Rotor Grinding in One Setup to Eliminate Clamping Errors
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Solution Overview
Problem
Current methods for manufacturing rotors for compressors, blowers, and vacuum pumps require multiple grinding operations across different machines, leading to inefficiencies, increased costs, and reduced quality due to clamping errors, heat accumulation, and the need for manual deburring, which increases the risk of damage and safety hazards.
Innovation Solution
A method that integrates cylindrical and profile grinding operations into a single grinding machine, allowing the workpiece to remain clamped throughout the process, reducing the need for multiple machines, minimizing clamping errors, and optimizing the use of a universal grinding spindle with automatic disk exchange and flushport configuration to enhance efficiency and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple grinding operations are performed on different machines, then manufacturing flexibility is improved, but manufacturing precision deteriorates due to clamping errors
Solution Approach 1:
The patent combines multiple grinding operations (cylindrical grinding and profile grinding) into a single grinding machine. The workpiece remains clamped between centers throughout all operations, eliminating the need to unclamp and reclamp between machines. This merging approach maintains manufacturing flexibility through programmable control while eliminating clamping errors that occur when transferring workpieces between multiple machines.
Solution Approach 2:
The grinding machine is designed with universal capability to perform both cylindrical grinding and profile grinding operations. The machine includes a controllable grinding wheel that can be positioned and oriented to execute different grinding paths, making a single machine capable of replacing multiple specialized machines while maintaining precision through consistent clamping.
2Manufacturing precision
If multiple grinding operations are performed sequentially on different machines, then manufacturing precision is improved, but productivity deteriorates due to repeated clamping and machine transfer
Solution Approach 1:
The patent enables continuous grinding operations without interruption for unclamping or machine transfer. The workpiece remains clamped and continuously processed through multiple grinding operations in sequence. The machine can perform cylindrical grinding, profile grinding, and intermediate operations without breaking the productive cycle, thereby maintaining high precision while significantly improving productivity.
Solution Approach 2:
The workpiece is clamped between centers in advance before any grinding operations begin. This preliminary clamping action establishes a fixed reference frame that remains valid throughout all subsequent operations, eliminating the need for repeated setup and positioning. The machine then executes multiple grinding operations in programmed sequence without requiring intermediate intervention.
3Productivity
If coarse profile grinding is performed first, then manufacturing speed is improved, but temperature increases due to heat accumulation
Solution Approach 1:
The patent implements periodic interruption of the grinding process to allow heat dissipation. After coarse profile grinding operations that generate significant heat, the machine automatically pauses the grinding cycle, maintains the workpiece in position, and allows thermal energy to dissipate before resuming operations. This periodic action prevents excessive heat accumulation while maintaining high productivity through efficient use of grinding time.
4Manufacturing precision
If manual deburring is performed after grinding, then manufacturing precision is improved, but safety deteriorates due to risk of damage and oil spills
Solution Approach 1:
The patent replaces manual deburring operations with automated mechanical deburring integrated into the grinding machine. After grinding operations, the machine automatically performs deburring using programmed tool paths and specialized tools. This substitution eliminates safety hazards associated with manual handling of sharp edges and hot workpieces, as well as reduces the risk of oil spills from manual cleaning operations, while maintaining or improving surface quality through consistent automated processing.
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
This approach reduces production time, minimizes errors, decreases the risk of damage, and improves the quality of the rotor by allowing all operations to be performed in one machine, optimizing machine capacity, and reducing the risk of oil spills and machine faults, while enabling the production of both male and female rotors simultaneously.
Implementation Method 1
a cylindrical grinding disk, for example of corundum or CBN, is placed at an oblique angle or otherwise with respect to the workpiece
Data Source
AI summary
A method for manufacturing a rotor includes the following operations: the clamping of a workpiece in a grinding machine; the performance of one or more cylindrical grinding operations whereby a rotor shaft section is ground to the desired diameter with a cylindrical grinding disk; the performance of one more profile grinding operations whereby a rotor body is profiled with a profile grinding disk. During the manufacture of the rotor in the grinding machine, the workpiece is not undamped and the cylindrical grinding operations and the profile grinding operations are done with the same grinding machine.