Gear Grinding Centering Control Using Spindle Torque Feedback
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Solution Overview
Problem
Existing gear grinding methods face challenges in achieving precise centering and monitoring the quality of centering due to factors like pitch error distribution, stock allowances, and deviations, leading to defects such as waviness and incomplete grinding.
Innovation Solution
Adjust the center position of the grinding tool relative to the gear teeth based on performance parameters of the workpiece spindle, such as torque or current consumption, to improve centering accuracy and quality by correcting the position using correction values on machine axes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional centering methods using centering sensors are used, then the centering process can be performed, but the centering quality is insufficient due to varying pitch error distribution, changing stock allowances, and other deviations
Solution Approach 1:
The patent implements feedback by monitoring the performance parameter (torque or current consumption) of the workpiece spindle during grinding and using this information to adjust the center position. The control unit compares the measured performance parameter with reference values and automatically corrects the center position, creating a closed-loop control system that continuously optimizes centering quality based on actual grinding conditions.
Solution Approach 2:
The patent replaces the mechanical centering sensor system with an electrical/mechanical measurement system that monitors the workpiece spindle's performance parameters (torque or current consumption). This substitution allows for more precise and dynamic centering by using electrical measurements that can be processed and adjusted in real-time, overcoming the limitations of mechanical sensor accuracy.
2Manufacturing precision
If tight tolerances are required for ground gear teeth quality, then higher centering quality is necessary, but traditional centering methods cannot achieve the required precision
Solution Approach 1:
The feedback mechanism monitors the workpiece spindle's performance parameter during grinding and automatically adjusts the center position to maintain consistent centering quality. This closed-loop control ensures that even with varying workpiece conditions, the centering quality remains within required tolerances, improving reliability of the grinding process.
Solution Approach 2:
The patent changes the approach to centering by using performance parameters (torque or current consumption) as the basis for adjustment rather than relying on fixed mechanical sensor readings. This allows dynamic adaptation to changing conditions, maintaining consistent centering quality across different workpieces and grinding stages.
3Ease of manufacture
If centering is performed without performance parameter monitoring, then the process is simpler, but gear defects such as waviness, shape defects, or incomplete grinding occur
Solution Approach 1:
The feedback system automatically monitors and adjusts centering based on performance parameters, eliminating the need for complex manual centering procedures while preventing gear defects. The control unit processes the performance parameter data and makes automatic corrections, maintaining process simplicity from the operator's perspective while ensuring high quality results.
Solution Approach 2:
The system performs self-correction by automatically adjusting the center position based on monitored performance parameters. The control unit independently detects deviations and applies corrections without requiring manual intervention, allowing the process to remain simple while preventing defects through automated quality control.
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 centering precision by up to 100 µm correction, ensuring accurate material removal and reducing defects, with adjustments made during or between grinding strokes based on tolerance ranges or threshold values.
Implementation Method 1
the performance parameter can be the torque of a motor or the workpiece spindle. The torque can be measured directly or indirectly.
Implementation Method 2
If a grinding tool is poorly centered to the gear teeth, i.e., the position of the tooth gaps to be ground relative to the grinding worm has not been correctly determined, then, for example, excessively high or too low torques requiring support in the area of the workpiece spindle will occur during grinding, as too much or too little material is removed.
Data Source
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AI summary
Method, comprising the method steps: generating grinding of gears (16), wherein a respective gear (16) is machined by means of several grinding strokes and wherein a centering position for positioning a grinding tool (10) relative to the respective gear (16) is predetermined for the grinding strokes, and adjusting the centering position based on a performance parameter (M2) of a workpiece spindle (6) receiving the respective gear (16).