Ballbar Mounting for Three-Plane Motion Assessment
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Solution Overview
Problem
Current ballbar equipment is not suitable for horizontal grinding machines as it cannot be fitted to grinding wheel arbors and only checks relative movements in the X-Y plane, failing to assess inaccuracies in all three planes essential for accurate grinding operations.
Innovation Solution
The development of ballbar equipment with tool and table mounting components featuring orthogonal receiving means, allowing the ballbar to be set up for motion checks in the XY, XZ, and YZ planes, including a ring that fits over the grinding wheel arbor and a mounting block secured to the machine tool table, with locking mechanisms to prevent arbor rotation during testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional ballbar mounting components are used, then the ballbar can be mounted on tool holders for checking X-Y plane movements, but it cannot be fitted to grinding wheel arbors and cannot check movements in all three planes
Solution Approach 1:
The mounting component is designed with three orthogonal receiving means that can accommodate ballbars for testing in all three planes (X-Y, X-Z, and Y-Z planes). The component can be universally mounted on both tool holders and grinding wheel arbors, making it adaptable to different machine tool types including horizontal grinding machines, vertical machining centers, and CNC mills.
Solution Approach 2:
The mounting component transitions from conventional two-dimensional (X-Y plane only) mounting to three-dimensional capability by incorporating three receiving means oriented orthogonally to each other. This allows the ballbar to be positioned for testing movements in any of the three spatial planes, adding the Z-axis dimension to the testing capability.
2Measurement precision
If the ballbar is used to check relative movements in all three planes, then motion inaccuracies in all planes can be assessed, but the mounting component requires orthogonal receiving means increasing its complexity
Solution Approach 1:
A single mounting component design with three orthogonal receiving means serves multiple functions: it can mount ballbars for testing in the X-Y plane, X-Z plane, and Y-Z plane. This multi-functional design enables comprehensive three-dimensional motion accuracy assessment without requiring separate mounting components for each plane.
Solution Approach 2:
The mounting component is segmented into three distinct receiving means, each oriented orthogonally to the others. This segmentation allows independent positioning and orientation of the ballbar for each testing plane, enabling precise measurement in three dimensions while maintaining a unified mounting structure.
3Adaptability or versatility
If the tool mounting component is adapted for grinding wheel arbors, then it can be used on horizontal grinding machines, but it requires locking means to prevent arbor rotation during testing
Solution Approach 1:
The tool mounting component is designed to be universally adaptable to both tool holders and grinding wheel arbors. When mounted on grinding wheel arbors, it includes integrated locking means to prevent arbor rotation during ballbar testing, enabling use on horizontal grinding machines without requiring a completely different mounting system.
Solution Approach 2:
The mounting component acts as an intermediary between the grinding wheel arbor and the ballbar. It includes a ring that fits over the arbor and locking means that engage with the arbor to prevent rotation, while providing orthogonal receiving means for the ballbar. This intermediary structure enables compatibility between the ballbar system and grinding machine arbors.
Data Source
AI summary
A ballbar is used to assess the accuracy of relative motion between an arbor and a table 4—of a machine tool. Mounting components are secured respectively to the arbor and the table-4. Each mounting component comprises a block that has provision on three orthogonal surfaces for receiving support means for a ballbar. By appropriate selection of the mounting faces, it is possible to set up the ballbar to check motion in all three of the operating planes of the machine. The mounting component comprises a ring for fitting over the arbor of the grinding machine, and the mounting block is connected to the ring by a rod.