Grinding Worm Geometry Sensing for Automatic Tool Centering
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Solution Overview
Problem
Existing gear cutting processes require manual or semi-automatic input of tool geometric parameters and centering, leading to increased setup times and potential misadjustments, and there is a lack of methods for fully automatic determination of process-relevant geometric parameters using non-contact measuring systems.
Innovation Solution
A method for automatically determining geometric parameters of a grinding worm using sensors, including calibration to determine the sensor's position relative to the grinding worm and within the gear cutting machine, enabling precise alignment and centering through computational processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual or semi-automatic methods are used for determining tool geometric parameters and centering, then the process can be performed with simple equipment, but setup times increase and misadjustments occur
Solution Approach 1:
The patent replaces manual mechanical measurement and positioning operations with an automated optical measurement system. The non-contact measuring system captures geometric parameters and centering data automatically, eliminating the need for manual operations with calipers, protractors, and other mechanical measuring tools, thereby reducing setup time while introducing automated measurement technology.
Solution Approach 2:
The measurement system enables the tool and workpiece to self-determine their geometric parameters and relative positions. By capturing images or measurement data and processing them computationally, the system automatically determines tool center positions, workpiece tooth gap positions, and geometric dimensions without requiring operator intervention, allowing the system to service itself.
2Measurement precision
If manual centering operations are performed, then the equipment remains simple, but positioning precision deteriorates due to operator error
Solution Approach 1:
The patent replaces manual visual estimation and mechanical positioning with an automated optical measurement and computational processing system. The system captures precise positional data of tool centers and workpiece features, then uses computational algorithms to determine accurate centering positions, eliminating operator error while implementing automated measurement and control.
Solution Approach 2:
The measurement system provides feedback by capturing actual geometric parameters and positions, processing this data computationally, and using the results to automatically adjust or verify tool and workpiece positioning. This closed-loop feedback mechanism ensures precise centering by continuously monitoring and correcting positions based on measured data.
3Reliability
If tool geometric parameters are manually input, then the system remains simple to operate, but incorrect settings occur leading to profile errors
Solution Approach 1:
The patent replaces manual data input operations with automated optical measurement and computational processing. Instead of operators manually reading and entering geometric parameters from tool drawings or measurements, the system automatically captures images or measurement data, processes it computationally, and extracts accurate geometric parameters, eliminating transcription errors and ensuring reliable data input.
Solution Approach 2:
The measurement system creates an optical or digital copy of the tool and workpiece geometry, then processes this copy computationally to determine accurate geometric parameters. By working with a digital representation rather than manual transcription, the system ensures parameter accuracy while automating the measurement and data extraction process.
Data Source
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AI summary
The invention relates to a method for automatically determining the geometric dimensions of a tool with a worm-shaped machining area, in particular a grinding worm (11), in a gear cutting machine, with at least one parameter of the tool being automatically detected and/or determined by means of at least one sensor (8).