Eccentric Disc Grinding with Flexible Layer for Uniform Finishes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing devices for producing an undefined finish on metal workpieces require complex overlapping movements of grinding units, leading to high manufacturing and operating costs, potential device damage, and non-uniform grinding patterns due to varying contact pressures.
Innovation Solution
A device with a single disc grinding unit that moves vertically and transversely, using a flexible nonwoven fiber grinding wheel and a friction brake to maintain consistent contact pressure and prevent excessive force on the workpiece edges, ensuring a uniform undefined finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If contact pressure is reduced to produce uniform undefined finish, then grinding uniformity is improved, but grinding performance decreases leading to long processing times
Solution Approach 1:
The grinding unit is made vertically displaceable instead of fixed, allowing it to dynamically adjust its position in response to workpiece variations. This dynamic capability enables the grinding unit to compensate for edge effects and maintain uniform contact pressure across the workpiece surface, achieving both uniform grinding and high productivity
2Productivity
If multiple disc grinders are used in parallel to improve grinding performance, then productivity is improved, but device complexity increases
Solution Approach 1:
The single grinding unit is divided into functionally independent components: the vertically displaceable grinding mechanism, the transverse movement system, and the conveyor belt transport. This segmentation allows each component to perform its specific function efficiently, achieving high productivity without requiring multiple complex grinding units
Solution Approach 2:
The invention adds vertical displacement capability to the traditional horizontal grinding arrangement. By moving the grinding unit in the vertical dimension in addition to transverse movement, the system achieves enhanced grinding performance and uniformity with a single unit rather than multiple parallel units
3Manufacturing precision
If overlapping movements of grinding units are coordinated to produce uniform finish, then grinding uniformity is improved, but device complexity and risk of damage increase
Solution Approach 1:
The invention extracts and eliminates the complex overlapping coordination mechanism from the system. Instead of using multiple grinding units with synchronized overlapping movements, the solution uses a single grinding unit with vertical displacement capability that inherently produces uniform grinding patterns without requiring complex inter-unit coordination
4Device complexity
If single disc grinder is used to reduce device complexity, then device complexity is reduced, but grinding performance decreases due to varying contact pressure
Solution Approach 1:
The single grinding unit is equipped with vertical displacement capability that allows it to dynamically adjust contact pressure distribution. This dynamic adjustment compensates for the naturally higher contact pressure at workpiece edges, maintaining uniform grinding performance throughout the workpiece surface while using only one grinding unit
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
The solution achieves high grinding performance with reduced energy consumption and device vibrations, allowing for uniform undefined finishes on metal workpieces, reducing manufacturing complexity and operating costs while enhancing device durability.
Implementation Method 1
a grinding unit (22) comprising a grinding disc (34) which rotates around a central axis (N)
Implementation Method 2
a friction brake (142) which acts on the grinding disc (34)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a device for producing an undefined finish on the surface of a metal workpiece in a continuous process, comprising a grinding unit (22) with at least one disc grinding unit (24) having a grinding disc (34) and a grinding wheel (35) held on the grinding disc (34), wherein the grinding wheel (35) has abrasive elements (37) arranged parallel to the surface of the workpiece and wherein the grinding disc (34) is held eccentrically on the disc grinding unit (24), with a transport device (10) for linearly transporting the workpiece under the grinding unit (22) and with a tool bridge (18) for mounting the grinding unit (22) above the transport device (10).Creating such a device, which produces a uniform grinding pattern with an undefined finish despite different contact pressures at the edge and inside the workpiece and at high grinding performance, is achieved by the grinding wheel (35) having a layer (36) at least 5 mm, preferably 6 mm and at most 15 mm thick, which is formed from an elastically deformable material that can be compressed when force is applied, wherein the compressed layer (36) tends to return to its original shape and wherein the abrasive (37) is embedded in or held against the layer (36).