Gear Toothing Machining with Real-Time Workpiece Control
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Solution Overview
Problem
Existing gear machining methods face challenges in achieving high machining accuracy with minimal rejects and efficient machining times, particularly due to complex gearing parameters and tooth flank modifications.
Innovation Solution
The method involves storing control information specific to each workpiece, allowing machining stations to perform only the necessary operations in real-time, and enabling flexible adjustments based on external conditions or machining operations without switching out of real-time systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If sequence control is carried out by control instructions given once within a process to processing stations, then automation and efficiency are improved, but flexibility to adapt to external conditions or machining operations deteriorates
Solution Approach 1:
The patent implements dynamic control information that can be modified in real-time during the machining process. Control information is no longer static but adapts to actual machining conditions, allowing the system to maintain automation while responding to external conditions and machining operations as they occur.
Solution Approach 2:
The system incorporates feedback mechanisms where control information is continuously updated based on monitoring machining operations and external conditions. This feedback loop enables the control system to adjust machining parameters and sequences dynamically, resolving the contradiction between automation and flexibility.
2Productivity
If machining operations are performed according to predefined control instructions, then machining time efficiency is improved, but machining accuracy and reject reduction deteriorate due to inability to correct deviations in real-time
Solution Approach 1:
The system monitors machining operations in real-time and uses feedback to update control information, enabling corrections to be made during the machining process. This maintains high productivity while improving machining accuracy by addressing deviations as they occur rather than discovering them after machining is complete.
Solution Approach 2:
The system performs preliminary monitoring and assessment of machining conditions, allowing proactive adjustments to control information before significant deviations occur. This preventive approach maintains both efficiency and accuracy by avoiding the need for rework or scrap.
3Adaptability or versatility
If switching out of real-time systems is required to make adjustments, then adaptability is improved, but machining time and productivity deteriorate
Solution Approach 1:
The control system is designed to be dynamically adjustable within the real-time environment. Control information can be modified on-the-fly without requiring system shutdown or mode switching, allowing the machine to maintain real-time operation while adapting to changing conditions and requirements.
Data Source
Figure 1a~1b
Figure 2
Figure 3a~3h
AI summary
The invention relates to a method for machining toothings provided on workpieces, in which a number of workpieces are fed to at least one machining station with at least two machining operations and/or to at least two machining stations each with at least one machining operation and the machining of the toothing there, involving a machining engagement of a toothing tool with the workpiece toothing, as at least one of these machining operations and the at least one further machining operation are performed in machine real time, wherein a sequence control of the machining operations takes place at least partly in dependence on control information that is assigned to each individual workpiece to be worked and is stored and verified in machine real time.