Servo Stroker for Honing Special Shapes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Honing processes face challenges with position feedback, velocity, acceleration, and jerk control, leading to inefficiencies and inaccuracies in producing special shapes like tapered or barrel shapes due to limitations in mechanical systems and control technologies.
Innovation Solution
A servo stroking system with digitalized motion profiles optimized for force application, minimizing machine component reactions, using parametric profile curves and direct coupling to reduce uncertainties, and integrating feedback from sensors for precise control of honing tool movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dedicated mechanical systems with hard limits locking are used for position feedback control, then safety and reliability are improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces dedicated mechanical control systems with microprocessor-based electronic control. The microprocessor executes pre-programmed instructions to control the reciprocating motion, eliminating the need for complex mechanical hard limits locking systems while maintaining safety and reliability through software-based control logic.
Solution Approach 2:
The patent implements feedback control through microprocessor monitoring of position, velocity, and acceleration parameters. The system continuously monitors these parameters and adjusts control signals accordingly, providing reliable safety control without requiring complex mechanical feedback systems.
2Productivity
If four bar linkage systems are used for reciprocating motion, then stroking output is improved, but manufacturing precision deteriorates due to position feedback limitations
Solution Approach 1:
The patent replaces mechanical position feedback systems with electronic sensors and microprocessor-based control. This substitution enables precise measurement and control of position, velocity, and acceleration parameters, maintaining high stroking output while achieving superior position accuracy through digital control algorithms.
Solution Approach 2:
The patent dynamically adjusts control parameters including position, velocity, and acceleration through microprocessor control. This enables optimization of both stroking output and position accuracy by modifying operational parameters in real-time based on process requirements and feedback signals.
3Productivity
If relative motion control is used for honing, then material removal efficiency is improved, but control precision deteriorates due to slow positioning feedback
Solution Approach 1:
The patent replaces slow mechanical positioning feedback systems with electronic sensors and microprocessor-based control. This enables high-speed acquisition and processing of position feedback signals, maintaining high material removal rates while achieving precise control through rapid electronic feedback loops.
Solution Approach 2:
The patent implements continuous control of relative motion between honing tool and workpiece through microprocessor-based systems. The system continuously adjusts position, velocity, and acceleration parameters throughout the honing process, maintaining optimal material removal rates while ensuring precise control through uninterrupted feedback and adjustment.
4Device complexity
If digital control systems are used to transfer rotational to linear motion, then device complexity is reduced, but manufacturing precision deteriorates due to control limitations
Solution Approach 1:
The patent uses microprocessor-based digital control systems that simplify the control architecture while maintaining high precision through software algorithms. The system digitally controls the conversion of rotational to linear motion, achieving both reduced complexity and high manufacturing precision through electronic control and computational algorithms.
Solution Approach 2:
The patent dynamically adjusts control parameters including position, velocity, and acceleration through microprocessor control. This enables optimization of both device simplicity and manufacturing precision by modifying operational parameters in real-time based on process requirements and feedback signals.
Data Source
AI summary
A servo stroking method and system for honing wherein the cam stroking motion is controlled via combined acceleration and deceleration cam profiles to produce a finite jerk profile, a precision positioning capability for the honing element or elements, and accurate position feedback. The stroking motion is synchronized with one or more other parameters of the honing operation, such as the feed or rotational position of the honing tool, for generating non-cylindrical and special honed shapes such as tapered, barrel, and helical shapes. The cam profile can be selected for example from a simple harmonic profile, a cycloidal profile, a modified trapezoidal profile, a polynomial profile, and a modified sine profile, or a mix of cam profiles. The servo controlled stroker mechanism can include for instance a ball screw mechanism, a linear motor, a fluid cylinder, a chain drive or a belt drive.