Gear Grinding Setup with Dual Closed-Loop Flank Correction
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Solution Overview
Problem
Existing gear grinding processes face challenges in achieving high accuracy for the final flank shape and precise corrections, as inaccuracies from pre-final grinding strokes often cannot be fully compensated in the final grinding stroke.
Innovation Solution
A multi-stage closed loop process is implemented, comprising a first quality control circuit for correcting pre-final target geometry and a second quality control circuit for achieving the final target geometry, allowing for more precise setup and correction of grinding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single quality control loop is used to correct deviations from the final target geometry, then the correction process is simple, but deviations from pre-final grinding strokes cannot be fully compensated, resulting in reduced manufacturing precision
Solution Approach 1:
The quality control loop is segmented into two independent loops: a first quality control loop for pre-final grinding strokes and a second quality control loop for the final grinding stroke. Each loop independently determines corrections based on its respective target geometry, allowing pre-final deviations to be compensated separately from final geometry corrections, thereby resolving the contradiction between maintaining simplicity and achieving high precision.
Solution Approach 2:
The first quality control loop performs preliminary correction by determining axis movements for pre-final grinding strokes to achieve a pre-final target geometry with stock allowance. This preliminary action ensures that deviations are corrected before the final grinding stroke, preventing their transfer to the final flank shape and enabling higher manufacturing precision without excessive complexity.
2Manufacturing precision
If corrections are applied identically to all grinding strokes based on final deviations, then the correction process is straightforward, but negative influences of pre-final grinding strokes on the final flank shape are not eliminated
Solution Approach 1:
The correction process is segmented into two independent correction processes: one for pre-final grinding strokes and one for the final grinding stroke. The first quality control loop determines corrections specifically for pre-final strokes based on pre-final target geometry, while the second loop determines corrections for the final stroke. This segmentation allows each correction to be optimized for its specific purpose, improving flank shape accuracy while maintaining ease of manufacture through systematic organization.
Solution Approach 2:
Corrections for pre-final grinding strokes are determined in advance by the first quality control loop before the final grinding stroke occurs. This preliminary determination of corrections ensures that pre-final deviations are compensated beforehand, preventing their transfer to the final flank shape and eliminating negative influences without complicating the overall correction application process.
3Productivity
If multiple grinding strokes are used to achieve the target geometry, then material removal is effective, but deviations from pre-final strokes are transferred to the final geometry, reducing measurement precision
Solution Approach 1:
The first quality control loop performs preliminary grinding and correction to achieve a pre-final target geometry with controlled deviations. By determining axis movements for pre-final grinding strokes in advance and correcting deviations before the final grinding stroke, this preliminary action prevents the transfer of deviations to the final geometry, ensuring high measurement precision while maintaining effective material removal through multiple strokes.
Solution Approach 2:
The first quality control loop implements a feedback mechanism by measuring the actual geometry after pre-final grinding strokes and using this information to determine corrected axis movements for subsequent pre-final strokes. This feedback ensures that deviations are detected and corrected before the final grinding stroke, preventing their transfer to the final geometry and maintaining high measurement precision throughout the multi-stroke process.
Data Source
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AI summary
Method for setting up a gear grinding process, comprising the process steps: determining axis movements and/or a geometry of a grinding tool (17) for one grinding stroke or for several grinding strokes by means of a first quality control loop (Q1) by repeating the steps grinding (18), measuring (20) and correcting (28) for a pre-final target geometry (12) of a gear (4) which has a stock allowance (14) to a final target geometry (8) of the gear (4), wherein the steps grinding (18), measuring (20) and correcting (28) of the first quality control loop (Q1) are repeated on one or more components (19) until a gear ground on the respective component (19) or components (19) has achieved a predetermined accuracy with respect to the pre-final target geometry (12);Determining axis movements and/or a geometry of a grinding tool (17) for one grinding stroke or for several grinding strokes by means of a second quality control loop (Q2) by repeating the steps grinding (18), measuring (20) and correcting (28) for the final target geometry (12) of the gear (4), wherein the steps grinding (18), measuring (20) and correcting (28) of the second quality control loop (Q2) are repeated on one component (19) or on several components (19) until a gear ground on the respective component (19) or components (19) has achieved a predetermined accuracy with respect to the final target geometry (8).