Kinematically Separated Grinding Spindles for Faster Tool Changes
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Solution Overview
Problem
Grinding machines face challenges in achieving high throughput due to the time-consuming process of producing complex surface geometries with high precision, which affects cost-effectiveness and efficiency.
Innovation Solution
A grinding machine design with a kinematically separated tool spindle from the workpiece spindle, allowing simultaneous movement for tool and workpiece changes, combined with a tool changer and advanced motor-driven axes for precise and quick tool changes, and integrated coolant management for optimized machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the tool spindle and workpiece spindle are integrated with multiple linear axles, then positioning precision can be achieved, but the structure becomes complex and tool change time increases
Solution Approach 1:
The grinding machine divides the spindle system into two independent units: a workpiece spindle and a tool spindle. Each spindle has its own drive and positioning system, eliminating the need for complex integrated mechanisms. This segmentation allows independent optimization of each spindle's function while reducing overall structural complexity.
Solution Approach 2:
The patent introduces a horizontal Y-axis for tool spindle movement, creating a kinematically decoupled architecture where workpiece spindle handles X-axis and rotational movements, while tool spindle handles Y-axis and Z-axis movements. This dimensional separation resolves the contradiction by distributing complexity across different spatial dimensions.
2Manufacturing precision
If the tool spindle is integrated with the workpiece spindle, then positioning can be controlled, but tool change and workpiece change cannot occur simultaneously
Solution Approach 1:
By segmenting the spindle system into independent workpiece spindle and tool spindle units, each with separate drive mechanisms, the patent enables simultaneous repositioning of both spindles during tool changes. This independence allows workpiece changes on one spindle while tool changes occur on the other, maximizing productivity.
Solution Approach 2:
The tool spindle can be pre-positioned and tools can be prepared for change before the workpiece is fully processed. The independent positioning systems allow preliminary movements to be executed without waiting for the workpiece spindle to complete its cycle, enabling overlapping operations that increase throughput.
3Productivity
If a tool changer is added to enable quick tool changes, then productivity increases, but the device complexity increases
Solution Approach 1:
The tool changer is integrated with the tool spindle assembly, merging the tool changing function into the existing tool spindle structure. This combination eliminates the need for separate tool changing mechanisms and reduces overall system complexity while maintaining high productivity benefits.
Solution Approach 2:
The tool changer is designed to automatically perform tool changes without external intervention. The system uses its own integrated mechanisms to grip, release, and exchange tools on the tool spindle, making the process self-contained and reducing the complexity of external tool changing systems.
4Productivity
If the tool changer moves with the tool spindle along Y-axis and Z-axis, then tool change path is minimized, but positioning precision requirements increase
Solution Approach 1:
The positioning system is segmented into independent axes with dedicated precision mechanisms. The Y-axis and Z-axis movements of the tool changer are handled by separate precision ball screws and motors, allowing each axis to be optimized independently for both speed and precision, resolving the contradiction between quick tool changes and positioning accuracy.
Data Source
Figure 1
Figure 2
AI summary
A grinding machine (1) with a machine bed (10) is provided, on which a workpiece spindle (20) with a workpiece holder (21) and a tool spindle (40) with a tool holder are arranged such that a workpiece held in the workpiece spindle (20) is movable relative to a tool (41) held in the tool holder (40) along an X-axis, which is an axis extending in a first direction parallel to the surface of the machine bed (10), along a Y-axis, which is an axis extending in a second direction parallel to the surface of the machine bed (10), along a Z-axis, which is an axis extending perpendicular to the surface of the machine bed (10), rotatable about an A-axis, which is an axis extending parallel to the surface of the machine bed (10), and rotatable about a C-axis, which is an axis extending perpendicular to the surface of the machine bed (10).in which the tool spindle (40) is completely kinematically separated from the workpiece spindle (20), wherein movements along the X-axis, around the A-axis and around the C-axis are performed by the workpiece spindle (20) and movements along the Y-axis and along the Z-axis are performed by the tool spindle (40), and a method for operating such a grinding machine (1) .