Panel Rectification Tool Positioning Using Vibration Wear Sensing
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Solution Overview
Problem
Existing rectification machines for ceramic and stone panels face challenges with manual adjustment of grinding wheels, leading to inconsistent quality and precision due to wear, and previous automated solutions can only adjust one wheel at a time, making them inefficient and prone to errors in dusty environments.
Innovation Solution
An automatic adjustment system using vibration sensors and data-processing to detect wear and adjust multiple grinding wheels simultaneously, ensuring precise positioning and continuous operation without manual intervention, utilizing a gear mechanism with a helical toothed wheel and endless screw for precise movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment of grinding wheels is used, then the machine structure remains simple, but the manufacturing precision and repeatability deteriorate due to operator experience dependency and wear compensation errors
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated system combining vibration sensors, data processing, and motorized positioning. The vibration sensor detects wheel wear through vibration signal changes, the data processing system analyzes these signals to determine adjustment needs, and the motorized system executes precise positioning adjustments, eliminating operator dependency and improving repeatability
Solution Approach 2:
The system enables self-adjustment through automatic detection of wheel wear via vibration sensors and autonomous positioning control. The machine monitors its own tool condition through vibration analysis and automatically compensates for wear without external intervention, maintaining precision continuously during operation
2Ease of operation
If automated adjustment system with light beam is used, then the ease of operation improves, but the productivity deteriorates because only one grinding wheel can be adjusted at a time
Solution Approach 1:
The patent divides the adjustment system into independent modular units, each equipped with its own vibration sensor and motorized positioning mechanism. This segmentation allows multiple grinding wheels across different stations to be adjusted simultaneously and independently, eliminating the sequential limitation of single-beam systems and maintaining high automation while improving productivity
Solution Approach 2:
The system transitions from a single light beam operating in one dimension to multiple vibration sensors distributed across multiple spatial dimensions and stations. This multi-dimensional sensor arrangement enables parallel monitoring and adjustment of multiple grinding wheels simultaneously, increasing throughput while maintaining automation
3Measurement precision
If multiple vibration sensors are distributed across all stations, then the measurement precision of wheel wear improves, but the device complexity increases
Solution Approach 1:
The patent employs a universal vibration sensor design that can be replicated and distributed across multiple stations without requiring different sensor types or complex configurations at each location. This standardized multi-functional sensor approach enables precise wear detection at all stations while minimizing system complexity through component uniformity and modular scalability
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
The system achieves high precision and repeatability in panel edge rectification, reducing machine downtime and the need for specialized operators, while maintaining consistent production quality by automatically compensating for grinding wheel wear and allowing simultaneous adjustment of multiple tools.
Implementation Method 1
at least one vibration sensor (64) which detects the vibrations of the rectification tool during contact with the panels
Data Source
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AI summary
A machine for rectifying panels for construction, for example, for wall coverings or for floorings, comprises a structure for supporting and moving panels in a supply direction (L). The machine further comprises at least one rectification tool (11) which is configured to operate on the panels and at least one movement mechanism (40) for adjusting the position of the rectification tool with respect to the supply direction (L) in an adjustment direction (T) in order to compensate for the progressive wear of the rectification tool (11) in contact with the panels. The machine also comprises at least one vibration sensor (64) which is provided to detect the vibrations of the at least one rectification tool (11) during use, during the contact with the panels. A data-processing system is programmed to receive the vibration data which are detected, during use, by the vibration sensor (64) and to compare them with reference vibration data which indicate a predetermined working condition of the rectification tool in contact with the panels, which corresponds to a predetermined position of the rectification tool with respect to the supply direction (T). The processing system outputs an adjustment activation instruction in order to activate the movement mechanism (40) in order to move the rectification tool in the adjustment direction (T) when a predetermined deviation between the vibration data which are detected by the vibration sensor with respect to the reference vibration data is exceeded. The processing system further outputs an adjustment deactivation instruction in order to deactivate the movement mechanism (40) in order to interrupt the movement of the rectification tool in the adjustment direction (T) when the deviation between the vibration data detected by the vibration sensor and the reference vibration data is within a predetermined value.