The present disclosure relates to a grinding apparatus that grinds upper and lower ends of a workpiece by causing the workpiece to pass through between a pair of rotary grindstones facing each other in the vertical direction.
In a conventionally known grinding apparatus of this type, a pair of workpiece supporting tables are supported on a rotary base, and each workpiece supporting table is provided with a plurality of workpiece accommodating holes at an outer edge part thereof. In this grinding apparatus, the rotary base is rotated by a first motor so that an any desired workpiece supporting table is disposed between the pair of rotary grindstones, and this workpiece supporting table is rotationally driven by a second motor so that workpieces in the plurality of workpiece accommodating holes are made to pass through between the pair of rotary grindstones, whereby the workpieces are ground (see, for example, FIGS. 1, 2, and 4 of JP 2018-34253 A).
However, it is required to reduce a manufacturing cost of the above-described conventional grinding apparatus.
A grinding apparatus according to one aspect made to solve the above problem is a grinding apparatus that grinds an upper end and a lower end of a workpiece while causing the workpiece to pass through a pair of rotary grindstones facing each other in a vertical direction. The grinding apparatus includes: a rotary base that is rotationally driven around a first rotation axis parallel to the vertical direction; a rotary table included in the rotary base and having an upper surface flush with an upper surface of a lower grindstone of the pair of rotary grindstones; a fixed base that rotatably supports the rotary base; a fixed table that is included in the fixed base, surrounds the rotary table, has a cutout receiving part of the lower rotary grindstone, and has an upper surface flush with the upper surface of the lower rotary grindstone; a plurality of workpiece supporting tables which are supported at a plurality of positions, around the first rotation axis, on the rotary base and each of which is rotationally driven around a center that is one of a plurality of second rotation axes parallel to the first rotation axis, wherein when the center of one of the workpiece supporting tables is positioned between the first rotation axis and the pair of rotary grindstones, an outer edge part of the one of the workpiece supporting tables is disposed between the pair of rotary grindstones; a plurality of workpiece receiving holes vertically passing through the outer edge part of each of the workpiece supporting tables, each of the workpiece receiving holes configured to receive a middle part, in the vertical direction, of one of a plurality of the workpieces; a first motor that is fixed to the fixed base to rotationally drive the rotary table and has a rotational position sensor; a plurality of second motors that are fixed to the rotary base to rotationally drive the workpiece supporting tables, and have no rotational position sensor; a controller that drives the first motor and the plurality of second motors; and a slip ring that is disposed below the plurality of second motors and has a plurality of blushes and a plurality of conductive rings that are respectively fixed to the rotary base and the fixed base or respectively fixed to the fixed base and the rotary base and are in sliding contact with each other, the slip ring conductively connecting between the controller and the plurality of second motors.
Hereinafter, a grinding apparatus 10 according to an embodiment of the present disclosure will be described with reference to
The grinding apparatus main body 11 has, for example: a main frame 12 having a vertically long housing structure; and a pair of rotary grindstones 13 and 14 disposed at a central part, in a vertical direction, of the main frame 12 so as to vertically face each other. The pair of rotary grindstones 13 and 14 both have, for example, a disk shape, and rotation axes of the rotary grindstones 13 and 14 are disposed substantially coaxially. Further, both the rotary grindstones 13 and 14 are rotationally driven by a pair of grindstone motors 13M and 14M (see
The rotary grindstones 13 and 14 may be rotationally driven in the same direction at different rotation speeds, or may be rotationally driven in opposite directions at the same rotation speed or different rotation speeds. Further, both the rotary grindstones 13 and 14 may be vertically movable, or only one of the rotary grindstones 13 and 14 (for example, the upper rotary grindstone 13) may be vertically movable.
A front opening 15 is formed at a central part in the vertical direction of a front face of the main frame 12, and the workpiece transfer device 16 is attached to a part, of the front face of the grinding apparatus main body 11, lower than the front opening 15. Hereinafter, the grinding apparatus main body 11 side of the workpiece transfer device 16 is referred to as a “rear side”, and the opposite side of the rear side is referred to as a “front side”.
The workpiece transfer device 16 has, for example: a fixed base 18 fixed to the main frame 12; and a rotary base 40 rotatably supported by the fixed base 18. The fixed base 18 includes a rectangular parallelepiped subframe 17. For example, the subframe 17 has a width substantially the same as that of the main frame 12, and is fixed at an intermediate position in the vertical direction on the front face of the main frame 12 and floats from the ground. In addition, at a front end part of the subframe 17, there are a pair of auxiliary legs 17K (only one auxiliary leg 17K is illustrated in
The subframe 17 has, for example, a substantially square shape in a plan view as illustrated in
As illustrated in
The fixed table 20 does not have to be circular, and may be a polygon such as a quadrangle, a hexagon, or an octagon. The fixed table 20 may be made of a single plate.
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Each workpiece supporting table 22 is provided with a plurality of workpiece receiving holes 22A that vertically pass through the outer edge part of the workpiece supporting table 22. The plurality of workpiece receiving holes 22A each have a circular cross-section whose central axis is at a constant distance from the second rotation axis J2, and the workpiece receiving holes 22A are arranged at regular intervals. In this arrangement, as illustrated in
The rotary table 21 does not have to be circular as long as the rotary table 21 cooperates with the fixed table 20 and faces, from below, all the workpiece receiving holes 22A of the pair of workpiece supporting tables 22. Further, the workpiece supporting tables 22 do not have to be circular as long as each workpiece supporting table 22 has a plurality of workpiece receiving holes 22A in the outer edge part. Further, hereinafter, the workpiece supporting table 22 whose second rotation axis J2 is closest to the third rotation axis J3 is referred to as “the workpiece supporting table 22 at the grinding performing position”, and the second motor 52 that is a drive source for such workpiece supporting table 22 is referred to as “the second motor 52 at the grinding performing position”. Further, the workpiece supporting table 22 whose second rotation axis J2 is farthest from the third rotation axis J3 is referred to as “the workpiece supporting table 22 at the standby position”, and the second motor 52 that is a drive source for such workpiece supporting table 22 is referred to as “the second motor 52 at the standby position”. In the present embodiment, the standby position is a “workpiece discharge position” and, at the same time, a “workpiece feeding position” according to the present disclosure.
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The first speed reducer 53 includes, for example: a cylindrical output shaft portion 53B that rotates, around the first rotation axis J1, with respect to a speed reducer main body 53H fixed to a lower surface of the subframe 17; and an input shaft portion 53A that rotates around a rotation axis parallel to the horizontal direction. A stator 51S of the first motor 51 is fixed to the speed reducer main body 53H, and a rotor 51R of the first motor 51 is integrally rotatably connected to the input shaft portion 53A. A conductive path support sleeve 54 is fitted inside the output shaft portion 53B of the first speed reducer 53 so as to be integrally rotatably connected, and an upper end part of the conductive path support sleeve 54 is integrally rotatably connected to the lower end part of the center shaft 39. With this arrangement, the center shaft 39 and the first motor 51 are connected to each other via the first speed reducer 53, as described above.
The first motor 51 is, for example, a three-phase alternating-current induction motor including a rotational position sensor 51E (for example, a resolver or an absolute encoder) that detects a rotational position of the rotor 51R. From the stator 51S, there extend a power cable 51L including a U-phase, V-phase, and W-phase and a plurality of signal cables 51M for the rotational position sensor 51E. The power cable 51L and the signal cables 51M are connected to a common servo amplifier 71 of the controller 70 illustrated in
Further, although the first motor 51 can hold any one of the workpiece supporting tables 22 at the grinding performing position; however, in order to reduce a load on the first motor 51, a locking mechanism is provided between the rotary base 40 and the fixed base 18, and the locking mechanism locks the rotary base 40 to a non-rotatable state with respect to the fixed base 18 when any one of the workpiece supporting tables 22 is disposed at the grinding performing position. As illustrated in
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Each of the pair of second motors 52 is, for example, a so-called sensor-less three-phase alternating-current induction motor that has no rotational position sensor for detecting a rotational position of the rotor 52R, and only a power cable 52L (see
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A lower part of the center shaft 39 includes, for example, a communication passage 39A communicating with the inside of the conductive path support sleeve 54, and an upper end of the communication passage 39A is bifurcated and opened, as a pair of side surface openings 39B, on a side surface of the center shaft 39. As illustrated in
Further, the cover 61 of the slip ring 60 is fixed to the speed reducer main body 53H of the first speed reducer 53, and inside the cover 61, there are provided a plurality of brushes 65 in sliding contact with the plurality of conductive rings 62 as illustrated in
As illustrated in
By the CPU 79A executing a plurality of control programs stored in the ROM 79B by multitask processing, the controller 70 is configured to have control blocks such as speed control units 73, position control units 74, pulse-width modulation (PWM) control units 75, a grindstone control unit 76, a general control unit 77, and a reverse control unit 78 illustrated in
When the grinding apparatus 10 is stopped, the locking actuator 35 locks the rotary base 40 in a non-rotatable state with respect to the fixed base 18. When the grinding apparatus 10 is activated, the general control unit 77 gives a command to the grindstone control unit 76 to rotate the grindstone motors 13M and 14M at a constant rotation speed, and the grinding apparatus 10 performs a workpiece feeding process.
In the workpiece feeding process, the general control unit 77 gives a workpiece feeding positioning command to the position control unit 74 related to the second motor 52 at the standby position. The position control unit 74 related to each second motor 52 executes the following reference point specifying process only when receiving the workpiece feeding positioning command for the first time immediately after the grinding apparatus 10 is activated.
In the reference point specifying process, the position control unit 74 gives a command to the PWM control unit 75 to cause the inverter circuit 72A to generate a predetermined low frequency three-phase alternating current, and energizes the second motor 52. Then, while the three-phase alternating current is supplied for one cycle, a phase of the three-phase alternating current matches a current electric angle of the rotor 52R of the second motor 52, and the rotor 52R is therefore activated, so that the rotor 52R rotates at a rotation speed corresponding to a frequency of the three-phase alternating current for the rotor 52R. During such a moment, the position control unit 74 captures a detection signal of the detection switch 41. Here, the detection signal of the detection switch 41 is turned on when the specific shape portion 42 comes close to the detection switch 41 as illustrated in
When the reference point specifying process is completed, the position control unit 74 stops the workpiece supporting table 22 in a state where the reference point of the workpiece supporting table 22 is made to coincide with an origin position (for example, the center position of the detection switch 41) previously determined on the rotary support 30J. That is, the workpiece supporting table 22 is positioned at the origin position. In the grinding apparatus 10 of the present embodiment, when the workpiece supporting table 22 is positioned at the origin position, one of the plurality of workpiece receiving holes 22A is located directly under the workpiece feeding port of the workpiece feeding device 98. Otherwise, the workpiece supporting table 22 is positioned by being rotated to such a position.
When any of the workpiece receiving holes 22A is in a workpiece feed waiting state where the workpiece receiving hole 22A is located directly under the workpiece feeding port of the workpiece feeding device 98 as described above, the position control unit 74 notifies the general control unit 77 of the situation. Then, the general control unit 77 drives the workpiece feeding actuator 98A to discharge one workpiece W from the workpiece feeding device 98, puts the workpiece W in the workpiece receiving hole 22A, and gives a command to the position control unit 74 to position the next workpiece receiving hole 22A directly under the workpiece feeding port of the workpiece feeding device 98.
Then, the position control unit 74 rotates the workpiece supporting table 22 by a constant angle to put the workpiece supporting table 22 in the workpiece feed waiting state, and notifies the general control unit 77 that the next workpiece supporting table 22 is in the workpiece feed waiting state. Hereinafter, this operation is repeated until all the workpiece receiving holes 22A are filled with workpieces W, and when the workpiece receiving holes 22A are all filled with workpieces W, the general control unit 77 does not give any more command to the position control unit 74, and, as a result, the workpiece feeding process is completed
When the workpiece feeding process is completed, a rotation drive command is given to the speed control unit 73 related to the second motor 52 at the standby position, and a reverse command is given to the reverse control unit 78 related to the first motor 51. Then, the speed control unit 73 causes the PWM control unit 75 to gradually increase a frequency of the three-phase alternating current applied to the second motor 52 from the inverter circuit 72A, and then to hold the frequency at a predetermined constant frequency. As a result, the workpiece supporting table 22 is rotated at a constant rotation speed.
Further, the reverse control unit 78 drives the locking actuator 35 to release the locking of the rotary base 40. Then, the reverse control unit 78 performs a position control and a speed control of the first motor 51 to exchange the positions of the pair of workpiece supporting tables 22, and then causes the locking actuator 35 to lock the rotary base 40. As a result, one of the workpiece supporting tables 22 filled with workpieces W is disposed at the grinding performing position while being rotated, and the workpieces W pass through between the pair of rotary grindstones 13 and 14, thereby being ground.
While the plurality of workpieces W on the one of the workpiece supporting tables 22 are being ground, the general control unit 77 gives the above-described workpiece feeding positioning command and the like to the position control unit 74 related to the second motor 52 newly disposed at the standby position, so that also the plurality of workpiece receiving holes 22A of the workpiece supporting table 22 are filled with workpieces W. Then, when the detection result of the length measuring device 99 reaches a predetermined specified length, the general control unit 77 gives the rotation drive command to the speed control unit 73 related to the second motor 52 at the standby position, and, at the same time, the general control unit 77 gives the reverse command to the reverse control unit 78 related to the first motor 51. Then, the general control unit 77 performs the workpiece discharging process and thereafter performs the above-described workpiece feeding process.
In the workpiece discharging process, the general control unit 77 gives a workpiece discharge positioning command to the position control unit 74. After receiving the workpiece discharge positioning command, the position control unit 74 performs the above-mentioned reference point specifying process, and then positions the workpiece supporting table 22 at the origin position. By this operation, as illustrated in
Then, the general control unit 77 causes the door actuator 38 to drive the door member 37 so as to put the discharge port 36 in an open state, and the general control unit 77 then gives a workpiece discharge command to the position control unit 74. Then, the position control unit 74 keeps stopping state of the workpiece supporting table 22 while waiting until a discharge time, which is previously obtained by actual measurement, required for the workpieces W to fall out from the workpiece receiving holes 22A elapses, and then the position control unit 74 rotates the workpiece supporting table 22 by a constant angle and stops the workpiece supporting table 22 so that the next some of the plurality of workpiece receiving holes 22A are located above the discharge port 36.
By repeating this operation, the workpieces W are discharged from the plurality of workpiece receiving holes 22A and collected in the collection box 36B (see
As described above, the grinding apparatus 10 of the present embodiment operates to grind a plurality of workpieces W. Unlike a conventional grinding apparatus in which a pair of second motors 52 for performing the above operation are fixed to the rotary base 40 and those components are fixed to the fixed base 18, the grinding apparatus 10 of the present embodiment does not need a plurality of gears, and the production cost can be reduced. Further, since the pair of second motors 52 and the controller 70 are electrically connected through the slip ring 60, the rotation of the rotary base 40 is not restricted by the power cables 52L of the second motors 52. Further, the slip ring 60 may be arranged above the first speed reducer 53 connected to the first motor 51, but since the slip ring 60 is located below the first speed reducer 53, an inside of a turning region of the pair of second motors 52 is slim, and the grinding apparatus 10 can be downsized. In addition, since the pair of second motors 52 have no rotational position sensor, the number of conductive lines is small, and the slip ring 60 itself is small.
Further, the second motors 52 may be direct-current motors; however, because alternating-current motors have no brushes, when alternating-current motors are used, the second motors 52 can be accordingly downsized. In addition, the rotation speed can be easily changed by changing the frequency of the alternating current applied to the second motor 52, and it is therefore easy to adjust a grinding amount of the workpiece W. Further, since the second motors 52 are alternating-current motors, it is also possible to rotate each workpiece supporting table 22 by an any desired angle, and it is also possible to stop each workpiece supporting table 22 at an any desired position. In addition, the detection switch 41 fixed to the fixed base 18 specifies the origin position with respect to the rotation of the workpiece supporting table 22, depending on whether the detection switch 41 faces the specific shape portion 42 that integrally rotates with the workpiece supporting table 22, and the workpiece supporting table 22 is rotated and stopped with the origin position taken as a reference. Therefore, an accuracy of position control is improved, and it is possible to accordingly stably perform the discharge of workpieces W from the workpiece receiving holes 22A to the discharge port 36 and to feed workpieces W in the workpiece receiving holes 22A.
(1) The grinding apparatus 10 of the above embodiment has no gear, but as long as the pair of second motors 52 are fixed to the rotary base 40, the grinding apparatus 10 may have a gear. The reason is as follows. When the pair of second motors 52 are fixed to the rotary base 40 as in the grinding apparatus 10 of the present embodiment, even though the number of gears is not zero, the number can be reduced as compared with the conventional grinding apparatus. Therefore, the manufacturing cost can be accordingly reduced. Specifically, the input shaft portion 55A of the second speed reducer 55 and the rotor 52R of the second motor 52 may be gear-connected to each other. Further, the output shaft portion 53B of the first speed reducer 53 may be offset from the first rotation axis J1, and the output shaft portion 53B and the conductive path support sleeve 54 may be gear-connected to each other.
(2) In the grinding apparatus 10 of the above embodiment, the first motor 51 is a common alternating-current motor having the rotational position sensor 51E, but the first motor 51 may also be an alternating-current motor having no rotational position sensor in the same manner as the second motors 52.
(3) The second motors 52 are alternating-current motors, but may be direct-current motors. In that case, the relationship between a current value of a current to the second motor 52 and the rotation speed of the second motor 52 is obtained by actual measurement and is stored as a map, and the map may be used to control the current to the second motor 52 so as to rotate the second motor 52 at a desired rotation speed.
(4) The detection switch 41 of the above embodiment is a proximity switch, but may be an optical sensor, a magnetic sensor, or the like. The detection switch may be a contact type switch.
(5) The specific shape portion 42 protrudes from one place in the circumferential direction of the table center member 33 as the “detection target rotary body” of the present disclosure, but one place in the circumferential direction of the table center member 33 may be depressed as the specific shape portion 42. Further, it is possible to provide an auxiliary detection rotary body that integrally rotates with the workpiece supporting table 22 and has a plurality of concavo-convexes at a plurality of positions in the circumferential direction such that the auxiliary detection rotary body faces an auxiliary detection switch which is different from the detection switch 41. Then, output of the auxiliary detection switch may be made to depend on where on the concavo-convexes of the auxiliary detection rotary body the auxiliary detection switch faces. With that arrangement, the output of the auxiliary detection switch may be used to detect a rotation amount of the workpiece supporting table 22 from the origin position, and the rotation amount may be used to control the position of the workpiece supporting table 22.
(6) In the above embodiment, each of the pair of second motors 52 includes no rotational position sensor for detecting the rotational position of the rotor 52R, but the second motor 52 may include a rotational position sensor.
(7) In the above embodiment, the slip ring 60 is disposed below the second motors 52, but the slip ring 60 may be disposed, for example, above or laterally to the second motors 52 (specifically, on an upper surface or a lower surface of the upper strip plate 31 of the rotary frame 30). Alternatively, in the case where the slip ring 60 is disposed below the second motors 52, the slip ring 60 may be disposed, for example, above the first speed reducer 53, the first motor 51, or the like, instead of below the first speed reducer 53 connected to the first motor 51.
(8) The slip ring 60 may be configured such that a plurality of conductive rings 62 are arranged side by side along the axial direction of the rings, or a plurality of conductive rings 62 are arranged concentrically in the radial direction of the rings. Further, the sliding contact positions of the brushes 65 to the conductive rings 62 are not limited to the outer peripheral surfaces of the conductive rings 62, and may be any side surfaces such as inner peripheral surfaces, upper end surfaces, or lower end surfaces.
(9) In the above embodiment, the conduction rings 62 of the slip ring 60 are connected to the second motor 52 side, and the brushes 65 are connected to the controller 70 side; however, the conductive rings 62 may be connected to any side.
(10) In the above embodiment, the input shaft portion 53A of the first speed reducer 53 is perpendicular to the first rotation axis J1, but for example, the input shaft portion 53A of the first speed reducer 53 may be offset with respect to the first rotation axis J1.
(11) The number of the workpiece supporting tables 22 is not limited to two, and may be three or more. Further, a plurality of workpiece supporting tables 22 may be arranged at equal intervals with respect to the first rotation axis J1, or may be arranged in any way.
Although the present specification and the drawings disclose specific examples of the techniques included in the claims, the techniques according to the claims are not limited to these specific examples, and include various variations and modifications of the specific examples and, in addition, include a part alone taken out from the specific examples.
Number | Date | Country | Kind |
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2021-044273 | Mar 2021 | JP | national |