Honing Feed System with Force Feedback for Rapid Contact
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Solution Overview
Problem
Existing honing machines face challenges in precisely controlling the feed system to ensure effective contact between the honing tool and the workpiece without damaging the tool, workpiece, or increasing honing cycle time, especially when the starting diameter of the workpiece varies.
Innovation Solution
A honing feed system that utilizes feedback from torque or force sensors to control the rapid advancement of the honing tool, allowing it to make contact with the bore surface at a fast rate while maintaining bore geometry, using methods like 'Rapid Until Load' and 'Rapid Until Force' to adjust the feed rate based on real-time torque or force measurements, and signal conditioning to filter out noise for accurate control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the feed system rapidly expands the tool to a specific feed position, then the honing cycle time is reduced, but the abrasive may impact the workpiece with too much force and damage the tool and/or fixture
Solution Approach 1:
The system employs feedback from torque or force sensors to monitor the actual contact force between the abrasive and workpiece. This feedback signal is processed through conditioning circuits that filter noise and extract meaningful contact information. The processed feedback is then used to dynamically adjust the feed rate, reducing it when contact force exceeds safe thresholds while maintaining rapid approach speeds, thus preventing tool and fixture damage while preserving productivity
Solution Approach 2:
The feed system transitions from static predetermined feed rates to dynamic feed rate control based on real-time conditions. The system continuously adjusts the feed rate during the honing cycle according to actual contact forces, workpiece diameter variations, and abrasive engagement conditions. This dynamic adaptation allows rapid tool advancement when no contact exists while automatically reducing speed when contact occurs, resolving the contradiction between speed and safety
2Object-affected harmful factors
If the system expands the tool too slowly to avoid damage, then tool and fixture safety is improved, but the honing cycle time increases unnecessarily
Solution Approach 1:
The feedback mechanism enables the system to distinguish between safe and unsafe conditions in real-time. During the approach phase, the system maintains high feed rates because sensors detect no contact force. Only when the abrasive actually engages the workpiece does the feedback trigger feed rate reduction. This selective slowing based on actual conditions eliminates unnecessary cycle time extension while ensuring safety when required
Solution Approach 2:
The system skips the cautious slow-feed phase entirely during the approach to contact, rushing the tool rapidly toward the workpiece. Only upon detecting actual contact through sensor feedback does the system transition to controlled feeding. This skipping of unnecessary caution phases during safe conditions dramatically reduces cycle time while maintaining safety through on-demand feed rate adjustment
3Object-affected harmful factors
If the system rapidly expands the tool to a position less than the minimum expected bore surface location, then tool safety is improved, but cycle time is wasted by honing air between the expanded position and actual bore wall
Solution Approach 1:
The torque/force sensor feedback system detects the exact moment when the abrasive contacts the bore surface, regardless of where the tool was positioned beforehand. This real-time detection eliminates the need to conservatively position the tool at the minimum expected bore location. The system can rapidly expand the tool beyond where the bore might be, then use feedback to identify actual contact and initiate proper feeding only then, thus eliminating wasted honing air time while maintaining tool safety
Solution Approach 2:
The system performs preliminary rapid expansion of the tool to a position that may exceed the minimum expected bore location, preparing the abrasive for contact. This preliminary action is followed by sensor-based detection of actual contact conditions. The feedback from this preliminary expansion phase enables the system to adjust feeding based on real bore location rather than conservative estimates, eliminating wasted cycle time while maintaining safety through controlled feeding initiation
4Adaptability or versatility
If the starting diameter of the un-honed workpiece varies from workpiece to workpiece, then adaptability is improved, but the system may waste cycle time by honing air between the pre-expanded position and actual bore position
Solution Approach 1:
The feedback system continuously monitors actual contact conditions during tool expansion, enabling the system to adapt to each workpiece's specific diameter regardless of variations. Rather than using a fixed conservative expansion position, the system rapidly expands and uses sensor feedback to detect when and where contact occurs. This real-time adaptation eliminates wasted honing air time for each specific workpiece while maintaining the ability to handle diameter variations, thus improving both adaptability and productivity
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 approach enables precise and repeatable initial conditions for the abrasive, reducing the risk of damage and unnecessary cycle time, improving productivity by ensuring accurate contact and maintaining bore geometry across varying workpiece diameters.
Implementation Method 1
feedback from torque or force sensors to control the rapid advancement of the honing tool
Implementation Method 2
signal conditioning to filter out noise for accurate control
Data Source
AI summary
The honing feed system and method utilizes feedback from various sources during rapid feeding of the honing tool while rotating and stroking, to detect initial contact with a bore surface, to slow the feed to a normal honing rate, involving conditioning the feedback signals to eliminate noise factors such as the stroking movement and forces generated to rotate and feed the tool unopposed.