Double-Sided Work Disk Gap Measurement for Flat Workpiece Thickness
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Solution Overview
Problem
Existing methods for determining workpiece thickness in double-sided machining tools lack accuracy due to deviations in gap geometry from plane parallelism, leading to measurement errors and inaccurate thickness determinations.
Innovation Solution
Measuring the distance between work disks at multiple radially spaced locations and combining measurement signals from multiple sensors to calculate the workpiece thickness, accounting for non-parallel gaps and adjusting for work coating thickness, allowing precise determination of workpiece thickness and optimal machining termination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single distance measurement is used to determine workpiece thickness, then the measurement process is simple, but measurement errors occur due to deviations in gap geometry from plane parallelism
Solution Approach 1:
The measurement system is segmented into multiple distance sensors positioned at different radial locations (inner and outer edges) of the work gap. Each sensor independently measures the distance between work disks at its specific location, providing multiple data points that collectively enable accurate thickness determination despite local geometric deviations.
Solution Approach 2:
The measurement approach transitions from a single-point measurement to a multi-dimensional measurement by adding radial position as a new dimension. By measuring at both inner and outer radial edges, the system captures the full geometric profile of the work gap, allowing calculation of the actual workpiece thickness that accounts for non-parallelism.
2Measurement precision
If multiple distance sensors are used to measure workpiece thickness, then measurement accuracy improves, but the complexity of the measurement system increases
Solution Approach 1:
The distance sensors serve multiple functions: they measure the distance between work disks at different radial positions, detect workpiece thickness, and provide data to control the machining process. This multi-functionality justifies the added complexity by delivering comprehensive measurement capabilities through a unified sensor system.
Solution Approach 2:
The measurement system provides continuous feedback on workpiece thickness to the control system. By monitoring the distance between work disks at multiple locations during machining, the system can adjust machining parameters in real-time to maintain desired thickness tolerances, making the additional measurement complexity worthwhile for process control.
3Manufacturing precision
If workpieces are machined to precisely the same thickness as the carrier, then thickness distribution quality improves, but carrier wear increases
Solution Approach 1:
The system performs preliminary thickness measurements during the machining process to determine when the workpiece has reached the desired thickness. By continuously monitoring the distance between work disks and calculating workpiece thickness in real-time, the system can stop machining at the optimal moment before the workpiece thickness matches the carrier thickness, preventing excessive carrier wear while ensuring sufficient thickness uniformity.
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
This approach enhances the precision of workpiece machining by accurately determining the workpiece thickness and ensuring precise termination of the machining process, reducing measurement errors and improving the quality of machined workpieces.
Implementation Method 1
U.S. Pat. No. 4,433,510 A thus describes the measurement of the distance between the work disks with an eddy current sensor
Data Source
AI summary
The invention relates to a method for machining flat workpieces in a double-sided machining tool, which has an upper and a lower work disk, wherein at least one of the work disks is rotatingly driven and the work disks each have an annular work surface, wherein the work surfaces amongst themselves limit an also annular work gap, in which at least one carrier is located, which guides at least one workpiece in the work gap, so that the at least one workpiece is machined in a double-sided manner between the work surfaces. The distance between the work disks is measured at at least two radially spaced measurement locations of the work gap and in that, from the measured distances, a distance between the work disks is determined at a location of the work gap representing the thickness of the at least one workpiece machined in the work gap.