Multi-Carrier Grinding for Simultaneous External Surface Machining
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Solution Overview
Problem
Existing grinding methods and machines are inefficient as only the workpiece holder with the currently machined workpiece rotates, limiting simultaneous processing of multiple workpieces of different heights and dimensions, and requiring separate tools for inner and outer surface grinding.
Innovation Solution
A grinding method where the workpiece carrier unit rotates around its axis, allowing multiple workpieces to be machined simultaneously with a single grinding tool, enabling efficient and precise processing of both outer and inner surfaces, including those of varying heights, by adjusting the rotational speed and orientation of workpiece carriers independently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If only the workpiece holder with the currently machined workpiece rotates, then the grinding process can be controlled efficiently, but multiple workpieces cannot be machined simultaneously and workpieces of different heights cannot be processed
Solution Approach 1:
The workpiece carrier unit is divided into multiple independently rotatable workpiece carriers (at least two), each capable of rotating about its own workpiece carrier axis. This segmentation allows each carrier to be positioned and rotated independently, enabling multiple workpieces to be machined simultaneously while maintaining individual control over each carrier's position and orientation.
Solution Approach 2:
The workpiece carriers are designed with dynamic rotational capability, where each carrier can rotate about its own axis independently of the others. This dynamic configuration allows the system to adapt to workpieces of different heights and dimensions, as each carrier can be rotated to the appropriate position and orientation for machining its specific workpiece.
2Adaptability or versatility
If a single grinding tool is used for all workpieces, then device complexity is reduced, but workpieces of different heights and inner/outer surfaces cannot be processed
Solution Approach 1:
The single grinding tool is designed with multi-functionality to process both outer surfaces and inner surfaces of workpieces. The tool can be positioned and oriented to grind outer surfaces when workpieces are on external surfaces of carriers, and can access inner surfaces when workpieces are positioned on internal surfaces of carriers. This universal capability allows one tool to replace multiple specialized tools while maintaining high productivity through simultaneous machining of multiple workpieces.
3Productivity
If workpiece carriers rotate independently about their own axes, then multiple workpieces can be machined simultaneously, but coordination and control complexity increases
Solution Approach 1:
The control system incorporates feedback mechanisms to monitor and coordinate the rotation of multiple workpiece carriers. Each carrier's rotational position and speed are sensed and fed back to the control system, which adjusts the rotation of individual carriers to ensure they are properly positioned for simultaneous machining. This feedback control maintains ease of operation by automatically coordinating the complex multi-carrier rotation without requiring manual intervention.
Data Source
Figure 1A
Figure 1B~1C
Figure 2A
AI summary
Illustrated and described is a grinding method for machining the surface of workpieces (6), in particular for machining external surfaces of workpieces (6), comprising the following steps: a) providing a grinding machine (1, 1') having a grinding tool (2, 2'), wherein the grinding tool (2, 2') is mounted so as to be rotatable about a grinding-tool axis (X2, X2'), b) providing at least two workpieces (6) to be machined, c) arranging the workpieces (6) on one of at least two workpiece carriers (5, 5', 5") of a workpiece-carrier unit (4), wherein the at least two workpiece carriers (5, 5', 5") are mounted so as each to be rotatable about a workpiece-carrier axis (X5), and wherein the workpiece-carrier unit (4) is mounted so as to be rotatable about a workpiece-carrier-unit axis (X4), and d) grinding the workpiece surfaces (8) of the workpieces (6), wherein the grinding tool (2, 2') rotates about the grinding-tool axis (X2, X2'), wherein the at least two workpiece carriers (5, 5', 5") each rotate about a workpiece-carrier axis (X5), and wherein the workpiece surfaces (8) of at least two workpieces (6) arranged on other workpiece carriers (5, 5', 5") are machined at the same time. Also illustrated and described are a workpiece-carrier unit (4) having a plurality of workpiece carriers (5, 5', 5"), and a grinding machine (1, 1') having at least one such workpiece-carrier unit (4).