Double-Sided Grinding Machine Force Sensor Feedback Control
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Solution Overview
Problem
Double-sided grinding machines face challenges in processing brake discs with hard, low-stability surfaces due to deformation during grinding, leading to inadequate axial run-out accuracy and surface roughness.
Innovation Solution
Incorporating a force sensor in the workpiece holding device to detect forces acting on the workpiece, allowing for real-time control of grinding parameters and matching machining forces from both grinding wheels, thereby minimizing deformation and maintaining surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high machining forces are applied to grind hard carbide particles on brake disc surfaces, then grinding quality is improved, but the brake disc deforms axially between the two grinding wheels
Solution Approach 1:
A force sensor is installed in the workpiece holding device to detect machining forces in real-time. The sensor provides feedback signals to the control unit, which adjusts the feed rates of the grinding wheels dynamically to maintain balanced forces and prevent axial deformation of the brake disc during grinding.
Solution Approach 2:
The system dynamically adjusts the feed rates of the first and second grinding wheels based on real-time force sensor measurements. The control unit modifies machining parameters during the grinding process to maintain optimal force distribution and prevent deformation of the flexible brake disc.
2Manufacturing precision
If the brake disc is ground in a deformed state to achieve satisfactory surface quality, then grinding is completed, but the brake disc exhibits insufficient flatness after deformation reverses
Solution Approach 1:
The force sensor continuously monitors machining forces and provides feedback to the control unit, which adjusts feed rates in real-time to maintain the brake disc in a stable, non-deformed state throughout the grinding process, ensuring both surface quality and final flatness accuracy.
Solution Approach 2:
The system preliminarily balances the machining forces from both grinding wheels before significant deformation occurs by using force sensor feedback to adjust feed rates proactively, preventing deformation rather than correcting it after occurrence.
3Manufacturing precision
If force sensor feedback control is implemented to equalize machining forces, then axial run-out accuracy is improved, but device complexity increases
Solution Approach 1:
A force sensor is integrated into the workpiece holding device to detect machining forces and provide feedback to the control unit, which automatically adjusts the feed rates of the grinding wheels to maintain balanced forces and improve axial run-out accuracy.
Solution Approach 2:
The control system automatically adjusts machining parameters based on force sensor feedback without requiring manual intervention. The system self-regulates the feed rates of both grinding wheels to maintain optimal force distribution and achieve precise axial run-out.
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
The solution ensures precise grinding of brake discs with high axial run-out accuracy and maximum surface roughness, even under high machining forces, by adjusting feed rates based on force sensor feedback.
Implementation Method 1
the workpiece holding device includes at least one force sensor for detecting forces that act on the workpiece holding device during grinding machining of the workpiece
Data Source
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AI summary
The invention relates to a double-sided grinding machine (10) comprising a first machine part (16) with a first grinding wheel (18) and a second machine part (20) with a second grinding wheel (22), wherein a distance between the first grinding wheel and the second grinding wheel is adjustable along a machine axis (14), further comprising a workpiece holding device (30) for holding a workpiece (26), wherein the workpiece holding device includes at least one force sensor for detecting forces acting on the workpiece holding device during grinding of the workpiece. The invention further relates to a method for grinding a brake disc.