Grinding Wheel Positioning via Automated Calculation
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Solution Overview
Problem
Conventional grinding techniques require skilled manual operations for setting the positional relationship between the grinding wheel and workpiece, leading to prolonged setup times and potential inaccuracies, resulting in inefficient and potentially defective products.
Innovation Solution
A grinding machine with a control system that calculates and sets a provisional grinding start position for the grinding wheel based on workpiece specifications, using an in-process gauge to adjust and fix the actual start position, eliminating the need for manual teaching operations and ensuring precise contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual teaching operation is used to set the grinding wheel position, then the worker can adjust the position based on experience, but the setup time is prolonged and the precision is inconsistent
Solution Approach 1:
The patent replaces the manual mechanical teaching operation with an automated calculation system. The control section computes the grinding start position S0 using the formula S0 = ID - WD - S4 - Sα, substituting human manual positioning with automated computational positioning based on workpiece and grinding wheel dimensions.
Solution Approach 2:
The system performs self-positioning by automatically calculating and setting the grinding start position without requiring manual intervention. The control section autonomously determines the correct position based on predetermined parameters, enabling the machine to serve itself in the positioning task.
2Manufacturing precision
If manual teaching operation is used, then the worker can bring the grinding wheel into contact with the workpiece, but skill differences cause position errors and defective products
Solution Approach 1:
The patent eliminates manual mechanical positioning by replacing it with automated calculation. The control section computes the precise grinding start position using the formula S0 = ID - WD - S4 - Sα, removing human skill variability from the positioning process and ensuring consistent accuracy across all operations.
Solution Approach 2:
The system incorporates feedback through the in-process gauge that measures the workpiece diameter ID during grinding. This measurement feeds back to the control section, which uses it to calculate and adjust the grinding start position, ensuring accurate positioning even with variations in workpiece dimensions.
3Productivity
If automated positioning is implemented, then setup time is reduced and precision is improved, but the system complexity increases
Solution Approach 1:
The patent replaces complex manual teaching operations with a simplified automated calculation system. Instead of requiring workers to manually position the grinding wheel through experience-based adjustments, the control section automatically computes the position using basic dimensional parameters, reducing operational complexity while improving productivity.
Data Source
AI summary
With the center position CP of a support shaft 6 supporting a grinding wheel 4 being a reference, a provisional grinding start position S0′ for a first workpiece 2 is calculated, based on a diameter ID of the first workpiece 2 before grinding, a diameter WD of the grinding wheel, a grinding completion position S4 on the first workpiece after the grinding, and an actual grinding start position S0 of the grinding wheel before grinding in second and subsequent grinding. S0 is determined by performing the grinding by moving the grinding wheel from S0′ and by moving the grinding wheel away from the first workpiece by a distance corresponding to S4 near the grinding completion position S4. S0′ is set by a calculation, S0′=ID−WD−S4−Sα, considering an allowance Sα between S0 and S0′.