide rail (301), a Z-axis motion table (304) is installed on the sliding table of the Z-axis linear module (302), and a Z-axis linear grating ruler (305) is installed on the side of the Z-axis linear module (302).

4. A toroidal double-envelope worm gear grinding machine according to claim 3, characterized in that, The working axis direct drive mechanism (400) includes a mounting base (401) fixedly installed on the top of one end of the Z-axis motion table (304). A working axis torque direct drive motor (402) is installed on one side of the top of the mounting base (401). A first angle encoder (403) is installed at the end of the working axis torque direct drive motor (402). A workpiece chuck (404) is installed at the output end of the working axis torque direct drive motor (402). The working axis torque direct drive motor (402) and the CNC controller (901) control the adjustment of the virtual toroidal center, and adjust the workpiece rotation speed and phase in real time according to the toroidal parameters to ensure the envelope motion accuracy of the grinding wheel (706) and the workpiece.

5. A toroidal secondary envelope worm gear grinding machine according to claim 4, characterized in that, The workpiece inspection mechanism (500) includes a mounting rail (501) fixedly installed in the middle of the top of the Z-axis motion table (304). A first cylinder mounting seat (502) is installed on the top of the mounting rail (501). A first drive cylinder (503) is installed on the top of the first cylinder mounting seat (502). A radial position sensor (504) is installed at the output end of the first drive cylinder (503) in conjunction with the fixed seat. A second cylinder mounting seat (505) is provided on one side of the mounting rail (501). A second drive cylinder (506) is mounted on the top of the second cylinder mounting seat (505). An axial position sensor (507) is mounted on the output end of the second drive cylinder (506) in conjunction with the fixed seat.

6. A toroidal double-envelope worm gear grinding machine according to claim 5, characterized in that, The B-axis direct drive mechanism (600) includes a B-axis motor mounting base (601) fixedly installed on the top of the sliding table of the X-axis linear module (202). A B-axis torque direct drive motor (602) is installed inside the B-axis motor mounting base (601), and a second angle encoder (603) is installed at the end of the B-axis torque direct drive motor (602). The physical rotation center of the B-axis torque direct drive motor (602) does not coincide with the actual toroidal center of the worm gear.

7. A toroidal double-envelope worm gear grinding machine according to claim 6, characterized in that, The grinding wheel drive mechanism (700) includes a mounting bracket (701) fixedly installed on the output end of the B-axis torque direct drive motor (602). An A-axis direct drive motor (702) is installed on one side of the mounting bracket (701). A grinding wheel variable frequency motor (703) is installed on the output end of the A-axis direct drive motor (702) in conjunction with the motor frame. A grinding wheel transmission chain box (704) is connected to the output end of the grinding wheel transmission chain box (704). A grinding wheel machine (705) is connected to the driven end of the grinding wheel transmission chain box (704). The output end of the grinding wheel machine (705) is fixedly connected to the grinding wheel (706). The second cylinder mounting seat (505) is fixedly connected to one side of the protective cover of the grinding wheel machine (705). The grinding wheel dressing mechanism (800) is a grinding wheel dresser (801), which is fixedly connected to one side of the mounting base (401).

8. A toroidal secondary envelope worm gear grinding machine according to claim 3, characterized in that, The tailstock clamping mechanism (1000) includes a sliding guide rail (1001) fixedly installed on the top of the Z-axis motion table (304). A pin slide seat (1002) is slidably installed on the sliding guide rail (1001). A lead screw nut (1003) is installed inside the pin slide seat (1002). A lead screw (1004) is threaded inside the lead screw nut (1003). A hand crank (1005) is installed at the end of the lead screw (1004). A pin cylinder (1006) is installed on the top of the pin slide seat (1002). A pin (1008) is installed at the output end of the pin cylinder (1006). The pin (1008) is coaxially arranged with the workpiece chuck (404).

9. A toroidal double-envelope worm gear grinding machine according to claim 1, characterized in that, The chip collection mechanism (1100) includes a sloping groove (1101) opened on the top of the bed (100), the sloping groove (1101) is located below the grinding position of the grinding wheel (706) and the workpiece, and the end of the sloping groove (1101) is provided with a chip outlet (1102).

10. A toroidal double-envelope worm gear grinding machine according to claim 7, characterized in that, It also includes a protective cover (1200) installed on the outside of the mounting frame (701). The protective cover (1200) has transparent observation windows (1201) installed on both sides. The protective cover (1200) has a coolant nozzle (1202) inside. The outlet end of the coolant nozzle (1202) passes through the protective cover of the grinding wheel machine (705) and is opposite to the position of the grinding wheel (706). The inlet end of the coolant nozzle (1202) is connected to a soft coolant supply pipe.

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