Honing Machine Spindle Alignment System
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Solution Overview
Problem
Conventional honing machines require extensive time and expertise to precisely align the spindle axis with the bore axis, often necessitating iterative grinding of shims, which is irreversible and prone to errors, limiting the ability to quickly and accurately set alignment post-maintenance or damage.
Innovation Solution
A honing machine with a continuously variable and reversible alignment system that allows independent adjustment of the spindle axis's position and orientation along two perpendicular axes, using separate setting units with wedge elements and actuating devices for precise, intuitive alignment, enabling less experienced operators to achieve accurate alignment quickly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If iterative grinding of shims is used to align the spindle axis with the bore axis, then manufacturing precision of alignment is improved, but loss of time and device complexity increase
Solution Approach 1:
The alignment system uses adjustable components that can be dynamically modified during the alignment process. Instead of fixed shims that require iterative grinding, the system allows real-time adjustment of the spindle axis position and orientation through mechanically adjustable elements, enabling quick corrections without time-consuming grinding operations.
Solution Approach 2:
The invention changes the physical state and adjustability parameters of the alignment components. Rather than using static shims with fixed thicknesses, the system employs adjustable components that can be modified in real-time, allowing operators to quickly adjust alignment parameters and correct errors without returning to previous iterative grinding steps.
2Manufacturing precision
If iterative grinding of shims is used to align the spindle axis with the bore axis, then manufacturing precision of alignment is improved, but device complexity increases
Solution Approach 1:
The alignment system is divided into separate adjustable components for different alignment dimensions. The system independently adjusts the spindle axis position in multiple directions and orientations through separate setting elements, making the complex alignment process modular and easier to manage compared to a monolithic shim grinding approach.
Solution Approach 2:
The invention replaces the traditional mechanical shim grinding process with a different mechanical adjustment system. Instead of using ground shims that require precision grinding equipment and skilled operators, the system employs adjustable mechanical components that can be quickly modified, reducing both the complexity of the alignment system and the skill level required.
3Device complexity
If rigid honing tool and rigid workpiece receptacle are used, then device complexity is reduced, but manufacturing precision of bore alignment deteriorates
Solution Approach 1:
The invention introduces dynamic adjustability to the workpiece receptacle, allowing it to adapt its position and orientation during the honing process. The receptacle can be adjusted to compensate for misalignments between the rigid honing tool and the workpiece, maintaining high machining precision without requiring complex tooling systems.
4Device complexity
If alignment is set during initial assembly, then device complexity is reduced, but reliability of alignment post-maintenance deteriorates
Solution Approach 1:
The alignment system is designed to be adjustable at any stage of the machine's operation, including after maintenance or damage. The adjustable components can be quickly modified to restore correct alignment, ensuring that the spindle axis remains properly aligned with the bore axis regardless of whether the machine is in initial assembly or post-maintenance operation.
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
Facilitates rapid and precise alignment of the spindle axis with the bore axis, reducing the need for highly experienced technicians and minimizing errors, as alignment errors can be corrected reversibly and setting work is decoupled for efficient operation.
Implementation Method 1
a wedge element with a first wedge surface, which faces towards the base element, and with a second wedge surface, which faces towards the main support, wherein the wedge element is displaceable along a displacement direction
Data Source
AI summary
A honing machine (100) for honing a bore in a workpiece comprises a support structure (120) fixed to the machine and at least one honing unit (130) which is mounted on the support structure and which has a main support (160), which can be mounted fixedly in relation to the support structure, and a spindle unit (150), which is supported by the main support and in which a spindle shaft (152) is rotatably mounted, wherein the spindle shaft (152) is rotatable about a spindle axis (155) by means of a rotary drive and, at a tool-side end (153), has a device for the fastening of a honing tool. The honing machine furthermore has a linear guide system which is arranged between the main support (160) and the spindle unit (150) and which serves for guiding a linear stroke movement of the spindle unit (150) relative to the main support (160), a stroke drive for generating the stroke movement of the spindle unit (150), and an alignment system (200) for setting the alignment of the spindle axis (155) in relation to the support structure (120). The alignment system (200) is designed for the continuously variable, reversible setting of the alignment of the spindle axis (155) in relation to the support structure (120), wherein the alignment system is designed for the independent setting of the position of the spindle axis (155) along two mutually perpendicular axes of translation and for the setting of the orientation of the spindle axis (155) in relation to two mutually perpendicular axes of rotation.