Grinding Machine Automatic Teaching Control System
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Solution Overview
Problem
Conventional grinding techniques require skilled workers for setting up workpiece positions, leading to prolonged setup times and potential dimensional inaccuracies, resulting in defective products, especially when starting up after temperature changes without an in-process gauge.
Innovation Solution
A grinding machine with a control system that presets contact positions, measures workpiece dimensions, and adjusts grinding wheel positions to ensure accurate grinding without manual skill, allowing for automatic calculation of residual grinding amounts and correction positions to achieve target dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a manual teaching operation is performed to position the grinding wheel, then the workpiece can be ground, but the setup time is prolonged and requires skilled workers
Solution Approach 1:
The system performs automatic teaching operations where the grinding wheel automatically approaches and contacts the workpiece, and the control system automatically records the contact position. This eliminates the need for skilled manual operation and reduces setup time significantly.
Solution Approach 2:
The manual mechanical teaching operation is replaced by an automated control system that uses sensors and programmable logic to position the grinding wheel. The control system automatically calculates and records the contact position without human intervention.
2Manufacturing precision
If manual teaching operation is used to position the grinding wheel, then grinding can be performed, but dimensional accuracy varies depending on worker skill and contact force
Solution Approach 1:
The control system automatically detects the contact position between the grinding wheel and workpiece using sensors, and uses this feedback information to precisely position the grinding wheel. This eliminates variations caused by manual contact force and ensures consistent dimensional accuracy.
Solution Approach 2:
The manual positioning method is replaced by an automated sensing and control system that objectively measures and records the contact position, eliminating human error and variability in positioning accuracy.
3Productivity
If the machine starts up after temperature changes, then operation can resume, but dimension changes occur leading to defective products
Solution Approach 1:
Upon machine startup, the system automatically performs a teaching operation to detect the current contact position between the grinding wheel and workpiece. This preliminary action accounts for any dimension changes due to temperature, ensuring accurate grinding from the first product after startup.
Solution Approach 2:
The system adapts to temperature-induced dimension changes by dynamically adjusting the grinding wheel position based on real-time teaching data. The control system modifies positioning parameters to compensate for thermal expansion or contraction of machine components.
Data Source
AI summary
Teaching (contacting) operation is performed, and from the contact position (SX), the workpiece (2) is ground by a given “test grinding amount (A).” Subsequently, the diameter of the workpiece is measured. Based on the result of the measurement, the residual amount to be ground (residual grinding amount) to obtain the finished dimensions is calculated, and grinding by the “residual grinding amount (R)” is performed.