Gear Workpiece Loading With Fixed Angular Positioning
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Solution Overview
Problem
The process of stock-dividing in gear manufacturing is time-consuming, leading to unproductive machine idle time and increased machining cycle times, as each gear-shaped workpiece must be individually positioned before finishing operations, such as grinding, which hinders productivity.
Innovation Solution
A method and apparatus that eliminate the need for stock-dividing each toothed workpiece by using a pallet with a locating element and a gripping mechanism with pin and ball elements to consistently orient workpieces in a predetermined rotational position, allowing subsequent workpieces of the same design to be loaded and machined without re-determining their rotary position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If stock-dividing is performed for each workpiece to ensure proper positioning, then machining precision is improved, but productivity deteriorates due to time-consuming operations
Solution Approach 1:
The workpiece is pre-oriented in a predetermined rotational position during loading, and the stock-dividing operation is performed only once to determine the adjustment amount. This preliminary positioning action eliminates the need to repeat stock-dividing for subsequent workpieces of the same design, reducing cycle time while maintaining precision
Solution Approach 2:
The adjustment amount determined from the first workpiece is copied and applied to subsequent workpieces of the same design. By using the same rotational adjustment for identical workpieces, the system avoids redundant measurement and positioning operations, thereby improving productivity without sacrificing machining precision
2Reliability
If stock-dividing operation is performed for each workpiece, then proper tool alignment is achieved, but machine idle time increases
Solution Approach 1:
The workpiece is pre-oriented in a predetermined rotational position during loading, and the stock-dividing operation is performed only once to determine the adjustment amount. This preliminary positioning action eliminates the need to repeat stock-dividing for subsequent workpieces of the same design, reducing cycle time while maintaining precision
Solution Approach 2:
The adjustment amount determined from the first workpiece is copied and applied to subsequent workpieces of the same design. By using the same rotational adjustment for identical workpieces, the system avoids redundant measurement and positioning operations, thereby improving productivity without sacrificing machining precision
Data Source
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AI summary
A method wherein a first workpiece (2, 40) is loaded to a spindle (30) of a workpiece processing machine with the first toothed workpiece having a predetermined design and being in a predetermined rotational load position. The first toothed workpiece is stock- divided and a machining position is determined based on the stock-dividing. The first toothed workpiece is rotationally adjusted to the machining position. The teeth (3, 42) of the first toothed workpiece are then machined and the first workpiece is removed from the spindle. A second toothed workpiece is loaded to the spindle of the workpiece processing machine. The second toothed workpiece has the same predetermined design and is in the same predetermined rotational load position as the first toothed workpiece. The second toothed workpiece is rotationally adjusted from the predetermined rotational load position to the machining position by the same adjustment amount as the first toothed workpiece. The second toothed workpiece is machined and then removed from the machine spindle. The process as performed for the second toothed workpiece can be repeated for subsequent workpieces having the same design and being in the same rotational load position as the first and second workpieces. For the second and subsequent toothed workpieces, the step of determining the rotary position of the teeth is not carried out.