A special ceramic production vibration polishing machine

Abstract

The application relates to the technical field of ceramic polishing, in particular to a special ceramic production vibration polishing machine, which comprises a base, a polishing cavity and a central column arranged in the polishing cavity, a first piezoelectric sensor, a second piezoelectric sensor and a third piezoelectric sensor are arranged in the polishing cavity, a fourth piezoelectric sensor is arranged in the middle of the side wall of the central column and is used for directly detecting whether a workpiece collides or sinks against the central column, the vibration driving mechanism comprises a main vibration motor and a multi-gear eccentric block assembly, four groups of piezoelectric sensors are arranged at different positions of the polishing cavity and the central column, the signal processing function of the built-in circuit of the controller is matched, the workpiece type and the sinking state are judged, and the problems that the existing vibration polishing equipment cannot distinguish different ceramic types and different working conditions, can only maintain a fixed amplitude and rotating speed and is difficult to adjust the centrifugal force size according to the workpiece floating state in real time, and the workpiece is damaged are solved.

Description

Technical Field

[0001] This invention relates to the field of ceramic polishing technology, and in particular to a vibratory polishing machine for the production of special ceramics. Background Technology

[0002] Alumina ceramics are a type of ceramic. They have high hardness and wear resistance and are commonly used in steel, power, machinery, mining, and chemical industries. After alumina ceramic products are formed, their surfaces need to be polished. Polishing improves the surface quality of alumina ceramic products. The most common polishing method is to use a vibratory polishing machine. The principle is to use the vibration of the vibratory polishing machine and the abrasive media inside the machine to uniformly polish the ceramic surface, removing burrs, flash, micro-protrusions, and surface deposits, thus improving the surface roughness and making the ceramic surface smooth and aesthetically pleasing.

[0003] In actual polishing processes, the immersion state (floating, semi-immersed, fully immersed) of special ceramic workpieces in the media bed dynamically changes with the vibration polishing process. However, existing basic equipment lacks immersion state recognition capabilities and can only operate using fixed vibration parameters, failing to adapt to the polishing requirements of different immersion conditions: When the workpiece is in a floating state, the contact between the grinding media and the workpiece surface is insufficient, resulting in inadequate polishing force and uneven polishing of the workpiece surface, leading to substandard precision. When the workpiece is in a fully immersed state, the excessive pressure exerted by the grinding media on the workpiece easily causes scratches and edge damage to the workpiece surface. When the workpiece is in a semi-immersed state, fixed parameters cannot balance polishing efficiency and workpiece protection, resulting in a low product yield and failing to meet the high-precision polishing requirements of special ceramics.

[0004] During the implementation of the above embodiments, it was found that thin-walled, irregularly shaped, and other fragile special ceramic workpieces are prone to breakage due to improper vibration or impact during polishing. Existing equipment and improved solutions lack accurate workpiece breakage identification functions and rely solely on manual observation of the working conditions, which cannot capture abnormal signals of workpiece breakage in real time, resulting in delayed fault response. Furthermore, broken workpiece fragments can mix with other workpieces, causing more scratches and damage, thus increasing losses. In addition, existing solutions lack clear breakage judgment criteria, which can easily lead to misjudgment or missed judgment, further reducing product yield and increasing production costs. Therefore, there is an urgent need for a polishing solution that can accurately determine whether a workpiece is broken and trigger protection in a timely manner. Summary of the Invention

[0005] The purpose of this invention is to provide a vibratory polishing machine for special ceramic production, which solves the problems of poor adaptability of existing vibratory polishing equipment, lack of automatic differentiation of different ceramic types and different working conditions, and the inability to maintain a fixed amplitude and speed, which makes it difficult to adjust in real time according to the floating state of the workpiece, resulting in workpiece damage.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A vibratory polishing machine for special ceramic production includes a base, a polishing chamber, and a central column disposed therein, and further includes:

[0008] The system comprises a first piezoelectric sensor, a second piezoelectric sensor, a third piezoelectric sensor, and a fourth piezoelectric sensor. The first piezoelectric sensor is used to detect whether the upper edge of the workpiece impacts the upper part of the cavity. The second piezoelectric sensor is used to detect whether the middle part of the workpiece is shaking or tilting. The third piezoelectric sensor is used to detect whether the medium bed is supporting the workpiece. The fourth piezoelectric sensor is located in the middle of the side wall of the central column and is used to directly detect whether the workpiece impacts or rests against the central column.

[0009] A vibration drive mechanism, comprising a main vibration motor and a multi-stage eccentric block assembly, wherein the multi-stage eccentric block assembly is disposed at the end of the output shaft of the main vibration motor.

[0010] Preferably, the multi-stage eccentric block assembly includes a fixed eccentric block and a rotating eccentric block. The fixed eccentric block is fixedly mounted on the output shaft of the main vibration motor, and the rotating eccentric block is rotatably mounted on the output shaft. A circular groove is provided at one end of the fixed eccentric block near the rotating eccentric block, and a worm gear is provided on the rotating eccentric block and inserted into the circular groove. A micro stepper motor is fixedly mounted on the fixed eccentric block, and a worm gear that meshes with the worm gear is provided at the output end of the micro stepper motor to adjust the eccentric mass distribution.

[0011] Preferably, the vibration drive mechanism further includes a plurality of vertically opposite connecting seats fixedly disposed on the top of the base and the bottom of the polishing cavity, a rigid spring being disposed between two vertically opposite connecting seats, and a buffer pad being disposed on the adjacent end faces of the polishing cavity and the central column.

[0012] Preferably, the base is provided with a controller, which includes a start timer, a peak detection circuit and a monostable trigger, and the start timer is set with a 5-second time window.

[0013] Preferably, the first piezoelectric sensor, the second piezoelectric sensor, the third piezoelectric sensor, the fourth piezoelectric sensor, and the micro stepper motor are all electrically connected to the controller, and the main vibration motor is electrically connected to the controller to receive start and stop control from the controller.

[0014] Preferably, when the ceramic workpiece is placed above the medium in the polishing chamber and the main vibration motor is started in low amplitude and low frequency mode, within a time window of 0-5 seconds after startup, the number of pulses N1 and N2 output by the first and second piezoelectric sensors are counted, and the average signal strength V3 of the third piezoelectric sensor is read. If the sum of N1 and N2 is greater than or equal to 3 and V3 is lower than the preset settling threshold, the workpiece is determined to be a thin-walled or irregularly shaped ceramic. At this time, the controller controls the micro stepper motor to move, so that the phase angle of the rotating eccentric block relative to the fixed eccentric block is set to 90°. Regardless of the state of the workpiece sinking, the maximum eccentricity of the multi-stage eccentric block assembly is limited to the medium amplitude stage for polishing.

[0015] Preferably, the ceramic workpiece is placed above the medium inside the polishing chamber, and the main vibration motor is started to run in a low amplitude and low frequency mode. Within 0-5 seconds, the number of pulses N1 and N2 of the first and second piezoelectric sensors are counted, and the average signal strength V3 of the third piezoelectric sensor is read. If N1+N2≥3 and V3 is lower than the preset settling threshold, it is determined to be a thin-walled or irregularly shaped ceramic. The controller controls the micro stepper motor to set the phase angle between the rotating eccentric block and the fixed eccentric block to a safe protection angle of 90°, and locks this phase angle throughout the polishing process so that it does not change with the change of the workpiece's sinking state, thereby limiting the maximum eccentricity of the multi-stage eccentric block assembly to not exceed the medium amplitude stage.

[0016] Preferably, when the workpiece is not determined to be a thin-walled or irregularly shaped ceramic, the rectified voltage V1 of the first piezoelectric sensor and the rectified voltage V3 of the third piezoelectric sensor are obtained, and the fourth piezoelectric sensor is detected to have an effective impact pulse within 0-5 seconds. If V1≥2V3 and there is no effective impact pulse, it is determined to be in a floating state. The controller controls the micro stepper motor to set the phase angle between the rotating eccentric block and the fixed eccentric block to 180°, and uses the minimum amplitude to cause the grinding medium to wrap around the workpiece and guide the workpiece to slowly sink.

[0017] Preferably, when the workpiece is not determined to be a thin-walled or irregularly shaped ceramic, if the third piezoelectric sensor V3≥1.5V1 and the fourth piezoelectric sensor detects at least one effective impact pulse within 0–5 seconds, it is determined to be in a fully submerged state. The controller controls the micro stepper motor to set the phase angle between the rotating eccentric block and the fixed eccentric block to 0°, thereby generating the maximum unidirectional superimposed amplitude.

[0018] Preferably, when the workpiece is not determined to be a thin-walled or irregularly shaped ceramic and does not meet the conditions for floating or fully submerged state, it is determined to be in a semi-submerged state. The phase angle between the rotating eccentric block and the fixed eccentric block is set to a 90° transition angle. When the workpiece is determined to enter the fully submerged state, the micro stepper motor is immediately controlled to automatically adjust the phase angle to 0° and switch to the full amplitude high-efficiency polishing mode.

[0019] Preferably, at any moment during the polishing process, if any piezoelectric sensor detects an impact pulse that lasts for less than 10 milliseconds and has an amplitude exceeding 5 times that of a normal polishing signal, it is determined to be a breakage characteristic pulse. The controller immediately shuts down the entire machine, removes the broken workpiece, and checks whether adjacent workpieces are broken.

[0020] Compared with the prior art, the beneficial effects of the present invention are:

[0021] 1. By configuring four sets of piezoelectric sensors at different positions in the polishing chamber and the central column, full-dimensional monitoring of workpiece impact along the upper edge, mid-section swaying, medium bed bearing capacity, and contact with the central column can be achieved. Combined with the signal processing function of the controller's built-in circuit, the motion characteristics of the workpiece can be quickly captured, thereby determining the workpiece type and sinking state, providing accurate data support for working condition judgment, and solving the problem of workpiece damage caused by blind spots in traditional devices. The multi-level eccentric block assembly adopts a structure that combines fixed eccentric blocks and rotating eccentric blocks. By determining the workpiece type and sinking state, the phase angle can be precisely adjusted through worm gear and worm drive, thereby adapting to the workpiece type and sinking state, and can stably output low, medium, and high amplitudes, effectively avoiding initial impact damage to the workpiece and meeting the polishing power requirements of different types of ceramic workpieces. Attached Figure Description

[0022] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0024] Figure 2 This is a schematic diagram of the structure of the present invention without the buffer pad.

[0025] Figure 3 This is a schematic diagram of the full cross-section structure of the present invention.

[0026] Figure 4 This is a schematic diagram of the structure of the cushioning pad of the present invention.

[0027] Figure 5 This is a schematic diagram of the rotating eccentric block and worm gear of the present invention.

[0028] Figure 6 This is a schematic diagram of the structure of the fixed eccentric block and the micro motor of the present invention.

[0029] In the diagram: 1. Polishing chamber; 101. First piezoelectric sensor; 102. Second piezoelectric sensor; 103. Third piezoelectric sensor; 104. Fourth piezoelectric sensor; 105. Buffer pad; 2. Central column; 3. Vibration drive mechanism; 31. Main vibration motor; 32. Multi-stage eccentric block assembly; 321. Fixed eccentric block; 322. Rotating eccentric block; 323. Circular groove; 324. Worm gear; 325. Worm wheel; 326. Miniature stepper motor; 331. Connecting seat; 332. Hard spring; 4. Base. Detailed Implementation

[0030] 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.

[0031] Example 1

[0032] Alumina ceramics are a type of ceramic. They have high hardness and wear resistance and are commonly used in steel, power, machinery, mining, and chemical industries. After alumina ceramic products are formed, their surfaces need to be polished. Polishing improves the surface quality of alumina ceramic products. The most common polishing method is to use a vibratory polishing machine. The principle is to use the vibration of the vibratory polishing machine and the abrasive media inside the machine to uniformly polish the ceramic surface, removing burrs, flash, micro-protrusions, and surface deposits, thus improving the surface roughness and making the ceramic surface smooth and aesthetically pleasing.

[0033] To resolve the above technical issues, please refer to Figures 1 to 6 As shown, this embodiment provides a vibratory polishing machine for special ceramic production, including a base 4, a polishing cavity 1 and a central column 2 disposed therein, and a vibration drive mechanism 3. The vibration drive mechanism 3 includes a main vibration motor 31 and a multi-stage eccentric block assembly 32. The multi-stage eccentric block assembly 32 is disposed at the output shaft end of the main vibration motor 31. The vibration drive mechanism 3 also includes a plurality of vertically opposite connecting seats 331 fixedly disposed on the top of the base 4 and the bottom of the polishing cavity 1. A hard spring 332 is disposed between two vertically opposite connecting seats 331. A buffer pad 105 is disposed on the adjacent end faces of the polishing cavity 1 and the central column 2.

[0034] The grinding media is slowly poured into the buffer pad 105 inside the polishing chamber 1 by hand, so that the grinding media is evenly spread on the buffer pad 105 to form a medium bed of uniform thickness. This ensures that after the workpiece is placed, the grinding media can completely cover the surface of the workpiece, laying the foundation for full contact between the grinding media and the workpiece during subsequent polishing. At this time, the buffer pad 105 is in a natural fit and does not deform.

[0035] The special ceramic workpiece to be polished is gently placed on the media bed layer by hand, ensuring that the workpiece is placed stably and does not directly contact the inner wall of the polishing cavity 1 or the central column 2. The weight of the workpiece itself will generate slight pressure on the grinding media below, causing the media bed layer to settle slightly. The buffer pad 105 is subjected to slight pressure from the media bed layer and generates slight elastic deformation, which plays a preliminary buffering role and avoids the initial collision between the workpiece and the central column 2 or the inner wall of the polishing cavity 1, thus preventing damage.

[0036] When the power start button of the main vibration motor 31 is pressed manually, the internal rotor of the main vibration motor 31 starts to rotate at high speed. The rotation of the rotor drives the output shaft to rotate at high speed synchronously. The rotation of the output shaft will directly drive the multi-stage eccentric block assembly 32 to rotate synchronously. During the rotation of the multi-stage eccentric block assembly 32, periodic centrifugal force will be generated, which will then generate periodic force on the main vibration motor 31. While starting the main vibration motor 31, it is necessary to observe whether there are ceramic workpieces that cannot sink. If so, it is necessary to manually assist by gently pressing the ceramic workpiece to make it slowly sink into the grinding medium.

[0037] The main vibration motor 31 is fixed on the base 4. The periodic force it receives is transmitted to each hard spring 332 through the base 4, causing the hard spring 332 to perform periodic extension and contraction. The extension and contraction of the hard spring 332 directly drives the polishing cavity 1, which is fixed to the connecting seat 331 on its top, to perform compound vibration in the vertical and horizontal directions. When the polishing cavity 1 vibrates, the grinding media inside it moves together with the polishing cavity 1 under the influence of the vibration. At the same time, due to the gravity and inertia of the grinding media itself, it will tumble and collide in the polishing cavity 1, directly acting on the surface of the workpiece, rubbing and impacting the burrs, flash and small protrusions on the surface of the workpiece, thereby polishing the surface of the workpiece.

[0038] According to the preset polishing time, the power off button of the main vibration motor 31 is pressed manually. After the main vibration motor 31 is powered off, the output shaft and the multi-stage eccentric block assembly 32 slowly stop rotating. The centrifugal force disappears, and each hard spring 332 no longer performs periodic extension and contraction after losing the effect of centrifugal force, and gradually returns to its natural elongation state. Under the reset action of the hard spring 332, the polishing cavity 1 gradually stops vibrating in the vertical and horizontal directions.

[0039] After the polishing chamber 1 stops vibrating, the grinding media inside it gradually stops tumbling under its own gravity and slowly settles on the buffer pad 105. The workpiece also settles with the media bed and eventually sinks above the media bed. The worker first removes the settled workpiece from the media bed, then pours the grinding media out of the polishing chamber 1, and then wipes the inner wall of the polishing chamber 1, the surface of the central column 2 and the surface of the buffer pad 105 to remove residual grinding debris.

[0040] After cleaning, check each component again: the hard spring 332 is not deformed, the multi-position eccentric block assembly 32 is not loose, the buffer pad 105 is not damaged, and the center column 2 is not offset. After confirming that there are no abnormalities, restore each component to its initial standby state and complete one basic polishing cycle.

[0041] By cooperating with the polishing chamber 1, the hard spring 332, and the vibration mechanism, basic vibration polishing of special ceramic workpieces is achieved. The structure is simple, operation is convenient, and manufacturing cost is low. It can meet the basic polishing requirements of special ceramic workpieces, effectively removing burrs, flash, and surface deposits, improving surface roughness, and making the workpiece surface smooth and aesthetically pleasing. The hard spring 332 and the buffer pad 105 can buffer the vibration impact, protecting the equipment structure such as the base 4, polishing chamber 1, and central column 2, as well as the workpiece surface.

[0042] Example 2

[0043] In actual polishing processes, the immersion state (floating, semi-immersed, fully immersed) of special ceramic workpieces in the media bed dynamically changes with the vibration polishing process. However, existing basic equipment lacks immersion state recognition capabilities and can only operate using fixed vibration parameters, failing to adapt to the polishing requirements of different immersion conditions: When the workpiece is in a floating state, the contact between the grinding media and the workpiece surface is insufficient, resulting in inadequate polishing force and uneven polishing of the workpiece surface, leading to substandard precision. When the workpiece is in a fully immersed state, the excessive pressure exerted by the grinding media on the workpiece easily causes scratches and edge damage to the workpiece surface. When the workpiece is in a semi-immersed state, fixed parameters cannot balance polishing efficiency and workpiece protection, resulting in a low product yield and failing to meet the high-precision polishing requirements of special ceramics.

[0044] To resolve the above technical issues, please refer to Figures 1 to 6As shown, the technical solution adopted includes a first piezoelectric sensor 101, a second piezoelectric sensor 102, a third piezoelectric sensor 103, and a fourth piezoelectric sensor 104. The first piezoelectric sensor 101 is used to detect whether the upper edge of the workpiece impacts the upper part of the cavity; the second piezoelectric sensor 102 is used to detect the shaking or tilting state of the middle part of the workpiece; the third piezoelectric sensor 103 is used to detect whether the medium bed supports the workpiece; and the fourth piezoelectric sensor 104 is located in the middle of the side wall of the central column 2 and is used to directly detect whether the workpiece impacts or rests against the central column 2. The first piezoelectric sensor 101, the second piezoelectric sensor 102, the third piezoelectric sensor 103, and the fourth piezoelectric sensor 104 are all annular. The multi-stage eccentric block assembly 32 includes a fixed eccentric block 321 and a rotating... A moving eccentric block 322 and a fixed eccentric block 321 are fixedly mounted on the output shaft of the main vibration motor 31. A rotating eccentric block 322 is rotatably mounted on the output shaft. A circular groove 323 is provided at one end of the fixed eccentric block 321 near the rotating eccentric block 322. A worm gear 325 is inserted into the circular groove 323 on the rotating eccentric block 322. A micro stepper motor 326 is fixedly mounted on the fixed eccentric block 321. A worm 324 meshing with the worm gear 325 is provided at the output end of the micro stepper motor 326 to adjust the eccentric mass distribution. A controller (not shown in the figure) is mounted on the base 4. The controller includes a start timer, a peak detection circuit, and a monostable trigger. The start timer is set with a 5-second time window. A first piezoelectric sensor 101 is also present. The second piezoelectric sensor 102, the third piezoelectric sensor 103, the fourth piezoelectric sensor 104, and the micro stepper motor 326 are all electrically connected to the controller. The main vibration motor 31 is electrically connected to the controller to receive start and stop control. When the ceramic workpiece is placed above the medium in the polishing chamber 1 and the main vibration motor 31 is started to run in low amplitude and low frequency mode, within a time window of 0-5 seconds after start-up, the number of pulses N1 and N2 output by the first piezoelectric sensor 101 and the second piezoelectric sensor 102 are counted, and the average signal strength V3 of the third piezoelectric sensor 103 is read. If the sum of N1 and N2 is greater than or equal to 3 and V3 is lower than the preset settling threshold, the workpiece is determined to be a thin-walled or irregularly shaped ceramic. At this time, the controller controls the micro stepper motor 326 to operate. The phase angle between the rotating eccentric block 322 and the fixed eccentric block 321 is set to 90° and locked throughout the polishing process. Regardless of the subsequent sinking state of the workpiece, the controller will not adjust the phase angle and will maintain medium amplitude operation until the polishing program ends. This prevents the thin-walled workpiece from breaking due to sudden or excessive amplitude changes. When the workpiece is not determined to be thin-walled or irregularly shaped ceramic, the rectified voltage V1 of the first piezoelectric sensor 101 and the rectified voltage V3 of the third piezoelectric sensor 103 are acquired, and the fourth piezoelectric sensor 104 is checked to see if a valid impact pulse is detected within 0–5 seconds. If V1 is greater than or equal to twice V3 and the fourth piezoelectric sensor 104 does not detect a valid impact pulse, the workpiece is determined to be in a floating state.At this time, the controller controls the micro stepper motor 326 to operate, setting the phase angle of the rotating eccentric block 322 relative to the fixed eccentric block 321 to 180°, so as to generate a specific vibration trajectory to induce the workpiece to sink. When the rectified voltage V3 of the third piezoelectric sensor 103 is detected to be greater than or equal to 1.5 times the rectified voltage V1 of the first piezoelectric sensor 101, and the fourth piezoelectric sensor 104 detects at least one effective impact pulse within 0-5 seconds, it is determined that the workpiece is in a fully submerged state. At this time, the controller controls the micro stepper motor 326 to operate, setting the phase angle of the rotating eccentric block 322 relative to the fixed eccentric block 321 to 0°, so as to generate the maximum unidirectional superimposed amplitude. For efficient polishing, if the workpiece is not determined to be thin-walled or irregularly shaped ceramic, and the sensor signal does not meet the criteria for either the floating or fully submerged state, the workpiece is determined to be in a semi-submerged state. At this time, the controller activates the micro-stepping motor 326, setting the phase angle of the rotating eccentric block 322 relative to the fixed eccentric block 321 to 90° to generate moderate centrifugal force to meet the vibration requirements of the transition phase. Simultaneously, the controller continuously monitors the signal from the second piezoelectric sensor 102. Once the workpiece is determined to be in a fully submerged state, the controller immediately activates the micro-stepping motor 326, automatically adjusting the phase angle to 0° and switching to the full-amplitude efficient polishing mode.

[0045] The main power supply of the equipment is manually turned on. After the controller is powered on, it automatically completes the initialization and then performs sensitivity calibration on each piezoelectric sensor. The controller sends calibration commands to the first piezoelectric sensor 101, the second piezoelectric sensor 102, the third piezoelectric sensor 103, and the fourth piezoelectric sensor 104 respectively. After each sensor is powered on, it outputs an initial calibration signal. The signal is transmitted to the controller through the wire. The controller compares the signal with the preset standard signal and automatically adjusts the sensitivity of each sensor to ensure that each sensor can accurately capture the corresponding signal.

[0046] A standard medium bed without workpiece support is laid out. The controller starts the main vibration motor 31. The main vibration motor 31 runs at a low speed, driving the output shaft and the multi-stage eccentric block assembly 32 to rotate, generating low amplitude vibration. The vibration lasts for 5 seconds. During this process, the third piezoelectric sensor 103 collects the pressure signal of the medium bed in real time and transmits the signal to the controller. The controller processes the signal, calculates the average signal amplitude within 5 seconds, takes 80% of the amplitude as the preset settlement threshold, and stores it in the controller database.

[0047] Meanwhile, the controller presets the rectified voltage judgment ratio (V3≥1.5V1, V1≥2V3), where V1 is the rectified voltage of the first piezoelectric sensor 101 and V3 is the rectified voltage of the third piezoelectric sensor 103. All of the above parameters are preset and stored to provide a basis for subsequent sinking state judgment. At this time, the micro stepper motor 326 and the main vibration motor 31 are both in standby state, the fixed eccentric block 321 and the rotating eccentric block 322 maintain the initial included angle of 180°, and the hard spring 332 is in the natural extension state.

[0048] According to the implementation process of the above embodiment 1, the grinding medium is manually poured into the buffer pad 105 inside the polishing cavity 1 to form a uniform medium bed. After the third piezoelectric sensor 103 is powered on, its sensing end face is in close contact with the medium bed. The medium bed generates continuous pressure on the third piezoelectric sensor 103, causing the third piezoelectric sensor 103 to output an electrical signal with an initial stable amplitude. The signal is transmitted to the controller in real time. After receiving the signal, the controller compares it with the preset standard signal of the medium bed to confirm that the medium bed is laid in place and has a uniform thickness.

[0049] Subsequently, the special ceramic workpiece to be processed is gently placed on top of the medium bed. The workpiece's own weight acts on the medium bed, causing slight settling and diffusion. The pressure of the settled medium bed on the third piezoelectric sensor 103 increases, resulting in a slight increase in the signal amplitude output by the third piezoelectric sensor 103 compared to the initial state. The controller detects the change in the signal amplitude of the third piezoelectric sensor 103, and since the change is within the preset range, it determines that the workpiece placement is complete and the position is not offset. At this time, the workpiece remains stable under the action of its own weight and the supporting force of the medium bed, and the buffer pad 105 undergoes slight elastic deformation under the pressure of the medium bed.

[0050] The controller sends a start command, and the main vibration motor 31 is powered on and started. The output shaft of the main vibration motor 31 rotates, which directly drives the fixed eccentric block 321, which is fixedly mounted on it, to rotate synchronously. Since the rotating eccentric block 322 is rotatably connected to the output shaft through a bearing, and the angle between the fixed eccentric block 321 and the rotating eccentric block 322 is 180° in the initial state, when the fixed eccentric block 321 rotates, the rotating eccentric block 322 is driven to rotate synchronously through the slight damping effect of the worm 324 and the worm wheel 325. At this time, the worm wheel 325 and the worm 324 have no relative movement. The rotating eccentric block 322 rotates together with the fixed eccentric block 321. The two together form an eccentric structure and generate a small centrifugal force.

[0051] The centrifugal force generated by the main vibration motor 31 driving the fixed eccentric block 321 and the rotating eccentric block 322 is transmitted to each hard spring 332, causing the hard spring 332 to perform periodic extension and contraction movements, which in turn causes the polishing cavity 1 to perform low-amplitude composite vibrations in the vertical and horizontal directions. The vibration of the polishing cavity 1 causes the internal media bed to vibrate and tumble synchronously, and the tumbling of the media bed causes the workpiece to move slowly.

[0052] Simultaneously, the controller controls the first piezoelectric sensor 101, the third piezoelectric sensor 103, and the fourth piezoelectric sensor 104 to enter the signal acquisition state, and the controller opens a 5-second time window. Each sensor continuously transmits the signals acquired in real time to the controller, providing data support for the sinking state judgment: the first piezoelectric sensor 101 acquires the pulse signal of the upper edge of the workpiece impacting the upper part of the polishing cavity 1, the third piezoelectric sensor 103 acquires the pressure signal of the medium bed carrying the workpiece, and the fourth piezoelectric sensor 104 acquires the impact pulse signal of the workpiece contacting the central column 2.

[0053] After receiving the signals transmitted from each sensor, the peak detection circuit built into the controller performs full-wave rectification processing on the signals, converting the AC pulse signals output by the sensors into DC signals. Then, the RC filter circuit filters out high-frequency noise and extracts stable DC voltage values, namely rectified voltages V1 and V3. The controller calls the preset rectified voltage judgment ratio and, combined with the pulse signal from the fourth piezoelectric sensor 104, comprehensively judges the workpiece sinking status.

[0054] If the rectified voltage V3 of the third piezoelectric sensor 103 is ≥ 1.5 times the rectified voltage V1 of the first piezoelectric sensor 101, and the fourth piezoelectric sensor 104 detects at least one valid impact pulse, the controller determines that the workpiece is fully submerged. If the rectified voltage V1 of the first piezoelectric sensor 101 is ≥ 2 times the rectified voltage V3 of the third piezoelectric sensor 103, and the fourth piezoelectric sensor 104 has no valid pulse signal, the controller determines that the workpiece is floating.

[0055] In other cases, the controller determines that the workpiece is in a semi-submerged state and adaptively adjusts and polishes: Based on the determined submerged state, the controller sends a corresponding adjustment command to the micro stepper motor 326. The micro stepper motor 326 is powered on and starts, and the output shaft of the micro stepper motor 326 rotates synchronously, driving the worm gear 324 to rotate synchronously. The worm gear 324 meshes with the worm wheel 325 fixed on the rotating eccentric block 322. The rotation of the worm gear 324 drives the worm wheel 325 to rotate synchronously. The rotation of the worm wheel 325 directly drives the rotating eccentric block 322, which is fixedly connected to it, to rotate around the axis of the output shaft of the main vibration motor 31, thereby adjusting the phase angle between the fixed eccentric block 321 and the rotating eccentric block 322, changing the eccentric mass distribution, and realizing the amplitude level switching.

[0056] If the special ceramic is determined to be fully submerged, the micro stepper motor 326 drives the rotating eccentric block 322 to rotate, so that the phase angle between the fixed eccentric block 321 and the rotating eccentric block 322 is adjusted to 0°. At this time, the two eccentric blocks are superimposed in the same direction, the eccentricity reaches the maximum, and the centrifugal force generated during rotation is the maximum. After being transmitted to the hard spring 332, the extension and contraction amplitude of the hard spring 332 increases, the vibration amplitude of the polishing cavity 1 increases, and thus enhances the tumbling force of the media bed, ensuring that the grinding media can fully contact the workpiece surface, avoiding the workpiece from sinking to the bottom and getting stuck, and ensuring polishing uniformity.

[0057] If the state is determined to be floating, the micro stepper motor 326 does not move, and the initial phase angle between the fixed eccentric block 321 and the rotating eccentric block 322 is maintained at 180°. The eccentricity is minimized, the centrifugal force generated during rotation is minimized, the polishing cavity 1 maintains low amplitude vibration, and the rolling force of the media bed is moderate, so that the workpiece slowly sinks into the media bed under its own gravity and the rolling action of the grinding media.

[0058] If the semi-submerged state is determined, the micro stepper motor 326 drives the rotating eccentric block 322 to rotate, so that the phase angle is adjusted to 90°. The two eccentric blocks form a moderate eccentricity, generating a moderate centrifugal force. The polishing cavity 1 is in a medium amplitude vibration state, which not only ensures the tumbling force of the grinding media to achieve efficient polishing, but also avoids the workpiece from hitting the inner wall of the polishing cavity 1 or the central column 2 due to excessive amplitude, thus protecting the surface of the workpiece.

[0059] After the amplitude adjustment is completed, the main vibration motor 31 continues to rotate, driving the multi-stage eccentric block assembly 32 to maintain the current phase angle rotation. The hard spring 332 continues to extend and retract with the centrifugal force, the polishing chamber 1 maintains the corresponding amplitude of composite vibration, the medium bed continues to tumble, polishing the workpiece surface, each piezoelectric sensor continuously collects signals, the controller monitors the sinking state in real time, and if the state changes, the phase angle is adjusted synchronously.

[0060] After the preset polishing time is reached, the controller sends a stop command, the main vibration motor 31 is de-energized, and then the multi-stage eccentric block assembly 32 slowly stops rotating. The centrifugal force disappears, the hard spring 332 loses the effect of centrifugal force, and gradually returns to its natural elongation state. After the hard spring 332 is reset and stabilized, the polishing chamber 1 gradually stops vibrating. The media bed and the workpiece stop moving with the polishing chamber 1 and gradually settle under their own gravity. The workpiece eventually sinks above the media bed.

[0061] The controller de-energizes the first piezoelectric sensor 101, the third piezoelectric sensor 103, the fourth piezoelectric sensor 104, and the micro stepper motor 326, causing all components to stop working. The workpiece and polishing medium are manually removed, and the inner wall of the polishing chamber 1, the central column 2, the sensing end faces of each sensor, and the buffer pad 105 are wiped. After checking that there are no abnormalities in each component, the micro stepper motor 326 drives the rotating eccentric block 322 to reset to the initial phase angle of 180° with the fixed eccentric block 321. All components return to the initial standby state, completing one polishing cycle.

[0062] Through the coordinated monitoring of the first piezoelectric sensor 101, the third piezoelectric sensor 103, and the fourth piezoelectric sensor 104, combined with the signal processing and judgment logic of the controller's peak detection circuit, the three states of floating, semi-submerged, and fully submerged can be accurately distinguished. This avoids problems such as uneven polishing and workpiece damage caused by fixed parameters. The amplitude switching is achieved by adjusting the angle of the fixed eccentric block 321 and the rotating eccentric block 322, matching the optimal polishing force for different submerged states. This ensures polishing accuracy while protecting the workpiece surface, significantly improving the product yield. The entire identification and control process is automated, requiring no manual intervention, reducing the difficulty of operation, and adapting to the high-precision, large-scale polishing needs of special ceramics. It solves the technical problem that existing basic equipment cannot adapt to different submerged working conditions.

[0063] Example 3

[0064] During the implementation of the above embodiments, it was found that thin-walled, irregularly shaped, and other fragile special ceramic workpieces are prone to breakage due to improper vibration or impact during polishing. Existing equipment and improved solutions lack accurate workpiece breakage identification functions and rely solely on manual observation of the working conditions, which cannot capture abnormal signals of workpiece breakage in real time, resulting in delayed fault response. Furthermore, broken workpiece fragments can mix with other workpieces, causing more scratches and damage, thus increasing losses. In addition, existing solutions lack clear breakage judgment criteria, which can easily lead to misjudgment or missed judgment, further reducing product yield and increasing production costs. Therefore, there is an urgent need for a polishing solution that can accurately determine whether a workpiece is broken and trigger protection in a timely manner.

[0065] Based on the above embodiments, in order to solve the above technical problems, please refer to... Figures 1 to 6 As shown, the technical solution adopted is as follows: when any piezoelectric sensor detects an impact pulse with a duration of less than 10 milliseconds and an amplitude exceeding 5 times the maximum value of the normal polishing signal at any time during the polishing process, it is determined that a breakage characteristic pulse has been detected. At this time, the controller immediately cuts off the power supply of the main vibration motor 31 and stops the operation of the micro stepper motor 326, and at the same time shuts down the vibration polishing machine, removes the broken workpiece, and detects whether the adjacent ceramic workpiece is broken.

[0066] Multiple ceramic workpieces of the same type as the workpiece to be polished are manually selected for polishing. The controller controls the main vibration motor 31 to start with different amplitudes in order to establish a database of workpiece breakage under different polishing conditions. During the polishing of special ceramics, the first piezoelectric sensor 101, the second piezoelectric sensor 102, the third piezoelectric sensor 103, and the fourth piezoelectric sensor 104 collect the impact pulse signal when the workpiece breaks in real time. After the signal is transmitted to the controller, it is first processed by the peak detection circuit and converted into a DC signal before being transmitted to the monostable trigger.

[0067] The monostable trigger identifies the duration and amplitude of the rupture pulse, calibrates the maximum value of the normal polishing signal, and then sets a rupture judgment threshold of "duration < 10 milliseconds and amplitude exceeding 5 times the maximum value of the normal polishing signal" and stores it in the controller database.

[0068] Simultaneously, the sensitivity of the second piezoelectric sensor 102 is calibrated. The controller sends a calibration command to the second piezoelectric sensor 102, and the sensor outputs a calibration signal when powered on. The controller compares the signal with the standard signal and adjusts the sensitivity of the second piezoelectric sensor 102 to ensure that it can accurately capture the shaking, tilting signals and impact signals when the workpiece breaks. At this time, all components are in standby mode. The fixed eccentric block 321 and the rotating eccentric block 322 maintain an initial phase angle of 180°. The hard spring 332 is in a naturally extended state, and all sensors are in a power-off standby state.

[0069] According to the implementation process of the above embodiment, the grinding media is laid out, the third piezoelectric sensor 103 is energized to collect the initial signal, the controller confirms that the media bed is laid out in place, the workpiece is gently placed on the media bed by the operator, and the controller determines that the workpiece placement is complete by the signal change of the third piezoelectric sensor 103.

[0070] Subsequently, the controller sends a start command, the main vibration motor 31 is powered on and starts, driving the output shaft and multi-stage eccentric block assembly 32 to rotate. The hard spring 332 extends and retracts with centrifugal force, driving the polishing cavity 1 to perform low-amplitude compound vibration. The media bed layer tumbles with the vibration of the polishing cavity 1, driving the workpiece to move slowly.

[0071] Simultaneously, the controller controls the first piezoelectric sensor 101, the second piezoelectric sensor 102, the third piezoelectric sensor 103, and the fourth piezoelectric sensor 104 to enter the signal acquisition state. The monostable trigger is synchronously powered on and enters the signal discrimination state. The controller opens a 5-second time window, and each sensor continuously transmits the signals acquired in real time to the controller. The first piezoelectric sensor 101 acquires the impact signal at the upper edge of the workpiece, the second piezoelectric sensor 102 acquires the shaking and cracking signal in the middle of the workpiece, the third piezoelectric sensor 103 acquires the pressure signal of the medium bed, and the fourth piezoelectric sensor 104 acquires the contact signal between the workpiece and the central column 2.

[0072] After the controller completes the sinking state judgment, it sends an adjustment command to the micro stepper motor 326. The micro stepper motor 326 drives the rotating eccentric block 322 to rotate, and adjusts the phase angle between the fixed eccentric block 321 and the rotating eccentric block 322 to the corresponding position. The polishing cavity 1 switches to the corresponding amplitude and enters the normal polishing stage.

[0073] During normal polishing, the main vibration motor 31 rotates continuously, driving the multi-stage eccentric block assembly 32 to maintain the current phase angle rotation, the hard spring 332 continuously performs periodic extension and contraction movements, the polishing cavity 1 maintains a composite vibration with the corresponding amplitude, the media bed continuously tumbles, polishing the workpiece surface, and the workpiece moves synchronously with the media bed.

[0074] Each piezoelectric sensor collects signals from the workpiece's movement and contact process in real time. After the signals are transmitted to the controller, they are first rectified and filtered by a peak detection circuit to convert them into stable DC signals, and then transmitted to a monostable multivibrator. The monostable multivibrator identifies the duration and amplitude of the signal in real time and feeds the identification results back to the controller. The controller compares the identified signals with a preset fracture judgment threshold. If any impact pulse signal detected by any piezoelectric sensor meets the condition of "duration < 10 milliseconds and amplitude exceeding 5 times the maximum value of a normal polishing signal", it is determined to be a workpiece fracture signal. If the signal does not meet the above conditions, it is determined to be a normal polishing signal, and the equipment continues to maintain normal polishing state.

[0075] After the controller determines that the workpiece is broken, it immediately sends an emergency stop command, instantly cutting off the power to the main vibration motor 31 and the micro stepper motor 326. After the main vibration motor 31 is de-energized, the internal rotor decelerates rapidly, the output shaft and the multi-stage eccentric block assembly 32 immediately stop rotating, the centrifugal force disappears instantly, the hard spring 332 loses the centrifugal force, stops its extension and retraction, and quickly returns to its natural elongation state. Under the reset action of the hard spring 332, the polishing chamber 1 quickly stops vibrating in the vertical direction. After the polishing chamber 1 stops vibrating, the media bed and workpiece fragments stop tumbling and gradually settle.

[0076] Simultaneously, the controller records the characteristics of the rupture signal, such as amplitude, duration, trigger time, and current operating parameters, such as amplitude setting and sensor signals, to facilitate subsequent investigation of the cause of the rupture. The manual immediately opens the polishing chamber 1, first removes the ruptured workpiece and fragments, and then checks whether adjacent workpieces are scratched or damaged by the fragments. If there are any damaged workpieces, they are removed together. Subsequently, the inner wall of the polishing chamber 1, the surface of the central column 2, the sensing end face of each sensor, and the buffer pad 105 are carefully cleaned with cleaning tools to remove residual workpiece fragments and grinding debris, ensuring that the sensing end face of each sensor is unobstructed and undamaged, and that the buffer pad 105 is undamaged.

[0077] After cleaning, manually check the status of each component: the hard spring 332 is not deformed, the multi-stage eccentric block assembly 32 is not loose, each sensor is not damaged, the buffer pad 105 is not damaged, and the center column 2 is not offset. After confirming that there are no abnormalities, manually restart the main power supply of the equipment, the controller is powered on to complete the initialization, and the preset parameters are re-called to recalibrate each sensor.

[0078] Subsequently, following the previous procedure, the grinding media is re-laid, the workpiece to be polished is placed, and the controller again completes the sinking state judgment and amplitude adjustment, and starts the polishing operation. If, during the entire polishing process, none of the piezoelectric sensors detect a breakage signal that meets the conditions, until the preset polishing time is reached, the controller sends a normal stop command, the main vibration motor 31 stops smoothly, all components reset according to the conventional procedure, the workpiece is manually removed, the equipment is cleaned, and the polishing cycle is completed.

[0079] By judging the number of impacts on special ceramic workpieces and other signals, the shortcomings of no abnormality monitoring and delayed fault response are made up for. By adding a second piezoelectric sensor 102 and a monostable trigger, the accurate identification of workpiece fracture is realized, avoiding secondary damage caused by fracture fragments, solving the problem of easy misjudgment and omission by manual observation, and significantly reducing production costs.

[0080] Meanwhile, a new emergency protection function for breakage has been added. This not only continues the advantages of precise adaptation to working conditions, protection of workpiece surface, and improvement of yield rate, but also further improves the abnormal protection system of the equipment. It solves the problem of breakage in the polishing process of thin-walled, irregularly shaped and other fragile special ceramics, making the equipment more suitable for the actual needs of high-precision and large-scale production of special ceramics. At the same time, the fault signal recording function also provides data support for subsequent equipment optimization and investigation of the cause of breakage, further reducing the difficulty of operation and maintenance.

[0081] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A vibratory polishing machine for special ceramic production, comprising a base, a polishing chamber, and a central column disposed therein, characterized in that, Also includes: The system comprises a first piezoelectric sensor, a second piezoelectric sensor, a third piezoelectric sensor, and a fourth piezoelectric sensor. The first piezoelectric sensor is used to detect whether the upper edge of the workpiece impacts the upper part of the cavity. The second piezoelectric sensor is used to detect whether the middle part of the workpiece is shaking or tilting. The third piezoelectric sensor is used to detect whether the medium bed is supporting the workpiece. The fourth piezoelectric sensor is located in the middle of the side wall of the central column and is used to directly detect whether the workpiece impacts or rests against the central column. A vibration drive mechanism, comprising a main vibration motor and a multi-stage eccentric block assembly, wherein the multi-stage eccentric block assembly is disposed at the end of the output shaft of the main vibration motor.

2. The vibratory polishing machine for special ceramic production according to claim 1, characterized in that, The multi-stage eccentric block assembly includes a fixed eccentric block and a rotating eccentric block. The fixed eccentric block is fixedly mounted on the output shaft of the main vibration motor, and the rotating eccentric block is rotatably mounted on the output shaft. The micro stepper motor is fixedly mounted on the fixed eccentric block. A circular groove is formed at one end of the fixed eccentric block near the rotating eccentric block. The rotating eccentric block is provided with a worm gear inserted into the circular groove. The output end of the micro stepper motor is provided with a worm that meshes with the worm gear to adjust the eccentric mass distribution.

3. The vibratory polishing machine for special ceramics production according to claim 2, characterized in that, The vibration drive mechanism also includes multiple vertically opposite connecting seats fixedly installed on the top of the base and the bottom of the polishing cavity. A stiff spring is provided between two vertically opposite connecting seats, and a buffer pad is provided on the adjacent end faces of the polishing cavity and the central column.

4. The vibratory polishing machine for special ceramic production according to claim 3, characterized in that, The base is equipped with a controller, which includes a start timer, a peak detection circuit and a monostable trigger. The start timer is set with a 5-second time window.

5. A vibratory polishing machine for special ceramic production according to claim 4, characterized in that, The first piezoelectric sensor, the second piezoelectric sensor, the third piezoelectric sensor, the fourth piezoelectric sensor, and the micro stepper motor are all electrically connected to the controller, and the main vibration motor is electrically connected to the controller to receive start and stop control from the controller.

6. A vibratory polishing machine for special ceramic production according to claim 5, characterized in that, The ceramic workpiece is placed above the medium inside the polishing chamber. The main vibration motor is started and runs in a low amplitude, low frequency mode. Within 0-5 seconds, the number of pulses N1 and N2 of the first and second piezoelectric sensors are counted, and the average signal strength V3 of the third piezoelectric sensor is read. If N1+N2≥3 and V3 is lower than the preset settling threshold, it is determined to be a thin-walled or irregularly shaped ceramic. The controller controls the micro stepper motor to set the phase angle between the rotating eccentric block and the fixed eccentric block to a safe protection angle of 90°. This phase angle is locked throughout the polishing process and does not change with the change of the workpiece's sinking state. The maximum eccentricity of the multi-stage eccentric block assembly is limited to the medium amplitude stage.

7. A vibratory polishing machine for special ceramics production according to claim 6, characterized in that, When the workpiece is not determined to be a thin-walled or irregularly shaped ceramic, the rectified voltage V1 of the first piezoelectric sensor and the rectified voltage V3 of the third piezoelectric sensor are obtained. The fourth piezoelectric sensor is checked for an effective impact pulse within 0–5 seconds. If V1 ≥ 2V3 and there is no effective impact pulse, it is determined to be in a floating state. The controller controls the micro stepper motor to set the phase angle between the rotating eccentric block and the fixed eccentric block to 180°. The minimum amplitude is used to cause the grinding medium to wrap around the workpiece and guide the workpiece to slowly sink.

8. A vibratory polishing machine for special ceramic production according to claim 7, characterized in that, When the workpiece is not determined to be a thin-walled or irregularly shaped ceramic, if the third piezoelectric sensor V3≥1.5V1 and the fourth piezoelectric sensor has at least one effective impact pulse within 0–5 seconds, it is determined to be in a fully submerged state. The controller controls the micro stepper motor to set the phase angle between the rotating eccentric block and the fixed eccentric block to 0°, generating the maximum unidirectional superimposed amplitude.

9. A vibratory polishing machine for special ceramics production according to claim 8, characterized in that, If the workpiece is not determined to be a thin-walled or irregularly shaped ceramic and does not meet the conditions for floating or fully submerged state, it is determined to be in a semi-submerged state. The phase angle between the rotating eccentric block and the fixed eccentric block is set to a 90° transition angle. When the workpiece is determined to enter the fully submerged state, the micro stepper motor is immediately controlled to automatically adjust the phase angle to 0° and switch to the full amplitude high-efficiency polishing mode.

10. A vibratory polishing machine for special ceramic production according to claim 9, characterized in that, If, at any moment during the polishing process, any piezoelectric sensor detects an impact pulse lasting less than 10 milliseconds and with an amplitude exceeding 5 times that of the normal polishing signal, it is determined to be a breakage characteristic pulse. The controller immediately shuts down the entire machine, removes the broken workpiece, and checks whether adjacent workpieces are broken.

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