Grinding Apparatus Load Control via Programmable Force Feedback
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Solution Overview
Problem
Conventional grinding machines for rock drill bits and cutters face issues with vibration, noise, high energy requirements, and long grinding times due to high rotational speeds and the need for large compressors, along with limited precision in controlling feed pressure.
Innovation Solution
A grinding apparatus with a support system that includes a motor-driven grinding cup, an arm or lever system for alignment, and a programmable control system with load cells to monitor and control force, speed, and movement, allowing for precise control of grinding pressure and movement, and a water and waste collection system for coolant recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high rotational speeds are used in conventional grinding machines, then material removal efficiency is improved, but vibration and noise increase
Solution Approach 1:
The grinding machine employs dynamic control of rotational speed through a variable speed drive system, allowing the spindle to operate at optimized speeds that balance material removal efficiency with vibration control. The system can adjust rotational speed in real-time based on grinding conditions, preventing excessive vibration while maintaining productivity.
Solution Approach 2:
The invention changes the operational parameters by implementing precise control over rotational speed, feed rate, and grinding depth. By optimizing these parameters rather than simply increasing rotational speed, the system achieves effective material removal while keeping vibration and noise levels acceptable.
2Force
If conventional pneumatic systems with large compressors are used, then grinding pressure is provided, but device complexity and energy consumption increase
Solution Approach 1:
The invention replaces the pneumatic compressor system with an electrically-driven mechanical pressing system. An electric motor coupled with a mechanical pressing mechanism directly applies grinding pressure, eliminating the need for large compressors, pneumatic hoses, and associated control systems while reducing device complexity and energy consumption.
Solution Approach 2:
The pneumatic compressor subsystem is extracted and removed from the system. The grinding machine uses only the essential mechanical pressing function, discarding the complex pneumatic infrastructure while maintaining adequate grinding pressure through simplified electric-mechanical means.
3Device complexity
If minimum grinding pressure equals the weight of the arm or lever section, then structural simplicity is maintained, but precision in controlling feed pressure is limited
Solution Approach 1:
The system incorporates feedback control through load cells that continuously measure the actual grinding pressure. This measurement is fed back to a control system that adjusts the pressing force to maintain the desired pressure level, enabling precise feed pressure control independent of the arm or lever weight.
Solution Approach 2:
The passive pressure control based on gravitational weight is replaced with an active electrically-controlled mechanical pressing system. This allows the feed pressure to be precisely controlled and varied independently of the structural components' weight, enabling pressure starting from zero and precise adjustment throughout the grinding process.
4Ease of operation
If conventional grinding machines are used, then basic grinding function is provided, but grinding time per button is extended
Solution Approach 1:
The grinding process maintains continuous useful action through optimized feed rates and rotational speeds, ensuring that material is removed efficiently throughout the entire grinding cycle without unnecessary interruptions or idle periods, thereby reducing total grinding time per button.
Solution Approach 2:
The invention optimizes multiple operational parameters simultaneously - increasing rotational speed within vibration limits, optimizing feed rate, and controlling grinding depth - to maximize material removal rate while maintaining grind quality, thus reducing the time required per button without sacrificing ease of operation.
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 reduces vibration and noise, improves precision in grinding, and allows for safer operation by controlling feed pressure from zero, potentially reducing energy consumption and shortening grinding times while maintaining effective material removal.
Implementation Method 1
The means to monitor and control one or more functions of the grinding apparatus includes one or more load cells to quantify and measure forces being applied during said one or more functions
Implementation Method 2
a grinding cup driven by a motor to rotate about its longitudinal axis
Implementation Method 3
A grinding cup or grinding pin, mounted on the end of the rotor or spindle, grinds the button and typically the face of the bit/cutter surrounding the base of the button to restore the button to substantially its original profile
Data Source
AI summary
The present disclosure relates to grinding apparatus for grinding the hard metal inserts of rock drill bits, said grinding apparatus having said grinding machine equipped with a grinding cup driven by a motor to rotate about its longitudinal axis wherein the support system comprises an arm or lever system to control vertical movement of the grinding machine and means to provide grinding pressure, wherein the means to provide grinding pressure may be a linear actuator and load cell assembly pivotally connected to the arm or lever system.