Generating Grinding Centering Using Spindle Torque Feedback
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Solution Overview
Problem
The accuracy of centering during generating grinding of toothings is affected by various influencing factors, leading to deviations such as waviness and form errors, which are exacerbated by tight tolerances in modern manufacturing demands.
Innovation Solution
Adapt the centering position based on performance parameters of the workpiece spindle, such as torque or current consumption, to correct and monitor the centering process, using correction values for machine axes to achieve precise alignment of the grinding tool relative to the toothing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional centering methods using centering sensors are used, then the centering process can be performed, but the centering accuracy is insufficient due to various influencing factors such as pitch error distribution and changing stock allowance
Solution Approach 1:
The patent applies feedback by continuously monitoring the performance parameter (torque or current consumption) of the workpiece spindle during grinding and using this information to adjust the centering position. The control system compares the measured performance parameter with reference values and dynamically corrects the centering position to maintain optimal grinding conditions, thereby improving both centering accuracy and toothing quality
Solution Approach 2:
The patent replaces traditional mechanical centering sensors with a sensorless approach that uses the workpiece spindle's performance parameters (torque or current consumption) as indirect indicators of centering accuracy. This substitution eliminates the need for direct mechanical contact sensors and uses the spindle's electrical/mechanical response to determine and adjust centering position
2Manufacturing precision
If tight tolerances are required for modern manufacturing demands, then the quality of ground toothings is improved, but the requirements for centering quality become increasingly demanding and harder to achieve
Solution Approach 1:
The feedback mechanism continuously monitors the workpiece spindle's performance parameter during grinding and dynamically adjusts the centering position to maintain optimal conditions even under tight tolerance requirements. This closed-loop control ensures that centering accuracy is maintained throughout the grinding process, enabling consistent production of high-quality toothings with tight tolerances
Solution Approach 2:
The patent implements dynamic adjustment of the centering position based on real-time monitoring of the workpiece spindle's performance parameter. Rather than using a fixed predetermined centering position, the system continuously adapts the centering position during the grinding process to account for variations in stock allowance, pitch errors, and other influencing factors, thereby maintaining centering accuracy under tight tolerance conditions
3Ease of operation
If a predetermined centering position is used for all grinding strokes, then the grinding process is simple to operate, but deviations in centering position lead to toothing errors such as waviness and form errors
Solution Approach 1:
The system maintains ease of operation by automatically monitoring and adjusting the centering position based on the workpiece spindle's performance parameter. The control system handles the complexity of dynamic adjustment internally, while the operator simply needs to initiate the grinding process. This feedback-driven automatic adjustment eliminates toothing errors without requiring complex manual intervention
Solution Approach 2:
The grinding system performs self-adjustment of the centering position by monitoring its own performance parameter (workpiece spindle torque or current consumption) and automatically correcting the centering position without external intervention. This self-service capability maintains both operational simplicity and high toothing quality, as the system corrects its own centering deviations in real-time
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
Improves centering accuracy by correcting the position of the grinding tool, reducing material removal errors and ensuring consistent quality in generating grinding processes.
Implementation Method 1
the torque or the current consumption of a drive of the workpiece spindle
Data Source
AI summary
Method, comprising the method steps of: generating grinding of toothings (16), wherein a respective toothing (16) is machined by means of a plurality of grinding strokes and wherein a centering position for positioning a grinding tool (10) relative to the respective toothing (16) is predetermined for the grinding strokes, and adapting the centering position on the basis of a performance parameter (M2) of a workpiece spindle (6) accommodating the respective toothing (16).