Method and apparatus for performing multiple manufacturing operations on an object

Abstract

To provide a multi-tool positioning and manufacturing system capable of automatically, quickly, repeatedly, and accurately moving a workpiece between tools without any manual intervention, and grinding an inner diameter, an outer diameter, and a rib of a taper roller bearing cone.SOLUTION: A multi-tool positioning and manufacturing system 200 moves a workpiece among many tools, such as grinding wheels 5 and 7, each of which performs a manufacturing operation on the workpiece. Because a machinist has no need to move the workpiece between machines for different operations, a total manufacturing process can be faster and higher yield rather than using separate tools. The system 200 can also move a single dresser 12 among the tools for dressing and adjusting, further increase manufacturing efficiency by eliminating need for separate dressers for the separate tools.SELECTED DRAWING: Figure 2

Description

[Background technology]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application is filed on June 12, 2018, under 35 U.S.C. § 119(e), entitled "Mechanism for performing multiple This application claims the benefit of priority to U.S. patent application Ser. No. 62 / 683,921, entitled "Manufacturing Operations on an Object," which is incorporated herein by reference in its entirety.

[0002] Typically, manufacturing a part such as a bearing involves multiple machining and / or manufacturing operations. Each operation is performed using different tooling, and the part is moved from machine to machine. Once moved to the machine, the part is precisely positioned, usually by the machinist operating the machine, so the machine can accurately perform the manufacturing operation. When that operation is complete, the machinist removes the part from the tooling, such as a shoe or chuck, and moves it across the shop floor to the next machine, where the machinist positions the part for that machine with different tooling. This positioning and repositioning process is costly and time-consuming, especially for complex parts. Additionally, each machine requires its own precision positioning system, grinding spindle that rotates the grinding wheel at high speed, and grinding wheel dressing system and tooling.

[0003] For example, consider a machined tapered roller bearing 100 such as that shown in FIG. 1. When assembled, tapered roller bearing 100 has a tapered rolling element 106 held by a cage 108 between an outer ring 102, also called the cup or outer race, and an inner ring 104, also called the cone or inner race. To perform the precision grinding operations necessary to manufacture the cone 104 of this tapered roller bearing 100, three separate grinding machines are required: one to grind the inside / inner diameter (ID), one to grind the outside / outer diameter (OD), and one to grind the ribs. Similarly, precision grinding of fuel injectors for internal combustion engines uses three separate machines: one to grind the inlet bore, one to grind the check valve seat, and one to grind the outlet bore. Summary of the Invention

[0004] The inventive precision positioning and manufacturing system can perform numerous manufacturing operations on a single part without having to manually adjust the part between operations. This also eliminates the need for separate precision positioning systems and grinding wheel dressing systems and tooling for multiple machines. Instead, a single precision positioning system and a single grinding wheel dresser can be used to perform numerous different grinding operations. For example, the inventive precision positioning and manufacturing system can perform three different grinding operations (e.g., grinding the ID, OD, and ribs of a tapered roller bearing) using three grinding wheels, only one precision positioning system, only one grinding wheel dressing system, and only one tooling set. This significantly reduces the capital equipment costs required to produce a part. In addition to reducing capital costs, quality is also improved by performing all operations with the same tooling. This also reduces transportation time and costs associated with producing a part by eliminating the need to move the part between three different grinding machines.

[0005] A system for performing multiple manufacturing processes may include a work head, a first tool, a second tool, and a positioning system supporting the work head. During operation, the work head holds a workpiece, the first tool performs a first machining operation on the workpiece, and the second tool performs a second machining operation on the workpiece. A second tool performs a second machining operation on the workpiece, and the positioning system linearly moves the workhead and workpiece in a plane intersecting the first and second tools and also rotates the workhead and workpiece about an axis perpendicular to the plane intersecting the first and second tools.

[0006] The first tool and the second tool can be a first grinding wheel and a second grinding wheel, respectively. The system can also include a grinding wheel dresser mounted on the positioning system. The positioning system moves the grinding wheel dresser in a plane intersecting the first grinding wheel and the second grinding wheel. The grinding wheel dresser then dresses the first grinding wheel and the second grinding wheel.

[0007] The positioning system can move the workpiece from the first tool to the second tool while the workpiece is on the work head, which can rotate the workpiece about its axis of symmetry.

[0008] The first axis may be an axis perpendicular to a plane intersecting the first tool and the second tool. The positioning system may include a first rotary table, a second rotary table, and a third rotary table. During operation, the first rotary table rotates about the first axis. The second rotary table supports the first rotary table and rotates about a second axis parallel to the first axis and perpendicular to the plane intersecting the first tool and the second tool. The second rotary table supports the first rotary table and rotates about a second axis parallel to the first axis and perpendicular to the plane intersecting the first tool and the second tool. The third rotary table supports the second rotary table and rotates about a third axis parallel to the first axis and the second axis and perpendicular to the plane intersecting the first tool and the second tool.

[0009] Alternatively, the positioning system may include a rotary table, a first slide supporting the rotary table, and a second slide supporting the first slide. The rotary table also rotates the work head about an axis perpendicular to a plane intersecting the first tool and the second tool. The first slide moves the work head and rotary table in a first direction within the plane intersecting the first tool and the second tool. The second slide moves the work head, rotary table, and first slide in a second direction different from the first direction within the plane intersecting the first tool and the second tool.

[0010] The system may include a spindle operably coupled to the first tool for rotating the first tool relative to the workpiece, and may also include a controller operably coupled to the positioning system for causing the positioning system to move the workpiece between the first tool and the second tool according to the movement plan, and may include a slide operably coupled to the first tool for translating the first tool in a plane relative to the workpiece.

[0011] A method for manufacturing a part from a workpiece includes securing the workpiece to a work head. Once the workpiece is secured, an eccentric positioning system moves the workpiece in the work head to a first tool, which performs a first manufacturing operation on the workpiece while it is in the work head. The eccentric positioning system moves the workpiece in the work head from the first tool to a second tool (e.g., within one minute) and performs a second manufacturing operation on the workpiece while it is in the work head. For example, the first and second manufacturing operations may include grinding the inner and outer diameters of a bearing or other part. After the second manufacturing operation is completed, the workpiece can be removed from the work head.

[0012] In some cases, a dresser (e.g., a rotary diamond dresser) mounted on an eccentric positioning system dresses a first tool, the eccentric positioning system moves the dresser from the first tool to a second tool, and the dresser dresses the second tool.

[0013] The multi-tool positioning and manufacturing system may also include a top plate, a work head, a first spindle, a second spindle, a third spindle, and an eccentric positioning system. The work head supports a workpiece in a plane parallel to the top plate. The first spindle, the second spindle, and the third spindle supported by the top plate spin the first grinding wheel, the second grinding wheel, and the third grinding wheel, respectively, in a plane parallel to the top plate. The eccentric positioning system supporting the work head and the grinding wheel dresser also moves the work head and the workpiece in the plane parallel to the first grinding wheel, to the second grinding wheel, and to the third grinding wheel.

[0014] The work head is capable of rotating the workpiece about its axis of symmetry.

[0015] The eccentric positioning system allows the work head to move laterally in a plane parallel to the top plate and to rotate about an axis perpendicular to the plane parallel to the top plate.

[0016] The positioning and manufacturing system, such as a multi-tool, may also include a first slide and a second slide mounted to the top plate, the first slide supporting and linearly translating the first and second spindles in a plane parallel to the top plate, and the second slide supporting and linearly translating the third spindle in a plane parallel to the top plate.

[0017] The multi-tool positioning and manufacturing system can also include a grinding wheel dresser mounted on the eccentric positioning system. The eccentric positioning system moves the grinding wheel dresser in a plane parallel to the upper plate. The dresser dresses the first grinding wheel, the second grinding wheel, and the third grinding wheel.

[0018] The eccentric positioning system may include a first rotary table, a second rotary table, and a third rotary table, where the first rotary table has a first axis of rotation, the second rotary table is mounted on the first rotary table and has a second axis of rotation parallel to the first axis of rotation, and the third rotary table is mounted on the second rotary table and has a third axis of rotation parallel to the first and second axes of rotation.

[0019] In one embodiment, the system uses eccentric rotational movement to position an object in three degrees of freedom, providing translational movement in a plane and rotation of the item about an axis perpendicular to that plane. In this embodiment, all tools are in fixed positions.

[0020] In another embodiment, the system uses eccentric rotational motion to position an object in three degrees of freedom, providing translational motion in a plane and rotation of the item about an axis perpendicular to that plane. In this embodiment, one or more tools can be moved in a direction or directions of interest along one or more translational axes.

[0021] In yet another embodiment, the system uses two linear positioning systems and a rotary table positioned at right angles to one another to position an object in three degrees of freedom, providing linear movement in a plane and rotation of the item about an axis perpendicular to that plane. All tools are in fixed positions.

[0022] In yet another embodiment, the system uses two linear positioning systems and a rotary table positioned at right angles to one another to position an object in three degrees of freedom, providing linear translation in a plane and rotation of the object about an axis orthogonal to the plane. In this embodiment, one or more tools can be moved in a direction or directions of interest along one or more linear translation axes. [Brief explanation of the drawings]

[0023] Other objects, features and advantages will occur to those skilled in the art from the following description of preferred embodiments of the present invention and the accompanying drawings.

[0024] [Figure 1] FIG. 1 shows an exploded view of a tapered roller bearing in which the cone (inner race) is made using three separate grinding operations: (1) grinding the inside diameter (ID), (2) grinding the outside diameter (OD), and (3) grinding the ribs. [Figure 2] A multi-tool precision positioning and manufacturing system is shown that includes a fixed tool and uses eccentric rotational movement to position an object, such as a workpiece supported by tooling rotated by a work head, with three degrees of freedom in a plane that includes the fixed tool. [Figure 3A]FIG. 3 is a perspective view of an eccentric positioning system suitable for moving objects in the multi-tool precision positioning and manufacturing system of FIG. [Figure 3B] FIG. 1 is a simplified top view of the bearings of a three-rotary eccentric positioning system suitable for positioning and repositioning a workpiece on a work head in a multi-tool precision positioning and manufacturing system. [Figure 3C] ~ [Figure 3D] 3C illustrates how a three-rotary eccentric positioning system can move an object, such as a workpiece on a work head, approximately 14 inches in a generally linear fashion from the position shown in FIG. 3C to the position shown in FIG. 3D. [Figure 3E] ~ [Figure 3F] FIG. 3 illustrates how three rotary eccentric positioning systems can move an object, such as a workpiece on a work head, in the "X" direction from the position shown in FIG. 3E (which is the same as the position shown in FIG. 3D) to the position shown in FIG. 3F. [Figure 4] 3 shows a flowchart for manufacturing a part using the multi-tool precision positioning and manufacturing system of FIG. 2. [Figure 5] 1 shows a multi-tool precision positioning and manufacturing system in which the work head is mounted on an eccentric positioning system and the tools are mounted on linear slides. [Figure 6] A multi-tool precision positioning and manufacturing system is shown having a fixed tool, a linear X-slide and a linear Z-slide, and a rotary table for positioning an object such as a workpiece on a work head in three degrees of freedom in a plane containing the fixed tool. [Figure 7] The linear X-slide and linear Z-slide and rotary table of FIG. 6 are shown. [Figure 8] A multi-tool precision positioning and manufacturing system is shown having a tool mounted on a linear slide, a linear X-slide and a linear Z-slide, and a rotary table for positioning an object such as a workpiece on a work head in three degrees of freedom in a plane containing the fixed tool. DETAILED DESCRIPTION OF THE INVENTION

[0025] The multi-tool precision positioning and manufacturing system can perform multiple manufacturing operations on a single part. For example, it can grind the inner and outer diameters of the inner and outer rings of a ball bearing, the inner diameter, outer diameter, and ribs of the inner ring of a tapered roller bearing, or three grinding operations to create a fuel injector. Furthermore, it can perform successive operations without any need to manually align or position the part between operations. The precision positioning system can move the part from tool to tool with an accuracy of 0.05 microns in under 60 seconds. The grinding operations are completed in less than 30 seconds (e.g., less than 15 seconds, less than 10 seconds, less than 5 seconds, less than 1 second, or even less than 0.5 seconds). If each manufacturing operation takes about 10 seconds, the total time for the three operations is less than 31 seconds. In contrast, simply transferring a workpiece from one grinding machine to another can take several minutes, which is longer than it would take to perform all the grinding operations using a multi-tool precision positioning and manufacturing system.

[0026] Replacing many tools with a single multi-tool precision positioning and manufacturing system also offers other advantages. First, a single multi-tool precision positioning and manufacturing system has a higher yield than two or more separate tools because parts are not moved from tooling to tooling or machine to machine, reducing the chance of misalignment. For example, when using a multi-tool precision positioning and manufacturing system to perform three grinding operations, the machinist places the part in the shoe only once, and there is only one chance for the part to be misaligned relative to the shoe. When performing three grinding operations on three separate grinding machines, the machinist must place the part in three separate shoes, and there are three chances for the part to be misaligned relative to the shoe. If a misalignment occurs during any of these situations, the part could be ruined.

[0027] The use of a single multi-tool precision positioning and manufacturing system instead of multiple tools also reduces energy consumption. Because systems and tools each consume approximately the same amount of baseline idle current, replacing conventional tools with fewer multi-tool precision positioning and manufacturing systems reduces total baseline current consumption. Additionally, a single multi-tool precision positioning and manufacturing system consumes less power to move and position workpieces than the total power consumed by separate machines to move and position the workpieces.

[0028] Additionally, a single multi-tool precision positioning and manufacturing system is more compact than the multiple tools it replaces. As a result, the system can be used in a smaller machine shop, or the machine shop can be made smaller. This translates into lower construction costs, rent, heating and cooling costs, etc. for the manufacturing facility. It also uses fewer components (e.g., one controller per tool vs. a single controller, one dressing system per tool vs. a single controller-dressing system, etc.), and is therefore less expensive than the multiple tools it replaces. All of this means that a multi-tool precision positioning and manufacturing system can be cheaper to purchase and operate than the multiple tools it replaces. Multi-tool positioning and manufacturing system with eccentric positioning

[0029] 2 shows a multi-tool positioning and manufacturing system 200 having an eccentric positioning system 2. The system 200 includes a base 1 that houses and protects the eccentric positioning system 2. The base 1 also supports a top plate 3, which in turn supports two or more tools. In this example, the top plate 3 supports a first tool 5 mounted on a first powered grinding spindle 4, a second tool 7 mounted on a second powered grinding spindle 6, a third tool 9 mounted on a third powered grinding spindle 8, and a non-turning tool 13. The first tool 5, second tool 7, third tool 9, and non-turning cutting tool 13 all intersect a plane that is parallel to the top plate 3.

[0030] The top plate 3 also defines a hole or opening for accessing the eccentric positioning system 2. The eccentric positioning system 2 or a work head 10 mounted on top of the eccentric positioning system 2 protrudes through this hole, allowing the eccentric positioning system 2 to be mounted on the top plate. The eccentric positioning system 2 allows the work head 10 to move relative to the components mounted on the top plate 3. The work head 10 locates, supports, and rotates a workpiece 11, such as the inner race of a tapered roller bearing made of hardened steel, about its axis of symmetry in the same plane that intersects the first tool 5, the second tool 7, the third tool 9, and the non-rotating cutting tool 13 and is parallel to the top plate 3. The eccentric positioning system 2 also supports and moves in this plane a rotating diamond dresser 12 for dressing and / or shaping the grinding wheels 5, 7, and 9 shown in FIG. 2, as described below.

[0031] The workpiece 11 may be secured to the work head 10 using tooling such as a shoe or chuck. During operation, the work head 10 can rotate the chuck or (magnetic) backing plate, which in turn rotates the workpiece 11. Installing the tooling (e.g., shoe and backing plate) on the work head 10 typically takes 30 to 60 minutes. Once the tooling is properly installed, the workpiece 11 (e.g., the part to be ground) can be secured to the tooling by a machine operator, robot, or dedicated workpiece loading / unloading mechanism. The machine operator, robot, or dedicated workpiece loading / unloading mechanism can also remove any parts that have just been ground. The length of time it takes to replace a ground part with an unground ("black") part varies depending on the part size, the type of tooling (e.g., three-jaw chuck, magnetic chuck, or shoe tooling), and the loading system (e.g., manual, dedicated electromechanical system, or general-purpose robot), and can take anywhere from 1 second to 20 minutes.

[0032] During operation, the eccentric positioning system 2 positions the workpiece 11 and work head 10 with three degrees of freedom in a plane parallel to the base 1. That is, the eccentric positioning system 2 can move the workpiece 11 linearly in that plane (two-dimensional translation) and rotate the workpiece 11 about an axis perpendicular to that plane (one-dimensional rotation). The eccentric positioning system 2 moves the workpiece 11 (and work head 10) to a particular tool, holds the workpiece 11 in place as the tool removes material from the workpiece 11, and then automatically moves the workpiece to the next tool. The workpiece 11 remains on the work head 10 during all operations performed by the tool, eliminating the need for any manual repositioning between operations with different tools.

[0033] For example, consider the fabrication of a tapered roller bearing cone using the multi-tool positioning and manufacturing system 200 of FIG. 2. First, a machinist secures the workpiece 11 to the work head 10. Next, the eccentric positioning system 2 moves the workpiece 11 to the first grinding wheel 5. The first motorized grinding spindle 4 rotates the first grinding wheel 5 to create the rib surface of the tapered roller bearing cone. Once the first grinding wheel 5 has finished grinding the rib surface, the first motorized grinding spindle 4 stops rotating, and the eccentric positioning system 2 moves the workpiece 11 to the second grinding wheel 7, which is turned by the second motorized grinding spindle 6 to grind the outer race of the tapered roller bearing cone. Then, once the second grinding wheel 7 has completed grinding the outer race surface, the second motorized grinding spindle 6 stops rotating, and the eccentric positioning system 2 moves the workpiece 11 to the third grinding wheel 9, which is turned by the third motorized grinding spindle 8 to grind the inner diameter of the tapered roller bearing cone. The third motorized grinding spindle 8 stops rotating once the inner diameter is ground. The eccentric positioning system 2 then moves the workpiece 11 to the non-rotating cutting tool 13, which removes material from both the inner and outer diameters of the raceway of the workpiece 11. (The operation performed by the non-rotating cutting tool 13 can be considered a superfinishing or honing operation.) Finally, the machinist removes the workpiece 11 from the work head 10.

[0034] The multi-tool positioning and manufacturing system may have other tools and may These operations can be performed similarly. For example, the tool need not rotate or spin, and need not be mounted on a motorized grinding spindle. For example, many operations performed by a lathe, such as drilling, countersinking, countersinking, or chamfering, can be performed with the tool mounted in a fixed chuck. The workpiece can be rotated relative to the tool, or the tool and chuck can be mounted on a top plate, as described below. One or more of these lathe operations can be performed on complex parts before or after one or more grinding steps. Other suitable tools include drilling lasers, milling cutters, and single- and multi-point turning (lathe) tools. At the extreme, a multi-tool positioning and manufacturing system replicates the functionality of a three-axis horizontal computer numerically controlled (CNC) milling machine combined with a grinding system.

[0035] The eccentric positioning system 2 also positions the rotary diamond dresser 12 for dressing or shaping the grinding wheels 5, 7, and 9 shown in FIG. 2. The rotary diamond dresser 12 removes metal, dull and deformed abrasive grains, and bond material from the grinding material on the grinding surfaces of the grinding wheels 5, 7, and 9. This sharpens the grinding wheels. The rotary diamond dresser 12 may also return the grinding surfaces to their original shape. It may also remove material from the grinding surfaces so that the resulting grinding surfaces will work properly against any other surfaces.

[0036] Because the rotary diamond dresser 12 is mounted on the eccentric positioning system 2, it can dress all three grinding wheels 5, 7, and 9, eliminating the need for a separate dresser for each wheel. Thus, the multi-tool positioning and manufacturing system 200 allows four machining operations and three dressing operations to be performed with one eccentric positioning system, reducing costs and increasing productivity, and improving manufacturing accuracy. Eccentric Positioning System

[0037] FIG. 3A is a cutaway view of a multi-tool positioning and manufacturing system 200 with components 3-9 and 13 omitted to show the eccentric positioning system 2 in more detail. The eccentric positioning system 2 consists of three circular eccentric turntables 20, 21, and 22. The work head 10 and rotary diamond dresser 12 are mounted on the upper eccentric turntable 22, which is mounted on the middle eccentric turntable 21, which is in turn mounted on the lower eccentric turntable 20. The eccentric turntables 20-22 are not concentric when viewed from above or below. Instead, the eccentric turntables 20-22 rotate about different parallel axes. This allows the eccentric positioning system 2 to translate the work head 10, workpiece 11, and rotary diamond dresser 12 in any direction within a plane perpendicular to their rotation axes. The eccentric positioning system 2 can also rotate the work head 10, workpiece 11, and rotary diamond dresser 12 about an axis that is parallel to or coincident with any one of the rotation axes of the eccentric rotary tables 20-22.

[0038] The eccentric positioning system 2 may be controlled by a computerized control system (not shown), which is used to control the position, angle of rotation, and linear and rotational speeds and accelerations of the upper rotary table 22. This may be programmed with a motion plan that sets the trajectory of the workpiece 11, as described in more detail below.

[0039] 3B is a simplified top view of the three nested bearings of the eccentric positioning system 2. The largest outer bearing 312 is surrounded by a medium sized bearing 314 and the smallest inner bearing 316. The outer bearing 312 includes a side bearing 316. The bearings are eccentrically mounted to allow each bearing to rotate about different but parallel axes, as described above, which may temporarily coincide as the rotation occurs. The bearings are supported such that when the inner race of the outer bearing 312 rotates, the other bearings 314 and 316 (and any structure or object supported by such bearings) also move about the axis of rotation of the outer bearing 312. Similarly, when the inner race of the middle bearing 314 is rotated, the inner bearing 316 (and any structure or object supported by the inner bearing 316) moves as well. The workpiece 11 is directly or indirectly connected to the inner race of the inner bearing 316 via the work head 10 and moves with the inner race of the inner bearing 316.

[0040] Solid circle 313 indicates the path of the center of mid-size bearing 314 as outer bearing 312 rotates. Dashed circle 315 indicates the path of the center of inner bearing 316 as mid-size bearing 314 rotates. Outer bearing 312 and / or mid-size bearing 314 control the movement of workpiece 11 in the XZ plane, which is parallel to the plane of the drawing. Workpiece 11 is coupled to inner bearing 316 to rotate workpiece 11 about the axis of rotation of inner bearing 316. Thus, inner bearing 316 controls the angular orientation (theta) of workpiece 11 in the XZ plane. As is clear from this drawing, inner bearing 316 has an effect on not only the X and Z position, but also the angular orientation.

[0041] 3C and 3D illustrate one example of the direction and extent of generally linear movement of the workpiece 11 along the "Z" axis, in degrees of rotational movement of bearings 312, 314, and 316, from the start position shown in FIG. 3C to the end position shown in FIG. 3D. The workpiece 11 has the same angular orientation at the beginning and end of this movement, as shown in FIGS. 3C and 3D. Movements can be simultaneous or sequential, as appropriately controlled by the system controller. In situations where the path of movement is important, for example, to prevent the workpiece 11 from hitting another object, linear or other intentionally directional object movement can be accomplished.

[0042] In this example, the outer bearing 312 has an OD of 43 inches and an ID of 33.75 inches. The medium size bearing 314 has an OD of 25 inches and an ID of 21.25 inches. And the inner bearing 316 has an OD of 12.75 inches and an ID of 10 inches. The movements include a clockwise movement of 138.7 degrees for the large bearing 312, a counterclockwise movement of 277.2 degrees for the medium size bearing 314, and a clockwise movement of 138.5 degrees for the smallest bearing 316. These dimensions and rotations translate into a movement of the workpiece of approximately 13.93 inches in the Z dimension.

[0043] Figures 3E and 3F illustrate a movement that moves the workpiece 11 in the X direction. In this case, the workpiece 11 translates from a start position shown in Figure 3E (which is the same as that shown in Figure 3D) to an end position shown in Figure 3F. The total (absolute) rotational movement of the inner races of bearings 312, 314, and 316 is 173.5 degrees clockwise, 294 degrees counterclockwise, and 120.4 degrees clockwise, respectively. For the bearing dimensions given above, this corresponds to 2.88 inches of linear movement in the "X" direction.

[0044] To maintain single-axis linear motion, the overall positioning can be performed in two steps, for example, Z-axis motion as shown in Figures 3C and 3D, followed by X-axis motion as shown in Figures 3E and 3F, in either order. The eccentric positioning system 2 is not limited to moving the workpiece 11 along a single axis, or even in a straight line, but can move the workpiece along a curved or bent path, as well as in a plane.

[0045] For more information regarding the eccentric positioning system 2, see this document in its entirety by reference. See US Pat. No. 7,803,034, which is incorporated herein by reference. Workpiece movement control

[0046] 4 illustrates a control system 700 for the eccentric positioning system 2. The control system 700 includes a controller 704, such as a Rockwell, ACS, Siemens, or FANUC controller, running appropriate motion control software. The controller 704 is coupled to servo motors 706 of the eccentric positioning system 2. These servo motors 706 are in turn coupled to a mechanical system 708 of the eccentric positioning system.

[0047] The control system 700 can be used to control the movement of the workpiece 11 or the grinding wheel dresser 12 depending on whether the current operation is modifying the workpiece 11 or shaping the grinding wheels 5, 7, and 9. The controller 704 moves the workpiece 11 or the grinding wheel dresser 12 according to a motion plan 702 that includes specific operator-entered motion control parameters for the workpiece 11. The motion control parameters in the motion plan 702 are selected so that the positioning system 2 moves the workpiece 11 from tool to tool and holds the workpiece 11 in a fixed position for each machining operation. The controller 704 uses these motion control parameters to generate and send appropriate control signals to the servo motors 706, which interact with a mechanical system 708 to cause object movement 710. Multi-tool positioning and manufacturing system with moving slides

[0048] 5 shows a multi-tool positioning and manufacturing system 500 with a moving slide for the tools. Again, the eccentric positioning system 2 positions the workpiece 11 with three degrees of freedom (two linear and one rotational) in a plane parallel to the top plate 3. The first and second motorized grinding spindles 4 and 6 are mounted on a first slide table 33 on a first base 34 mounted to the top plate 3. The third motorized grinding spindle 8 and non-rotating cutting tool 13 are mounted on a second slide table 31 on a second base 32 mounted to the top plate 3.

[0049] Slides 31 and 33 can move the spindles in the X direction independently of workpiece 11 and rotary diamond dresser 12 and can be controlled by the same controller (e.g., controller 704 in FIG. 4 ) that controls eccentric positioning system 2. (In this example, first slide 33 moves first motorized grinding spindle 4 and second motorized grinding spindle 6 together, i.e., as a single unit.) Slides 31 and 33 can be used to position tools beyond the range of the eccentric positioning system, such as gas turbine engine bearings, which can be several feet in diameter. Because there is virtually no limit to the slide length, a single long slide can support several spindles. The slides can move these spindles back and forth to roughly align the workpiece with the work head before the positioning system performs fine positioning for grinding.

[0050] Slides 31 and 33 may also be mounted differently to move in different directions and / or modified to move in additional directions. For example, either slide could be rotated 90° to move the corresponding tool in the Z direction. This is merely one example, and other slide orientations (e.g., 30°, 45°, 60°, etc.) are possible. Similarly, either slide could move the corresponding tool(s) in the Y direction, toward or away from top plate 3. Slides are also fabricated to move laterally in two dimensions (e.g., X and Z). Y movement is useful in applications where workpiece 11 does not have an axis of symmetry. It is particularly useful in grinding, surface grinding, and grinding gear teeth to fit gears of different diameters. Multi-tool positioning and manufacturing system with rotational and linear movements

[0051] 6 and 7 show a multi-tool positioning and manufacturing system 600 that has a rotary and linear positioning system 602 instead of an eccentric positioning system. The rotary and linear positioning system 602 includes a rotary table 622, a Z linear slide 621, and an X linear slide 620 inside the base 1 and covered by a top plate 3. The top plate 3 supports the spindles 4, 6, and 8, and the rotary tool 13. The work head 10 and rotary diamond dresser 12 are mounted on the rotary table 622 and protrude through holes in the top plate 3 (or at least a portion of the rotary table 622 protrudes through holes in the top plate 3).

[0052] The rotary table 622, Z linear slide 621, and X linear slide 620 together move the work head 10 (and the workpiece 11 on the work head 10) and the rotary diamond dresser 12 in a plane parallel to the top of the upper plate 3. The X linear slide 620 and Z linear slide 621 move the work head 10, the workpiece 11, and the rotary diamond dresser 12 in the X and Z directions, respectively. The rotary table 622 rotates the work head 10, the workpiece 11, and the rotary diamond dresser 12 about an axis extending in the Y direction. This rotation axis can be repositioned by moving the rotary table 622 using the X linear slide 620 and Z linear slide 621.

[0053] X linear slide 620, Z linear slide 621, and rotary table 622 may be moved simultaneously, sequentially, and independently according to a motion plan executed by a suitably programmed control system (e.g., control system 700 of FIG. 4). This control system is used to control the position, angle of rotation, and linear and rotational speeds and accelerations of work head 10 and rotary table 622, on which rotary diamond dresser 12 is mounted. As explained above, rotary diamond dresser 12 is used to dress or shape grinding wheels 5, 7, and 9. Work head 10 also locates, supports, and rotates workpiece 11 about its axis of symmetry.

[0054] For example, consider the case where the workpiece 11 is the inner race of a tapered roller bearing made of hardened steel. The work head 10 is used to locate, support, and rotate the inner race about its axis of symmetry. The rotational and linear positioning system 602 moves the inner race to a first motorized grinding spindle 4, which rotates a first grinding wheel 5 to grind the rib surface of the inner race. Next, the rotational and linear positioning system 602 moves the inner race to a second motorized grinding spindle 6, which rotates a second grinding wheel 7 to grind the outer diameter of the inner race. Next, the rotational and linear positioning system 602 moves the inner race to a third motorized grinding spindle 8, which rotates a third grinding wheel 9 to grind the inner diameter of the inner race. Finally, the rotational and linear positioning system 602 moves the inner race to a non-rotating cutting tool 13, which removes material from both the inner and outer diameters of the inner race.

[0055] Figure 8 shows a multi-tool positioning and manufacturing system 800 having a rotary and linear positioning system 602 with slides for the tools. This is similar to the embodiment shown in Figure 6, but the tools are mounted on two slides that provide independent movement of the tools in the X direction. Figure 8 shows two X-direction slides (slide tables 31 and 33), which are mounted to bases 32 and 34, respectively, as in Figure 5. , and provides the same degrees of freedom as described above with respect to FIG. Spindle and workhead position

[0056] If desired, the tool can be positioned on the positioning system, and the work head and rotary diamond dresser can be mounted directly on the top plate or on a slide mounted on the top plate. The positioning system would then move the tool to the workpiece and / or rotary diamond dresser, instead of moving the workpiece and / or rotary diamond dresser to the tool. When making tapered roller bearing cones using three different grinders on an eccentric positioning system, for example, the eccentric positioning system would move the first grinder to the workpiece, then the second grinder to the workpiece, and so on, in a process similar to that described above. The upper rotary table of the positioning system may be larger (e.g., 1 meter in diameter) to accommodate the grinders, spindles, etc. The spindle may be positioned on the rotary table with the grinding and cutting surfaces radially outward, like the spokes of a wheel. conclusion

[0057] While various inventive embodiments have been described and illustrated herein, those skilled in the art will readily envision various other means and / or structures for performing the functions and / or obtaining the results and / or one or more advantages described herein, and each such variation and / or modification is deemed to be within the scope of the inventive embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary, and that the actual parameters, dimensions, materials, and / or configurations will depend on the specific application(s) for which the teachings of the present invention are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein. Accordingly, the foregoing embodiments are presented by way of example only, and it will be understood that, within the scope of the appended claims and their equivalents, inventive embodiments may be practiced other than as specifically described and claimed. The inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and / or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and / or methods is included within the inventive scope of the present disclosure, if such features, systems, articles, materials, kits, and / or methods are not mutually inconsistent.

[0058] Also, various inventive concepts may be embodied as one or more methods, examples of which have been provided. The acts performed as part of a method may be ordered in any suitable manner. As a result, embodiments may be constructed in which acts are performed in an order different from that illustrated, which may include performing some acts simultaneously, even though the exemplary embodiments show acts as sequential.

[0059] All definitions defined and used herein should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0060] As used in this specification and the claims, the indefinite articles "a" and "an" should be understood to mean "at least one," unless expressly indicated otherwise.

[0061] As used in this specification and claims, the term "and / or" means "either or both" of the associated elements, i.e., in some cases conjunctively. "A and / or" should be understood to mean elements that are present in some cases and disjunctively present in others. Multiple elements listed with "and / or" should be construed in the same manner, i.e., "one or more" of the conjunctive elements. Other elements, whether related or unrelated to the elements specifically identified, may optionally be present other than the elements specifically identified by the "and / or" clause. Thus, as a non-limiting example, a reference to "A and / or B," when used in conjunction with open-ended language such as "comprising," can refer in one embodiment to A only (optionally including elements other than B), in another embodiment to B only (optionally including elements other than A), in yet another embodiment to both A and B (optionally including other elements), etc.

[0062] As used in this specification and the claims, "or" should be understood to have the same meaning as "and / or" as defined above. For example, when separating items in a list, "or" or "and / or" shall be construed as inclusive, i.e., including at least one, but also more than one, of a number or list of elements, and optionally, additional items not listed. Only terms clearly indicated to the contrary, e.g., "only one of" or "exactly one of," or, when used in the claims, "consisting of," shall refer to the inclusion of exactly one element of a number or list of elements. Generally, as used herein, the term "or" shall only be construed to indicate exclusive alternatives (i.e., "one or the other, but not both") when preceded by exclusive terms, such as "either," "one of," "only one of," or "exactly one of." "Consisting essentially of," when used in the claims, shall have its ordinary meaning as used in the field of patent law.

[0063] As used in this specification and claims, the phrase "at least one" in connection with a list of one or more elements should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements, and not excluding any combination of elements in the list of elements. This definition also allows that elements other than those specifically identified in the list of elements to which the phrase "at least one" refers may optionally be present, whether related or unrelated to the specifically identified elements. Thus, as a non-limiting example, "at least one of A and B" (or, equivalently, "at least one of A or B," or, equivalently, "at least one of A and / or B") can refer to, in one embodiment, at least one A (optionally including elements other than B), with no B present, optionally including two or more As; in another embodiment, at least one B (optionally including elements other than A), with no A present, optionally including two or more Bs; in yet another embodiment, at least one A, optionally including two or more As, and at least one B (optionally including other elements), optionally including two or more Bs; etc.

[0064] In the claims, as well as in the above specification, all transitional phrases, such as "comprising," "including," "carrying," "having," "containing," "involving," "holding," "composed of," and the like, are to be understood as open-ended, i.e., meaning including but not limited to. Only the transitional phrases "consisting of" and "consisting essentially of" shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedures, Section 2111.03.

Claims

1. 1. A system for performing a plurality of manufacturing processes, comprising: An upper plate; a work head for supporting a workpiece in a plane parallel to said upper plate; a first tool coupled to the top plate for performing a first machining operation on the workpiece; a second tool coupled to the top plate for performing a second machining operation on the workpiece; a positioning system disposed below the top plate for directly supporting the work head and for moving the work head and the workpiece with three degrees of freedom in a plane parallel to the top plate, the three degrees of freedom including two-dimensional translation of the work head and the workpiece in any direction in the plane parallel to the top plate and rotation of the work head and the workpiece about an axis perpendicular to the plane parallel to the top plate, the positioning system being configured to move directly below the top plate, the first tool, and the second tool; 10. A system for performing the plurality of manufacturing steps, comprising:

2. The system of claim 1 , wherein the first tool is a first grinding wheel and the second tool is a second grinding wheel.

3. a grinding wheel dresser mounted on the positioning system to dress the first grinding wheel and the second grinding wheel; and the positioning system is configured to move the grinding wheel dresser in the plane parallel to the top plate; The system of claim 2 .

4. The system of claim 1 , wherein the positioning system is configured to move the workpiece from the first tool to the second tool while the workpiece is on the work head.

5. the axis perpendicular to the plane parallel to the upper plate is a first axis perpendicular to the plane intersecting the first tool and the second tool, and the positioning system is a first rotary table that rotates about the first axis; a second rotary table supporting the first rotary table for rotation about a second axis parallel to the first axis and perpendicular to the plane parallel to the upper plate; a third rotary table supporting the second rotary table so as to rotate about a third axis that is parallel to the first axis and the second axis and perpendicular to the plane parallel to the upper plate; The system of claim 1 .

6. the positioning system a rotary table for rotating the work head about the axis perpendicular to the plane parallel to the upper plate; a first slide operatively connected to the rotary table for moving the work head and the rotary table in a first direction within the plane parallel to the top plate; and a second slide operatively connected to the first slide for moving the work head, the rotary table, and the first slide in a second direction different from the first direction within the plane parallel to the top plate. The system of claim 1 , comprising:

7. The system of claim 1 , further comprising a spindle operably coupled to the first tool for rotating the first tool relative to the workpiece.

8. 10. The system of claim 1, further comprising a controller operatively coupled to the positioning system for causing the positioning system to move the workpiece between the first tool and the second tool according to a movement plan.

9. The system of claim 1 , wherein the work head is configured to rotate the workpiece about an axis of symmetry of the workpiece.

10. The system of claim 1 , further comprising a slide operatively coupled to the first tool for translating the first tool in the plane relative to the workpiece.

11. 1. A method for producing a part from a workpiece, comprising: Fixing the workpiece to a work head; positioning the workpiece and the work head relative to a first tool in a plane using three degrees of freedom of a positioning system, the three degrees of freedom including two-dimensional translation of the work head and the workpiece in any direction within the plane and rotation of the work head and the workpiece about an axis perpendicular to the plane, the first tool being mounted to a top plate; performing a first manufacturing operation on the workpiece using the first tool while the workpiece is within the work head; moving the workpiece and the work head using the positioning system in the plane from the first tool to the second tool, the plane being parallel to the top plate on which the first tool and the second tool are mounted, and moving the workpiece and the work head using the positioning system in the plane from the first tool to the second tool; performing a second manufacturing operation on the workpiece using the second tool while the workpiece is within the work head; Removing the workpiece from the work head; Including, The method, wherein the positioning system is configured to move beneath the top plate, the first tool, and the second tool when positioning the workpiece and the work head.

12. 12. The method of claim 11, wherein transferring the workpiece and the work head from the first tool to the second tool occurs in less than one minute.

13. 12. The method of claim 11, wherein performing the first manufacturing operation on the workpiece includes grinding one of an inner diameter or an outer diameter, and performing the second manufacturing operation on the workpiece includes grinding the other of the inner diameter or the outer diameter.

14. dressing the first tool using a dresser mounted to the positioning system; moving the dresser from the first tool to the second tool using the positioning system; dressing the second tool with the dresser; The method of claim 11 further comprising:

15. 1. A multi-tool positioning and manufacturing system comprising: An upper plate; a work head for supporting a workpiece in a plane parallel to said upper plate; a first spindle supported by the top plate for rotating a first grinding wheel about a first axis parallel to the top plate; a second spindle supported by the top plate for rotating a second grinding wheel about a second axis parallel to the top plate; a third spindle supported by the top plate for rotating a third grinding wheel about a third axis parallel to the top plate; an eccentric positioning system for supporting the work head and a grinding wheel dresser configured to shape the first grinding wheel, the second grinding wheel, and the third grinding wheel, and for moving the work head, the workpiece, and the grinding wheel dresser from the first grinding wheel to the second grinding wheel to the third grinding wheel within the plane parallel to the top plate, the eccentric positioning system comprising: a first eccentric rotary table having a first axis of rotation; a second eccentric rotary table mounted on the first eccentric rotary table and having a second axis of rotation parallel to the first axis of rotation; and a third eccentric rotary table mounted on the second eccentric rotary table and having a third axis of rotation parallel to the first and second axes of rotation, the grinding wheel dresser being mounted directly to the eccentric positioning system and fixed in position relative to the work head and located proximate to the work head; The multi-tool positioning and manufacturing system comprises:

16. 16. The multi-tool positioning and manufacturing system of claim 15, wherein the work head is configured to rotate the workpiece about an axis of symmetry of the workpiece.

17. 16. The multi-tool positioning and manufacturing system of claim 15, wherein the eccentric positioning system is configured to move the work head laterally in the plane parallel to the top plate and to rotate the work head about an axis perpendicular to the plane parallel to the top plate.

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