Gear Grinding Synchronization With Motor Cogging Compensation
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Solution Overview
Problem
Existing grinding systems face challenges in accurately grinding gear tooth surfaces due to rotational speed fluctuations caused by motor cogging, leading to potential grinding errors and abnormal noise generation in electric vehicles.
Innovation Solution
A grinding system and method that includes a signal acquisition unit to detect rotational speeds, a synchronization signal generation unit for synchronized rotation, and a command signal generation unit to suppress fluctuations using a canceling signal, thereby controlling the motor to reduce cogging-induced errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a motor rotates the workpiece during grinding, then the workpiece can be processed, but rotational speed fluctuation caused by motor cogging leads to grinding errors
Solution Approach 1:
The control device generates a canceling signal that opposes the cogging-induced rotational speed fluctuations before they affect grinding accuracy. By applying this counteracting signal to the motor command, the system preemptively neutralizes the harmful vibrations and speed variations, thereby maintaining both grinding precision and rotational stability
Solution Approach 2:
The system detects actual rotational speed fluctuations and uses this feedback to generate appropriate canceling signals. The control device continuously monitors the motor's rotational behavior and adjusts the command signal in real-time to compensate for cogging effects, ensuring stable rotation and accurate grinding throughout the process
2Manufacturing precision
If the workpiece and grinding tool are synchronized, then grinding quality improves, but complex signal coordination is required between multiple rotating bodies
Solution Approach 1:
The control device integrates the synchronization control and cogging compensation functions into a unified signal processing system. By combining the synchronization signal generation with the canceling signal generation in a single control unit, the system achieves precise tooth surface grinding while avoiding the complexity of separate coordination systems for multiple rotating bodies
3Reliability
If motor cogging is suppressed using a canceling signal, then rotational speed stability improves, but additional signal processing complexity is introduced
Solution Approach 1:
The control device is designed to perform multiple functions simultaneously: it generates synchronization signals for coordinated rotation, produces canceling signals to suppress cogging fluctuations, and manages motor control all within a single integrated system. This multi-functionality reduces overall system complexity while maintaining rotational speed stability
Data Source
AI summary
A grinding system includes a signal acquisition unit configured to acquire a first signal and a second signal, a synchronization signal generation unit configured to generate, based on the first signal and the second signal, a synchronization signal for synchronously rotating a first rotating body with respect to a second rotating body, a command signal generation unit configured to generate a command signal based on the synchronization signal and a pre-determined canceling signal for suppressing the fluctuation of the rotational speed of the first rotating body caused by the cogging of a motor that rotates the first rotating body, and a signal output unit configured to output the command signal generated by the command signal generation unit and control the motor.