Ultrasonic Grinding Wheel Diameter Measurement
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Solution Overview
Problem
Existing grinding methods face inefficiencies due to the need for time-consuming measurement processes and potential errors in measuring the outside diameter of grinding wheels, particularly during grinding or truing operations, which can lead to decreased machine operation rates and increased costs.
Innovation Solution
A method that calculates the outside diameter of the grinding wheel by determining the time difference in ultrasonic wave arrival between the grinding layer and the core, using sonic velocities in the grinding layer materials to accurately measure the diameter, even with adhering grinding fluid, and continuously monitors wear during grinding or truing, allowing for real-time adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a touch probe and arm made of low thermal expansion material are used to measure the outside diameter of the grinding wheel, then measurement accuracy is improved, but the measuring process time increases and operation rate decreases
Solution Approach 1:
The patent replaces the mechanical touch probe measurement system with an ultrasonic measurement system. The ultrasonic sensor measures the outside diameter of the grinding wheel by detecting the time of flight of ultrasonic waves through the grinding wheel material, eliminating the need for mechanical contact and complex positioning apparatus, thereby reducing measurement time while maintaining accuracy
Solution Approach 2:
The patent introduces an ultrasonic wave as an intermediary to measure the outside diameter. The ultrasonic wave propagates through the grinding wheel material and its travel time is used to calculate the diameter, providing a non-contact measurement method that is both fast and accurate
2Productivity
If an ultrasonic sensor head is used to measure wear of the grinding wheel, then measurement speed is improved, but measurement accuracy deteriorates due to thermal expansion affecting the distance between the sensor and grinding wheel
Solution Approach 1:
The patent employs a feedback mechanism where the ultrasonic measurement system continuously monitors the outside diameter of the grinding wheel during operation. The measured values are fed back to the control system, which automatically adjusts grinding parameters to compensate for thermal expansion effects, ensuring accurate wear measurement despite temperature variations
Solution Approach 2:
The patent changes the measurement parameter from direct distance measurement to ultrasonic time of flight measurement. By measuring the time it takes for ultrasonic waves to traverse the grinding wheel material and using the known sound velocity in the material, the system calculates diameter independently of the absolute distance between sensor and wheel, thereby eliminating thermal expansion errors
3Productivity
If the grinding wheel outside diameter is measured during grinding or truing operations, then productivity is improved by reducing idle time, but measurement complexity increases due to presence of grinding fluid
Solution Approach 1:
The patent enables continuous measurement of the grinding wheel outside diameter during grinding and truing operations. The ultrasonic sensor is positioned to measure the rotating grinding wheel without interrupting the grinding process, and measurements are taken continuously or at frequent intervals, allowing real-time monitoring and control while maintaining production flow
Solution Approach 2:
The patent uses a simple, inexpensive ultrasonic sensor that can operate in the harsh environment of grinding fluid and high temperatures. The sensor design is robust and maintenance-free, allowing it to function reliably during continuous grinding operations without requiring complex protection or cooling systems
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 enables rapid and accurate measurement of the grinding wheel diameter, reducing idle time, improving operation efficiency, and minimizing unnecessary grinding wheel removal, thus enhancing the overall grinding process and reducing costs.
Implementation Method 1
calculating a time difference in arrival at an ultrasonic sensor between a reflected wave from a surface of the grinding layer and a reflected wave from a surface of the outer periphery of the core
Implementation Method 2
A reduction amount of the grinding wheel diameter is measured on the basis of a sonic velocity in the grinding layer and a difference between an arrival time difference
Data Source
AI summary
A core grinding wheel that has a grinding layer on an outer periphery of a core is used. An ultrasonic wave is output from an ultrasonic sensor to the grinding layer via grinding fluid. An ultrasonic measuring device control unit calculates a thickness of the grinding layer on the basis of a sonic velocity in the grinding layer and an arrival time difference between a reflected wave from a surface of the grinding layer and a reflected wave from a surface of the outer periphery of the core. A grinding process and a truing process are controlled on the basis of an outside diameter of the grinding wheel, which is calculated on the basis of the measured thickness of the grinding layer and an outside diameter of the core.