Grinding Module Cylinder Linear Actuator Workpiece Shaping
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Solution Overview
Problem
The casting process results in variable excess solidified materials that require post-processing, which is inefficient due to reliance on skilled operators in manual grinding and high setup costs in CNC milling/turning processes.
Innovation Solution
A grinding module with a rotatable cylinder and linear actuator system that automatically feeds a workpiece to a grinding belt, allowing for efficient shaping and grinding without the need for custom fixtures or frequent operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual grinding process is used, then flexibility in handling variable excess solidified materials is improved, but productivity and consistency deteriorate due to dependency on skilled operator skills
Solution Approach 1:
The invention uses a programmable robot arm that replicates the grinding actions of a skilled operator through programmed sequences. The robot arm copies the precise movements, pressures, and trajectories that an expert operator would use, transferring this expertise into automated code that can consistently reproduce the same high-quality grinding results without human variability
Solution Approach 2:
The invention replaces the manual mechanical system of operator-controlled grinding with an automated robotic mechanical system. The robot arm equipped with a grinding tool substitutes the human operator's hand and grinding tool, eliminating the dependency on operator skill while maintaining the flexibility to handle variable excess materials through programmable adaptation
2Productivity
If CNC milling/turning process is used, then productivity and precision are improved, but device complexity and setup cost worsen due to requirement for custom fixtures
Solution Approach 1:
The robot arm system serves multiple functions: it can grind various types of excess solidified materials, adapt to different workpiece geometries, and handle multiple grinding operations without requiring custom fixtures for each application. This universal capability eliminates the need for dedicated CNC setups for different parts
Solution Approach 2:
The robot arm provides dynamic adaptability through programmable motion control, allowing it to adjust its trajectory, speed, and grinding pressure in real-time based on the specific characteristics of each workpiece. This dynamic capability replaces the static, pre-configured nature of traditional CNC fixtures
3Ease of manufacture
If manual grinding process is used, then setup cost is reduced, but loss of time worsens due to constant operator intervention and adjustment
Solution Approach 1:
The grinding parameters, trajectories, and sequences are pre-programmed into the robot arm before production begins. This preliminary programming action captures all the expertise and adjustments that would normally require repeated operator intervention, allowing the automated system to execute the complete grinding sequence without pause or human input during operation
4Manufacturing precision
If skilled operator is required for manual grinding, then grinding quality is improved, but ease of operation worsens due to high skill requirement
Solution Approach 1:
The robot arm system is self-sufficient in executing the grinding operation with high precision. Once programmed, it autonomously performs all grinding tasks without requiring skilled operators during operation. The system serves itself by automatically controlling the grinding tool's position, pressure, and movement, eliminating the need for human skill intervention while maintaining consistent quality
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 solution significantly reduces processing time, improves consistency, and lowers operational costs by enabling unskilled workers to operate the system safely and efficiently, while also enhancing environmental and health safety through automated processes.
Implementation Method 1
the grinding belt is adapted to grind and shape the surface of the workpiece to conform to the curved profile
Data Source
AI summary
According to various embodiments, there is provided a grinding module including a base; a cylinder mounted to the base with a longitudinal axis of the cylinder arranged at least substantially perpendicular to a surface of the base, wherein the cylinder is rotatable about the longitudinal axis of the cylinder, and wherein a cylindrical surface of the cylinder is adapted to receive a grinding belt; a linear actuator mounted to the base with a centreline of linear motion of the linear actuator arranged to intersect the longitudinal axis of the cylinder; and a holder connected to the linear actuator, the holder adapted to hold a workpiece with a surface of the workpiece facing the cylindrical surface of the cylinder, wherein the linear actuator is adapted to move the holder relative to the cylinder along the centreline of linear motion of the linear actuator, and wherein the cylindrical surface of the cylinder is adapted to define a curved profile so that the grinding belt is adapted to grind and shape the surface of the workpiece to conform to the curved profile.