Rotor Grinding in One Setup to Eliminate Re-Clamping Errors

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Solution Overview

Problem

Existing methods for manufacturing rotors for compressors, blowers, and expanders require multiple grinding machines, leading to high costs, space requirements, labor-intensive operations, clamping errors, and quality issues due to geometric anomalies and heat accumulation, resulting in inefficient production and potential damage to the workpiece.

Innovation Solution

A method that utilizes a single grinding machine to perform both cylindrical and profile grinding operations without unclamping the workpiece, employing a universal grinding spindle and automated tool exchange to minimize clamping errors and heat-related issues, allowing for efficient and accurate production of rotors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple grinding machines are used for cylindrical and profile grinding operations, then manufacturing precision can be maintained, but device complexity and space requirements increase

Engineering Contradiction:

Improverotor manufacturing precisionVSAvoidnumber of grinding machines

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines cylindrical grinding and profile grinding operations into a single universal grinding machine. The machine is equipped with both a cylindrical grinding spindle and a profile grinding spindle, allowing both operations to be performed on the same workpiece without requiring multiple separate machines. This merging eliminates the need for transporting workpieces between different machines and reduces overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The grinding machine is designed as a universal machine capable of performing multiple grinding operations. It includes a cylindrical grinding spindle for cylindrical surfaces and a profile grinding spindle for complex rotor profiles. The machine can switch between different grinding operations by changing the spindle or grinding tools, making it a multi-functional device that replaces multiple specialized machines.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If workpiece is unclamped and re-clamped between operations, then different grinding operations can be performed, but clamping errors and manufacturing precision deteriorate

Engineering Contradiction:

Improvegrinding operation flexibilityVSAvoidclamping accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

Both cylindrical and profile grinding operations are performed on the workpiece while it remains clamped in the same position. The universal grinding machine allows the workpiece to stay secured during operation changes, eliminating the need to unclamp and reclamp between different grinding tasks. This continuous clamping state prevents accumulation of clamping errors.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If multiple grinding operations are performed sequentially on different machines, then various rotor features can be created, but production time and loss of time increase

Engineering Contradiction:

Improve rotor feature creationVSAvoidproduction time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent enables continuous grinding operations without interruption for workpiece handling. The universal grinding machine performs cylindrical grinding and profile grinding in sequence on the same clamped workpiece without requiring unclamping, transportation, or re-clamping operations. This continuity eliminates idle time and maintains productive action throughout the manufacturing process.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

Multiple grinding operations that would traditionally require separate machines and sequential handling are merged into a single machine operation. The workpiece undergoes both cylindrical and profile grinding during one setup, eliminating the time losses associated with machine changes and workpiece handling.

Inventive Principle:

Principle #5Merging (Combining)

4Manufacturing precision

If cylindrical and profile grinding are performed on separate machines, then specialized grinding can be achieved, but heat accumulation and harmful factors increase

Engineering Contradiction:

Improvespecialized grinding qualityVSAvoidheat accumulation

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

Both cylindrical and profile grinding operations are performed in the same machine environment with unified cooling and chip removal systems. The integrated design allows for coordinated heat management during sequential operations, preventing heat accumulation that would occur with separate machines requiring workpiece handling and repositioning.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12358064B2Method for manufacturing of a rotor

Publication Date: 2025.07.15 ATLAS COPCO AIRPOWER NV

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.