Compression Spring Grinding Machine with Wheel Condition Sensors
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Solution Overview
Problem
Existing spring end grinding machines lack precise control and monitoring capabilities, leading to excessive heat generation, damage to components, and inefficiencies in the grinding process.
Innovation Solution
Integration of sensors within the grinding wheel to monitor parameters such as temperature and abrasion, enabling precise control of the grinding process through wireless communication with a processing unit for real-time adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional grinding machines are used without integrated sensors, then the device complexity is low, but the measurement precision and manufacturing precision deteriorate due to inability to monitor temperature and abrasion
Solution Approach 1:
The sensor is integrated into the grinding wheel structure itself, with the sensor housing formed as part of the grinding wheel. This nesting approach allows the sensor to be positioned exactly where measurements are needed without adding external complexity to the overall system architecture.
Solution Approach 2:
The sensor continuously monitors grinding wheel temperature and abrasion, transmits this data wirelessly to a control unit, which then provides feedback to adjust grinding parameters in real-time. This closed-loop feedback system enables precise measurement and control while managing system complexity through automated decision-making.
2Manufacturing precision
If grinding process is monitored with higher precision using integrated sensors, then the manufacturing precision improves, but the device complexity increases due to sensor integration requirements
Solution Approach 1:
The grinding wheel is equipped with its own integrated sensor and wireless transmission capability, allowing it to autonomously monitor its own condition (temperature, abrasion) and communicate this information without requiring external monitoring equipment. This self-service approach improves manufacturing precision while minimizing additional system complexity.
Solution Approach 2:
The sensor housing serves multiple functions: it provides structural support for the sensor, acts as part of the grinding wheel assembly, and facilitates wireless communication. This multi-functionality approach allows the sensor integration to improve manufacturing precision without proportionally increasing device complexity.
3Reliability
If real-time monitoring of grinding wheel conditions is implemented, then the reliability of the grinding process improves, but the device complexity increases due to transmission device and processing unit requirements
Solution Approach 1:
The patent replaces complex wired mechanical connection systems with wireless transmission technology. The sensor data is transmitted wirelessly to the control unit, eliminating the need for physical data cables and reducing mechanical complexity while maintaining reliable real-time monitoring of grinding wheel conditions.
Solution Approach 2:
The wireless transmission device acts as an intermediary between the sensor and the control unit, enabling reliable data communication without direct physical connections. This intermediary approach simplifies the overall system architecture while ensuring reliable transmission of temperature and abrasion data for improved process control.
4Temperature
If cooling air flow is increased to prevent overheating, then the temperature control improves, but the loss of energy increases and the grinding efficiency decreases
Solution Approach 1:
The cooling air flow is made dynamic rather than static - it is adjusted in real-time based on actual grinding wheel temperature measurements from the integrated sensor. The control unit modulates cooling air flow to match actual thermal conditions, preventing overheating while minimizing energy consumption and maintaining grinding efficiency.
Solution Approach 2:
The system dynamically changes the cooling air flow parameter based on real-time temperature data. Instead of maintaining constant high cooling flow, the system adjusts the cooling parameter (air flow rate) to match actual thermal conditions, achieving effective temperature control with reduced energy loss and optimized grinding efficiency.
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
Enhances process precision, reduces component damage, and optimizes grinding efficiency by allowing for real-time adjustments based on grinding wheel conditions.
Implementation Method 1
at least one sensor for detecting grinding wheel information, in particular a temperature and/or a degree of abrasion of the grinding wheel
Implementation Method 2
a degree of abrasion of the grinding wheel
Implementation Method 3
a transmission device for transmitting grinding wheel information from the sensor to the processing unit
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a grinding machine (1), in particular a spring end grinding machine, comprising: - at least one loading plate (10) rotatably mounted about an axis of rotation (A) for loading workpieces (2), in particular coil springs; - a grinding unit (11) with at least one grinding wheel (13) rotatably mounted about an axis of rotation (B), wherein the axis of rotation (B) of the grinding wheel (13) is substantially parallel to the axis of rotation (A) of the loading plate (10); - at least one sensor (30) for detecting grinding wheel information, in particular a temperature and/or abrasion dimension of the grinding wheel (13); - a control unit (40) configured to issue a control command for controlling the grinding machine (1) based on grinding wheel information transmitted to the control unit (40); - a transmission device (50) for transmitting grinding wheel information from the sensor (30) to the control unit (40);wherein the sensor (30) is integrated into the grinding wheel (13), in particular incorporated into the grinding wheel (13), and the grinding wheel (13) comprises a storage unit (14) for storing grinding wheel data containing grinding wheel information, and a data transmission interface for reading out recorded grinding wheel data, in particular grinding wheel data sets describing temporal profiles of grinding wheel information.