Numerical-Control Scraping for Machine Tool Rail Flatness
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Solution Overview
Problem
Conventional methods for determining and achieving surface roughness in scraping processes for machine tool rails are imprecise due to human error and inability to accurately analyze three-dimensional surfaces.
Innovation Solution
A numerical-control method utilizing a multi-axis machine tool, laser displacement meter, and auto scraping apparatus, with computer-controlled scanning, parameter inputting, and auto-scraping steps to calculate and achieve desired surface finishes and oil distribution on three-dimensional surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional manual scraping methods are used, then the process is simple to operate, but the measurement precision and manufacturing precision are insufficient due to human error
Solution Approach 1:
The patent replaces manual visual inspection and manual scraping with automated optical detection (CCD camera) and computer-controlled scraping systems. The CCD camera captures images of the scraped surface, and the computer automatically calculates high point positions and controls the scraping process, eliminating human error in measurement and operation.
Solution Approach 2:
The patent uses ink transfer to create a copy of the surface topology - ink is applied to the scraped surface and transferred to paper, creating a visual map of high and low points. This copying method enables precise measurement of surface roughness without direct manual measurement, improving detection accuracy.
2Manufacturing precision
If conventional ink transfer method with CCD screening is used, then automation is partially achieved, but the measurement precision is still insufficient for accurate three-dimensional surface analysis
Solution Approach 1:
The patent transitions from two-dimensional ink transfer images to three-dimensional surface reconstruction by using the CCD camera to capture height information at multiple points. The computer processes this data to create a 3D model of the surface, enabling accurate analysis of three-dimensional surface topology and precise control of scraping depth at each location.
Solution Approach 2:
The patent replaces manual measurement tools with laser displacement meters and CCD-based optical measurement systems. These devices automatically measure surface height at multiple points, and the computer calculates the three-dimensional surface profile, eliminating the limitations of conventional two-dimensional ink transfer methods.
3Manufacturing precision
If multiple high points are scraped repeatedly to achieve uniform distribution, then the surface flatness improves, but the production time increases significantly
Solution Approach 1:
The patent performs preliminary detection and planning before the actual scraping process. The CCD camera scans the entire surface first, the computer calculates all high point positions and scraping parameters in advance, and generates a complete scraping path. This preliminary action allows the scraping to be completed in fewer passes, improving productivity while maintaining uniform high point distribution.
Solution Approach 2:
The patent implements a closed-loop feedback system where the CCD camera continuously monitors the scraped surface, the computer analyzes the results, and automatically adjusts the scraping parameters for the next pass. This real-time feedback ensures uniform high point distribution is achieved more quickly, reducing the number of repeated scraping operations needed.
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
Enables precise and accurate scraping of three-dimensional surfaces, ensuring uniform oil distribution and improved mobility of moving elements by reducing human error and enhancing the precision of surface analysis.
Implementation Method 1
a laser displacement meter to scan the variation of a top surface of the work piece
Data Source
AI summary
A method of numerical-control scraping of a work piece has a preparing step, a scanning step, a flatness-parameter inputting step, a surface-finishing step, a related-parameter inputting step, an auto-scraping step and an analyzing step. The preparing step comprises preparing a multi-axis machine tool, a laser displacement meter, an auto scraping apparatus and a computer. The scanning step comprises scanning the work piece. The flatness-parameter inputting step comprises inputting a flatness-parameter. The surface-finishing step comprises calculating out the to-be-scraped ranges of the work piece and scraping the work piece. The related-parameter inputting step comprises inputting desired PPI and POP in the computer, calculating out the HOP, the DOS and the oil content to obtain the length, the width and the depth of a single scraping process. The auto-scraping step comprises scraping the work piece to meet the requirement. The analyzing step comprises detecting the 3D-appearance drawing of the work piece.