Valve Spool Grinding-Deburring via CCD Overlap Measurement
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Solution Overview
Problem
The traditional manufacturing process of electro-hydraulic servo valves has poor processing efficiency and a high rejection rate due to the lack of measurement and feedback of performance indicators in deburring processes, which is not suitable for high-precision servo valve production.
Innovation Solution
A synchronous grinding-deburring method and system that integrates a synchronous grinding-deburring machine, a loading-unloading robot, and a computer-based pneumatic mate-grinding test platform, utilizing a CCD-based industrial visual camera for real-time control and measurement of the overlap value, enabling automated and precise grinding and deburring of valve spools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual deburring process is used, then labor intensity is high and processing efficiency is poor, but equipment complexity and investment cost increase significantly
Solution Approach 1:
The system is divided into distinct functional modules: CNC grinding unit, deburring unit, CCD measurement unit, and pneumatic testing platform. Each module performs a specific function and can be independently controlled, allowing automated processing without requiring a completely complex integrated system.
Solution Approach 2:
The CNC machine tool is equipped with multiple functions including grinding, deburring, and measurement capabilities. The pneumatic testing platform serves both as an assembly fixture and a measurement device for detecting overlap values, reducing the need for separate specialized equipment.
2Manufacturing precision
If traditional process without measurement feedback is used, then processing speed is fast, but manufacturing precision and yield are poor due to lack of performance indicator measurement
Solution Approach 1:
The system incorporates CCD-based visual measurement to detect the overlap value of the valve spool working edge after deburring. This measurement feedback is transmitted to the CNC control system, which automatically adjusts processing parameters to maintain precision without requiring multiple manual inspection cycles.
Solution Approach 2:
The measurement and adjustment process is integrated into the continuous manufacturing flow. The CCD measurement and CNC parameter adjustment occur automatically during production, eliminating separate inspection and rework cycles that would consume additional time.
3Ease of operation
If automated deburring systems are used, then labor intensity is reduced, but the integrity of working edge is prone to damage and measurement feedback is not implemented
Solution Approach 1:
The system replaces manual mechanical deburring operations with automated CNC-controlled deburring tools. The precision and consistency of automated control prevent the working edge from being damaged, while the integrated CCD measurement ensures proper positioning and overlap value verification.
Solution Approach 2:
The system performs preliminary measurement of the working edge position using CCD vision technology before the deburring operation. This allows the CNC system to pre-adjust tool positioning and parameters, ensuring the deburring process maintains working edge integrity without requiring manual intervention.
4Productivity
If high-precision grinding and manual deburring are used, then manufacturing quality can be maintained, but processing efficiency is poor and rejection rate is high
Solution Approach 1:
The system merges grinding and deburring operations into a single synchronized CNC process. The grinding and deburring tools operate simultaneously on the valve spool, completing both operations in one setup and significantly reducing processing time while maintaining quality through integrated control.
Data Source
AI summary
A synchronous grinding-deburring method and system for a valve spool based on measurement of an overlap value. In the system, a synchronous grinding-deburring machine is configured to complete automatic clamping of the valve spool workpiece and synchronous precise grinding-deburring processing of a working edge; a loading-unloading robot is configured to grab and transport the valve spool workpiece; and a charged-coupled device (CCD)-based industrial visual camera is provided to facilitate an automatic assembly of a slide valve pair; a computer-based pneumatic mate-grinding test bench for an electro-hydraulic servo valve is provided for automatic clamping of the servo valve and automatic detection of the overlap value of a servo valve; and an industrial control console is provided for real-time control of a complete workflow and adaptive control of a processing parameter.