Roll Grinding Device with Online Surface Quality Feedback
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Solution Overview
Problem
Conventional roll grinding methods rely heavily on operator experience and struggle to consistently achieve high surface quality due to variations in grinding tool parameters, cooling lubricants, and machine characteristics, leading to unreliable and time-consuming processes.
Innovation Solution
A method and device for grinding rolls that continuously measure surface quality parameters during the grinding process, allowing for real-time adjustment of operating parameters to maintain consistent surface quality, independent of operator expertise, using a roll grinding device with integrated measurement and control systems to actively regulate the grinding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional CNC cylindrical grinding methods are used with manual or semi-automated control, then the roll geometry and diameter can be controlled, but the surface quality (roughness, gloss, pattern freedom) cannot be reliably maintained due to variations in grinding tool parameters, cooling lubricants, and machine characteristics
Solution Approach 1:
The patent implements online measurement of the roll surface during the grinding process, creating a closed-loop feedback system. The measurement device continuously monitors surface quality parameters and feeds this information back to the control device, which automatically adjusts grinding parameters to maintain consistent surface quality, eliminating the need for manual intervention and experience-based control.
Solution Approach 2:
The patent replaces manual visual inspection and experience-based control with automated optical or contactless measurement systems. The measuring device uses non-contact methods (such as optical scanning) to detect surface characteristics, substituting human sensory and decision-making processes with automated sensing and control systems.
2Measurement precision
If offline or online measuring methods are used to support operators, then surface assessment can be performed, but the grinding process must be interrupted at intervals and manual corrections are required, increasing grinding time
Solution Approach 1:
The patent enables continuous measurement and control during the grinding process without interruptions. The online measurement system operates simultaneously with the grinding operation, allowing the process to proceed continuously while surface quality is monitored and controlled in real-time, eliminating idle measurement time and manual intervention delays.
Solution Approach 2:
The system performs self-control through automated feedback loops. The control device automatically adjusts grinding parameters based on real-time measurement data without requiring operator intervention. The system serves itself by detecting deviations and correcting them autonomously, eliminating the need for manual corrections and repeated grinding passes.
3Manufacturing precision
If high surface quality requirements are imposed on rolls for high-quality rolled products, then product quality improves, but the grinding process becomes more complex and time-consuming
Solution Approach 1:
The automated feedback system simplifies the control of complex grinding processes by using real-time measurement data to automatically adjust parameters. Rather than requiring complex manual control procedures, the feedback system handles the complexity through automated sensing, processing, and adjustment, making high-precision grinding more manageable and reproducible.
Solution Approach 2:
The system dynamically changes grinding parameters (such as wheel speed, feed rate, or depth of cut) based on real-time surface quality measurements. This adaptive parameter adjustment allows the system to maintain optimal grinding conditions throughout the process, achieving high surface quality without requiring excessively complex fixed-parameter procedures.
4Manufacturing precision
If multiple grinding passes are performed to achieve desired surface quality, then surface quality improves, but grinding time and operational costs increase
Solution Approach 1:
The automated feedback and control system enables the grinding process to self-correct and self-optimize in real-time, achieving the desired surface quality in fewer passes. The system continuously monitors surface quality and adjusts parameters to maintain optimal grinding conditions, eliminating the need for multiple repetitive passes and manual quality checks.
Solution Approach 2:
The continuous measurement and control during the grinding process ensures that surface quality requirements are met throughout the operation, preventing the need for additional corrective passes. The uninterrupted monitoring and adjustment maintain consistent quality from start to finish, reducing total grinding time and associated costs.
Data Source
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AI summary
The invention relates to a method for grinding a roll (20) by means of a roll grinding device (10). In said method, a roll (20) is ground by means of a grinding tool (40) of the roll grinding device (10), at least one measurable value of at least one variable that relates to the surface quality of the roll (20) is measured during the grinding operation, and at least one operating parameter of the roll grinding device (10) is adjusted during the grinding operation in accordance with the measured variable. The invention further relates to a roll grinding device (10) for grinding a roll (20), comprising a roll mount (30) that includes two bearings (32, 34) designed to rotatably support the roll (20), also comprising a drive (36) designed to rotatingly drive the roll (20) at an adjustable roll speed, as well as a grinding tool (40) designed to accommodate and rotatingly drive a grinding member (42) at an adjustable grinding member speed and position the grinding member (42) against the roll. The roll grinding device (10) further comprises a measuring apparatus (70) designed to measure measurable values of a variable that relates to the surface quality of the roll (20), as well as a control unit (80) designed to control the roll grinding device and, during the grinding operation, trigger the measuring apparatus (70) to measure at least one measurable value, and adjust at least one operating parameter of the roll grinding device (10) in accordance with the measured variable.