Gearwheel Grinding with In-Process Tooth Flank Oversize Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing grinding and polishing machines with multiple workpiece spindles cannot accurately determine the actual allowance on the flanks of gear-like profiles, limiting the optimization of the machining process without external measuring systems.
Innovation Solution
The method involves using a tactile measuring element or non-contact device to scan the tooth or profile flanks of a workpiece on one spindle while grinding or polishing another, allowing for the determination of effective oversize and hardening distortion, which informs optimized grinding or polishing parameters such as feed rate and infeed size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If a non-contact inductive sensor is used to detect the position of tooth gaps, then the alignment speed and cycle time are improved, but the measurement precision of the actual allowance on tooth flanks deteriorates
Solution Approach 1:
The measurement task is segmented into two parts: gap position detection (performed by inductive sensor for speed) and allowance measurement (performed by tactile probe or optical sensor for precision). Each sensor type handles the aspect it excels at, resolving the contradiction between speed and precision.
Solution Approach 2:
The patent combines multiple measurement methods (inductive sensing for gap detection, tactile probing or optical scanning for allowance measurement) into a unified measurement system that leverages the strengths of each approach to achieve both speed and precision.
2Measurement precision
If a tactile measuring element or non-contact measuring device is used to scan tooth flanks, then the measurement precision of allowance is improved, but the processing time increases
Solution Approach 1:
The measurement of the second workpiece is performed in advance during the grinding of the first workpiece. This preliminary measurement action ensures that when the second workpiece is ready for grinding, all necessary measurement data is already available, eliminating time loss.
Solution Approach 2:
The measurement process is made continuous by overlapping it with the grinding process of another workpiece. The measuring device operates continuously on the second workpiece while the grinding tool works on the first workpiece, ensuring no idle time in the production cycle.
3Productivity
If multiple workpiece spindles are used for concurrent machining, then the productivity is improved, but the device complexity increases
Solution Approach 1:
The grinding machine is designed with multi-functionality by incorporating both grinding tools and measuring devices (tactile probes or optical sensors) that can operate on multiple workpiece spindles. This universal design allows the same machine to perform both machining and measurement functions across multiple spindles, improving productivity without proportionally increasing complexity.
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
This approach enables improved workpiece positioning and machining results without additional processing time or external measuring systems, allowing for real-time adjustment of parameters to maintain consistent material removal and reduce deviations due to hardening distortion.
Implementation Method 1
a non-contact inductive sensor is typically used to detect the position of the tooth gaps or profile gaps
Implementation Method 2
scanning the tooth or profile flanks of at least one tooth or profile gap by means of a tactile measuring element
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a method for grinding or polishing a gearwheel (1, 2) in a grinding or polishing machine (3), wherein the machine (3) has two workpiece spindles (4, 5) for receiving a workpiece (1, 2) and at least one grinding or polishing spindle (6) with a grinding or polishing tool (7). In order to allow optimal working without additional machining times and without external measurement systems, the invention provides that the method has the steps of: a) grinding or polishing a first workpiece (1) received on a workpiece spindle (4); b) in a temporally parallel manner to the grinding or polishing of the first workpiece (1): receiving a second workpiece (2) on the further workpiece spindle (5) and measuring the toothing (8) of the workpiece (2) in order to determine the positions of the tooth gaps (9), wherein the measurement of the toothing (8) comprises the scanning of the tooth or profile flanks (10) of at least one tooth gap (9) by means of a tactile measuring element (11) or a contactless measurement means, in order to determine the effective oversize on the tooth flanks (10); c) following completion of the grinding or polishing of the first workpiece (1): grinding or polishing the second workpiece (2) received on the further workpiece spindle (5) using the determined positions of the tooth gaps (9) and/or the measured effective oversize on the tooth flank (10) as a basis.