Integrated Measuring Steady Rest for Crankshaft Grinding
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Solution Overview
Problem
Existing steady rests for supporting and measuring central workpiece regions, such as crankshafts, require additional space for measurement devices, leading to limited accuracy and the need to interrupt the grinding process for measurements, which complicates the machining process and reduces precision.
Innovation Solution
A measuring steady rest with integrated measurement devices that directly contact the workpiece, allowing for simultaneous support and measurement without additional space, using a CNC-controlled configuration with supporting parts that pivot and a measurement device aligned with the angle bisector for precise diameter measurement and adjustment during the grinding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a separate measurement device is added to the grinding machine, then measurement capability is improved, but the device complexity and space requirements increase
Solution Approach 1:
The patent combines the measurement device with the steady rest to form an integrated measuring steady rest. The measurement device is positioned within the steady rest structure, allowing simultaneous support and measurement functions to be performed by a single integrated unit, thereby avoiding the need for separate measurement devices and reducing overall system complexity.
Solution Approach 2:
The steady rest is designed to perform multiple functions: both supporting the workpiece during grinding and measuring the workpiece dimensions. By integrating the measurement capability into the steady rest, the device becomes multi-functional, eliminating the need for additional dedicated measurement equipment and reducing device complexity.
2Measurement precision
If a separate measurement device is added to the grinding machine, then measurement capability is improved, but the available space is reduced due to limited machine space
Solution Approach 1:
The measurement device is nested within the steady rest structure. The measurement components are positioned inside or within the confines of the steady rest body, allowing the measurement function to be accommodated without requiring additional external space on the grinding machine.
Solution Approach 2:
By merging the measurement device with the steady rest, the patent eliminates the need for separate measurement equipment that would occupy additional machine space. The integrated design allows both functions to share the same physical footprint.
3Measurement precision
If measurements are taken by interrupting the grinding process, then measurement accuracy is improved, but the productivity decreases
Solution Approach 1:
The patent enables continuous measurement during the grinding process by integrating the measurement device with the steady rest. The measurement device continuously monitors workpiece dimensions while the grinding operation proceeds uninterrupted, eliminating the need to stop the grinding process for measurements and thereby maintaining high productivity.
Solution Approach 2:
The integrated measurement device provides real-time feedback on workpiece dimensions during the grinding process. This continuous feedback allows for in-process adjustments and ensures measurement accuracy without interrupting the grinding operation, maintaining both high accuracy and productivity.
4Ease of operation
If three-jaw steady rest is used with permanent mechanical coupling, then self-centering capability is improved, but the system complexity and forces required increase
Solution Approach 1:
The patent removes the permanent mechanical coupling between the three jaws of the steady rest. Instead, each jaw is independently controlled by separate CNC axes, eliminating the complex mechanical linkage system while maintaining the self-centering capability through coordinated independent jaw movements.
Solution Approach 2:
The patent replaces the mechanical coupling system with a CNC-controlled system. The permanent mechanical linkage between jaws is substituted with electronic control and programming that coordinates jaw movements, reducing mechanical complexity while maintaining self-centering functionality.
5Ease of operation
If three-jaw steady rest with permanent mechanical coupling is used, then self-centering capability is improved, but the forces required for infeeding increase leading to track marks
Solution Approach 1:
By removing the permanent mechanical coupling, the patent eliminates the requirement for high infeeding forces that were necessary to operate the mechanically coupled three-jaw system. Each jaw can be independently fed with lower forces, preventing track marks on the workpiece.
Solution Approach 2:
The replacement of the mechanical coupling system with CNC control allows for precise, low-force independent jaw movement. The electronic control system can coordinate jaw positions without requiring the high forces that were necessary to overcome the mechanical linkage friction and stiffness.
Data Source
AI summary
The present invention relates to a measuring steady rest which has a device for supporting central workpiece regions, in particular, bearing points on shaft parts, in particular crankshafts, and a measurement device integrated therein for directly adjusting the measurement of the workpiece regions before and/or during machining of the shaft parts. The measuring steady rest is preferably designed in the form of a prism, the measurement device being arranged on the bottom of the prism between the lateral flanks of the prism. The present invention further relates to a grinding machine comprising such a measuring steady rest, and to a method for supporting and measuring central workpiece regions on such a grinding machine comprising such a measuring steady rest.