3D-Guided Convex Grinding With Variable Tool Angle
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Solution Overview
Problem
Existing convex portion grinding technologies struggle to automatically handle a wide variety of products, are costly due to large-scale line sealing and vacuuming requirements, and rely heavily on human labor for visual inspection and control, making high-speed grinding of convex portions on diverse products difficult, especially with materials like high-alloy steel.
Innovation Solution
A system and method utilizing a three-dimensional shape measuring device, convex portion detection, and grinding tool control to automate the grinding process, including measuring, recognizing convex portions, controlling grinding reaction force, and inspecting for remaining convex portions, with variable contact angle grinding to enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual grinding is used to handle diverse convex portions, then adaptability to various products is improved, but labor burden and processing time increase significantly
Solution Approach 1:
The system uses vision sensors to automatically detect convex portions and their geometries, then autonomously plans and executes grinding trajectories without human intervention. The control system self-adjusts grinding parameters based on real-time feedback, enabling the system to adapt to various products while maintaining high productivity
Solution Approach 2:
The grinding system dynamically adjusts the grindstone contact angle and movement trajectory based on the detected convex portion characteristics. The robot arm and grindstone orientation are continuously modified during the grinding process to optimize material removal while adapting to different product geometries
2Extent of automation
If fixed trajectory grinding is used to automate the process, then labor burden is reduced, but adaptability to diverse product shapes is lost
Solution Approach 1:
The vision system performs preliminary detection and 3D reconstruction of the workpiece and convex portions before grinding begins. This preliminary action captures the geometry and position of convex portions, enabling the control system to generate customized grinding trajectories for each specific product variant
Solution Approach 2:
The system continuously monitors the grinding process using vision sensors and force feedback, comparing actual results with the planned trajectory. The control system adjusts the grinding path and parameters in real-time based on this feedback, maintaining both automation and adaptability to product variations
3Device complexity
If constant contact angle grinding is used to simplify the process, then device complexity is reduced, but grinding efficiency and surface quality deteriorate
Solution Approach 1:
The system dynamically changes the grindstone contact angle during the grinding process based on the convex portion geometry and machining stage. The contact angle is adjusted to optimize material removal rate during roughing and improve surface quality during finishing, significantly enhancing grinding efficiency
4Device complexity
If constant contact angle grinding is used to reduce control complexity, then device complexity is reduced, but surface finish quality and material removal efficiency worsen
Solution Approach 1:
The system employs periodic adjustment of the grindstone contact angle during the grinding process, switching between different angle ranges to alternately remove material efficiently and refine surface quality. This periodic variation in grinding parameters achieves both high productivity and excellent surface finish
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Automates the grinding of convex portions on diverse products, reducing labor burden and facility costs, enabling high-speed grinding and improving productivity by accurately removing convex portions on various materials.
Implementation Method 1
measuring shape and orientation of a workpiece based on visual information
Implementation Method 2
grinding while applying a constant pressing force along a predetermined machining trajectory
Data Source
AI summary
A convex portion grinding system including: a shape measuring device (3) that measures three-dimensional shape and orientation of a target material; a convex portion detection device (4) that detects a convex portion on a surface of the target material and recognizes position and shape of the convex portion; a grinding device (7) including a grinding tool that grinds the convex portion; and a grinding tool control device (5) that calculates a trajectory along which the grinding tool moves based on the measured three-dimensional shape and orientation of the target material and the detected position and shape of the convex portion, and controls the grinding device so that the grinding tool moves along the trajectory while changing the contact angle of the grinding tool with respect to the convex portion.