Two-Roller Centering Tool for Precise Circular Workpiece Alignment
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Solution Overview
Problem
Existing centering methods for circular workpieces are inadequate for high-precision machining, as they either rely on one-point contact or continuous pushing, which fails to align the center of the maximum inscribed circle, and lack accurate post-centering pass or fail determination, especially in precision machining applications.
Innovation Solution
A centering tool with a pair of rollers and a displacement sensor that follows the workpiece's shape, allowing precise detection and alignment of the inscribed circle's center, reducing misalignment to an allowable range by controlling the tool's movement based on the sensor's detection signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If one-point contact centering is used, then the centering process is simple, but the machining allowance cannot be ensured for high-precision machining
Solution Approach 1:
The centering tool uses a pair of rollers instead of one-point contact, dividing the contact into two separate points. This segmentation allows the tool to follow the workpiece shape more accurately while maintaining a relatively simple centering process structure.
Solution Approach 2:
The invention transitions from one-point contact to two-point contact along the circumference of the workpiece. By adding the dimensional aspect of circumferential distribution, the centering accuracy improves while ensuring machining allowance for high-precision operations.
2Duration of action of moving object
If continuous pushing centering is used, then the centering process is continuous, but accurate post-centering determination is lacking
Solution Approach 1:
The invention incorporates a displacement sensor that provides feedback signals during the centering process. This feedback mechanism enables accurate determination of whether centering has been achieved, allowing for precise post-centering verification while maintaining continuous centering action.
Solution Approach 2:
The invention replaces purely mechanical continuous pushing with a hybrid system that incorporates electrical measurement (displacement sensor). This substitution enables precise determination of centering completion while maintaining the continuity of the centering process.
3Device complexity
If one-point contact is used, then the tool structure is simple, but the centering accuracy for inscribed circle cannot be achieved
Solution Approach 1:
The centering tool divides the contact into two separate rollers instead of one-point contact. This segmentation enables the tool to accurately follow the workpiece shape and determine the inscribed circle center while keeping the overall tool structure relatively simple and modular.
Solution Approach 2:
The pair of rollers serves multiple functions: they follow the workpiece shape, provide stable contact during rotation, and enable accurate determination of the inscribed circle center. This multi-functionality achieves high centering accuracy without significantly increasing device complexity.
4Manufacturing precision
If automatic centering with displacement sensor is used, then the centering precision is improved, but the device complexity increases
Solution Approach 1:
The displacement sensor acts as an intermediary between the mechanical centering process and the control system. It converts mechanical displacement into electrical signals for automated determination, improving centering precision while adding only moderate complexity through a single sensor component.
Solution Approach 2:
The invention replaces complex mechanical measurement mechanisms with a relatively simple displacement sensor and control system. This substitution achieves high centering precision while keeping the overall device complexity manageable through electronic rather than mechanical measurement.
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
Enables high-precision centering of circular workpieces by accurately determining the feed target position and confirming the centering result, ensuring machining allowance and reducing misalignment, thus improving the precision of machining processes.
Implementation Method 1
a displacement sensor provided integrally with the shank portion and detecting displacement in the direction orthogonal to the axis at an intermediate position between the pair of contacts
Implementation Method 2
a rotating member rotatably supported by the shank portion and having a pair of contacts disposed apart from each other in a direction orthogonal to an axis of the shank portion
Data Source
AI summary
A centering tool includes: a shank portion having a shaft portion for attachment; a rotating member rotatably supported by the shank portion and having a pair of contacts disposed apart from each other in a direction orthogonal to an axis of the shank portion; and a displacement sensor provided integrally with the shank portion and detecting displacement in the direction orthogonal to the axis of the shank portion at an intermediate position between the pair of contacts, in which a circular workpiece is centered by being pushed toward a rotation center of a rotary table while each of the pair of contacts is caused to abut against a peripheral surface of the circular workpiece disposed on the rotary table.