Grinding Wheel Feedback for Ceramic and Stone Edge Machining
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Solution Overview
Problem
Existing machines for squaring ceramic products and natural stones require manual adjustment of grinding wheels based on operator experience, leading to inconsistent results due to wear and varying skill levels, and lack automation, resulting in suboptimal machining precision and increased costs.
Innovation Solution
A machine equipped with measuring means downstream of each grinding wheel to detect material removal and adjust wheel positions automatically or with operator input, using contact or non-contact distance measurement, and a control unit to compensate for wheel wear and misalignment, ensuring precise machining without operator expertise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment of grinding wheels is performed based on operator experience, then the machine can operate with simple structure, but the machining precision deteriorates due to varying skill levels and wheel wear
Solution Approach 1:
The patent implements a feedback mechanism where sensors detect the actual position of ground edges and provide this information to a control unit. The control unit compares measured positions with target positions and automatically adjusts grinding wheel positions accordingly. This closed-loop feedback system eliminates the need for manual operator judgment while maintaining simple overall machine structure.
Solution Approach 2:
The machine performs self-adjustment of grinding wheel positions through automatic control based on sensor feedback. The system monitors its own machining results and makes corrective adjustments without external operator intervention, enabling the machine to maintain precision autonomously while keeping the device structure relatively simple.
2Manufacturing precision
If automated adjustment systems are implemented, then machining precision improves, but the device complexity and costs increase
Solution Approach 1:
The patent uses a cost-effective feedback approach with sensors positioned to detect edge positions and a control unit that processes this information to automatically adjust wheel positions. This feedback system achieves high machining precision without requiring complex automated adjustment mechanisms, as the feedback loop enables simple actuators to make precise corrections.
Solution Approach 2:
The patent replaces complex mechanical adjustment systems with a combination of simple sensors and control electronics. Instead of using elaborate mechanical mechanisms for wheel positioning, the system uses electronic sensing and control to achieve automated adjustment, reducing mechanical complexity while improving precision.
3Reliability
If grinding wheels are used without measurement feedback, then the device structure remains simple, but the reliability of machining results deteriorates due to wheel wear
Solution Approach 1:
The patent implements measurement feedback using sensors that detect the position of ground edges at each machining station. This feedback information is transmitted to a control unit that monitors wheel performance and detects wear. The system reliably maintains machining quality by continuously measuring results and making adjustments based on actual performance rather than relying on wheel life estimates.
4Productivity
If multiple pairs of grinding wheels are used for progressive machining, then productivity improves, but the difficulty of detecting and measuring individual wheel contributions deteriorates
Solution Approach 1:
The patent divides the machining process into distinct segments, with each grinding wheel pair responsible for a specific machining step. Sensors are positioned downstream of each wheel pair to measure the contribution of that specific segment. This segmentation allows the system to monitor and control each wheel's performance independently, making measurement straightforward despite having multiple wheels working in sequence.
Solution Approach 2:
The patent adds a measurement dimension by placing sensors in the advancement direction downstream of each grinding wheel. This spatial arrangement allows independent measurement of each wheel's contribution to material removal, transforming a complex multi-wheel measurement problem into a series of simple single-point measurements along the production flow.
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
Enables easy, precise, and automated adjustment of grinding wheel positions, improving machining accuracy and reducing reliance on operator experience, while maintaining symmetry and minimizing mechanical clearances to enhance overall machining quality and efficiency.
Implementation Method 1
a measuring device located behind the stations in advance direction. The measuring device has stationary optical measurers on either side of the conveyor, to determine the distance between the measurers and a side surface of a brick already worked on
Data Source
Figure 1
Figure 2
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AI summary
A machine (1) for machining elements (A), such as ceramic products or natural stones and the like, which are provided with two edges (B) to be machined, comprises a support structure (4) for at least one conveyor belt (5) for transferring and advancing the elements (A) according to a specific advancement direction (X) on a respective support plane (6), the edge (B) being arranged substantially parallel to the advancement direction (X), driven grinding wheels (2) for machining the edge (B), the driven grinding wheels (2) being provided with means (21) for adjusting the position with respect to the edge (B) of the elements (A), with measuring means (8) arranged downstream of each wheel (2), with respect to the advancement direction (X), which measure a distance (L) of the edge (B) with respect to a reference of the machine (1), and by means of the distance (L) the measuring means (8) calculate a measurement of the machining carried out on the edge (B) by the wheel (2) which immediately precedes said measuring means (8); a method is also provided for machining the edge (B) of the elements (A).