The present invention relates to a grinding device for grinding a workpiece, and particularly relates to a grinding device that performs a scarf sanding process in repair work of a composite material such as, e.g., CFRP (carbon fiber reinforced plastics) that is used as a material of a body of an aircraft.
In recent years, in the field of production of an aircraft, CFRP (carbon fiber reinforced plastics) that is light and has high strength is frequently used. In some of the recent latest passenger aircrafts, the CFRP accounts for 50% or more of the total weight of the aircraft. For example, a composite material formed of CFRP (carbon fiber reinforced plastics) or the like is used in an outer plate forming the outer surface of a fuselage or a wing of an aircraft, and the composite material is formed by stacking a plurality of CFRP sheets in layers.
On the other hand, when a portion of the body of the aircraft in which CFRP is used (CFRP portion) is damaged by an impact or the like, restoration and repair need to be performed. For example, when the portion damaged by the impact or the like (defective portion) is found during maintenance of the body, repair work in which the defective portion is removed and a concave portion formed by the removal is filled with the composite material is performed.
Patent Literature 1: Japanese Patent Application Publication No. 2014-100847
The entire process for restoring and repairing the CFRP portion described above is performed manually by a worker under present conditions. In particular, a “scarf sanding” process for grinding the portion around the defective portion into the bowl-like shape needs sophisticated techniques, and hence a skilled worker spends a long time performing the “scarf sanding” process under present conditions. In addition, the quality of the scarf sanding significantly depends on the skill of the worker, and there is a possibility that the quality thereof is not stabilized. Further; the number of workmen who are able so to perform the “scarf sanding” process is limited. Consequently in the case where the repair of the CFRP portion is performed, the repair needs a long time period, and hence management of aircrafts in an airline company is significantly influenced.
In addition, most of the surface of the body of the aircraft is formed of a curved surface and the curvature of the curved surface varies from one portion of the body of the aircraft to another, which has made it difficult to mechanize the scarf sanding.
To cope with this, an object of the present invention is to provide a grinding device for scarf sanding capable of performing a scarf sanding process.
A grinding device of the present invention for achieving the above object is a grinding device for grinding a workpiece, the grinding device including: a main frame that rotates about a rotary shaft and is able to move in parallel on a horizontal plane vertically intersecting an axial direction; a first swingable frame that is disposed so as to be spaced from the main frame in the axial direction and is swingably mounted to the main frame; a pitch feed frame that is mounted to the first swingable frame so as to be able to move in parallel on a horizontal plane intersecting the axial direction; and a second swingable frame that is swingably mounted to the pitch feed frame, wherein the first swingable frame is coupled to the main frame at a first pivot provided so as to be displaced from a shaft center, and is able to swing relative to the main frame about the first pivot, the second swingable frame has a contact that comes into contact with a surface of the workpiece and a grindstone that grinds the workpiece, is coupled to the pitch feed frame at a second pivot provided on a perpendicular extending from a center of a contact position of the contact that is displaced from the shaft center, and is able to swing relative to the pitch feed frame about the second pivot, and the grindstone is mounted to the second swingable frame so as to grind a portion in a vicinity of the contact position of the contact.
According to the present invention, it is possible to perform the scarf sanding process by using the device without depending on manual work by a worker, and quantify and standardize the scarf sanding work. In addition, it is possible to perform the scarf sanding process on the workpiece having any shape such as a flat surface shape or a curved surface shape.
Hereinbelow, an embodiment of the present invention will be described with reference to the drawings. Note that the embodiment is not intended to limit the technical scope of the present invention.
A main frame 16 has a horizontal frame portion 16a that is a square outer frame disposed so as to face a horizontal plane vertically intersecting the axial direction, and a space frame portion 16b that extends vertically downward from one end side of the horizontal frame portion 16a. That is, the main frame 16 is the frame having an L-shaped cross section, the horizontal frame portion 16a of the main frame 16 is provided with an auxiliary frame (not illustrated) that partitions the horizontal frame portion 16a, and the main frame 16 is mounted to the rotary shaft 12 so as to be able to rotate in response to the rotation of the rotary shaft 12. In addition, the main frame 16 is mounted to the rotary shaft 12 via a slide guide rail 16c fixed to the horizontal frame portion 16a of the main frame 16, and the main frame 16 is thereby able to move in parallel in sliding directions (an arrow P) of the slide guide rail 16c on the horizontal plane vertically intersecting the axial direction. The main frame 16 is coupled to a cam 18 that is formed so as to conform to a grinding shape, and moves in parallel to the rotary shaft 12 by following the shape of the cam 18 while rotating. The cam 18 is, e.g., a grooved cam, and has a groove portion formed into the grinding shape. A cam follower 17 extending from the main frame 16 is guided along the groove portion, whereby the main frame 16 rotates along the cam 18 and, in the case where the groove portion is not circular, the main frame 16 moves in parallel along the slide guide rail 16c in accordance with a change in diameter. Note that the configuration in which the main frame 16 is caused to rotate and move in parallel along the shape of the cam 18 is not limited to the above-described configuration in which the main frame 16 is mounted to the rotary shaft 12 via the slide guide rail 16c, and it is also possible to adopt, e.g., a configuration in which the main frame 16 is caused to rotate and move in parallel by directly coupling the main frame 16 to the rotary shaft 12, and causing the rotary shaft 12 to rotate along the cam 18 and move in parallel along the slide guide rail.
The space frame portion 16b of the main frame 16 forms space in the axial direction, a first swingable frame 20 is disposed beyond the space so as to face the horizontal plane vertically intersecting the axial direction, and is swingably mounted to a pivot A that is positioned at the lower end of the space frame portion 16b of the main frame 16 and is displaced from the shaft center on one side of the first swingable frame 20. The pivot A may also be provided in a portion in which the horizontal frame portion 16a and the space frame portion 16b are coupled to each other. In this case, the space frame portion 16b is formed to have the L-shaped cross section.
The first swingable frame 20 is provided with an auxiliary frame (not illustrated) that partitions the first swingable frame 20, and a slide guide rail 20a is mounted to the auxiliary frame. In addition, a pitch feed frame 24 is mounted to the slide guide rail 20a. The pitch feed frame 24 is able to move in parallel to the first swingable frame 20 along the slide guide rail 20a.
The pitch feed frame 24 adjusts the grinding pitch of the grindstone mounted to a second swingable frame 28 coupled to the pitch feed frame 24 by moving in parallel to the first swingable frame 20. The parallel movement of the pitch feed frame 24 may be manual parallel movement or electrically controlled parallel movement.
The second swingable frame 28 has the contact 30 that comes into contact with the surface of the workpiece, and the grindstone 32 that grinds the workpiece, is coupled to the pitch feed frame 24 at a pivot B provided on a perpendicular extending from the center of the contact position of the contact 30 that is displaced from the shaft center, and is able to swing in directions of an arrow R in
The second swingable frame 28 has a horizontal frame portion 28a that is disposed so as to face a plane intersecting the axial direction, a contact holding unit 28b that extends vertically downward from the position of the horizontal frame portion 28a that is displaced from the shaft center, and a grindstone holding unit 28c that is provided in the vicinity of the contact holding unit 28b. The contact 30 formed of two bails is rotatably mounted to the lower end portion of the contact holding unit 28b.
The grindstone 32 is a grinding disk, and a diamond wheel is preferably used as the grindstone 32. The grindstone 32 is mounted to the grindstone holding unit 28c in a state in which the disk stands vertically such that the peripheral surface of the grindstone 32 grinds the workpiece. The grindstone 32 grinds the workpiece using the peripheral surface while rotating and revolving around the machining center of the workpiece in accordance with the rotation of the main frame 16. The grindstone 32 is preferably mounted so as to be inclined at about 2 degrees relative to its vertical state (see
In addition, the grindstone holding unit 28c includes an adjustment mechanism 28d with, e.g., a screw that adjusts the grinding depth (cut-in amount) of the grindstone, and is able to adjust the grinding depth appropriately. The adjustment of the cut-in amount may be manual adjustment or electrically controlled adjustment.
There is provided a fixing mechanism 34 that fixes the second swingable frame 28 to the pitch feed frame 24. By fixing the second swingable frame 28 to the pitch feed frame 24, it is possible to prevent the second swingable frame 28 from shaking when the second swingable frame 28 is caused to move vertically, e.g., at the start and end of grinding. When grinding is performed, by releasing the fixing mechanism 34, the second swingable frame 28 is allowed to swing about the pivot. B relative to the pitch feed frame 24. The fixing mechanism 34 of the second swingable frame 28 is constituted by, e.g., a disk brake.
Additionally, in order to further prevent the second swingable frame 28 from shaking when the second swingable frame 28 is fixed by the fixing mechanism 34, there are provided pressure cylinders 36 that press the second swingable frame 28 against the pitch feed frame 24. The pressure cylinders 36 control the pressing force of the contact 30 mounted to the lower end portion of the contact holding unit 28b, and stabilize the grinding depth.
When the contact 30 mounted to the second swingable frame 28 comes into contact with the workpiece having a curved surface shape, the heights of the contact 30 and the grindstone 32 are maintained and do not change.
The grindstone 32 grinds the workpiece using the peripheral surface while rotating in accordance with the rotation of the main frame 16. During the rotation, the contact 30 follows the curved surface shape and the second swingable frame 28 swings, whereby it is possible to control the grinding depth of the grindstone during the rotation to a constant value.
By changing the grinding depth adjusted by the adjustment mechanism every round and further causing the second swingable frame 28 to move in parallel at a pitch shorter than the thickness of the peripheral surface of the grindstone 32 at a predetermined round timing, it becomes possible to perform layer-by-layer grinding (layer grinding) in which the workpiece is grinded into the bowl-like shape including the shaft center as the bottom.
Thus, scarf sanding in the bowl-like shape including the shaft center as the bottom is allowed by causing the grindstone 32 to grind the workpiece using the peripheral surface while rotating in accordance with the rotation of the main frame 16, changing the grinding depth adjusted by the adjustment mechanism 28d every round, and further causing the second swingable frame 28 to move in parallel at the pitch shorter than the thickness of the peripheral surface of the grindstone 32 at the predetermined round timing.
Further, the step in which the grinding depth is set back to 0.2 mm, the pitch feed frame 24 is caused to slide by 6 mm, and grinding is performed is repeated and, lastly, the shape of scarf sanding illustrated in
The pivot A is the only pivot of the swing, and hence the contact 30 is formed of one ball, and the number of contact positions thereof is one. Similarly to the first configuration, the contact position of the ball to the workpiece is disposed so as to be arranged on the line connecting the shaft center and the grinding center of the grindstone. Even when the contact is made based on one contact position, in the case of a relatively gentle curved surface, it is possible to follow the curved surface shape with relatively high accuracy. In addition, in the case where the workpiece is formed of a fiat surface, it is possible to follow the shape even with one contact position.
In the above embodiment, the workpiece is the composite material in which the CFRP used as the material of the body of the aircraft is stacked in layers. However, the workpiece is not limited thereto, and it is also possible to use, as the workpiece, other composite materials such as, e.g., GFRP (glass fiber reinforced plastics), and other materials that can be grinded. In addition, the grinding device is not limited to the material used in the body of the aircraft, and can also be applied to workpieces used in other fields such as the field of an automobile and the fields of a rocket and space.
In addition, the above-described embodiment has described the configuration in which the workpiece placed on the stand is grinded (vertically downward grinding) by way of example, and it is possible to perform an operation irrespective of the orientation of a machined surface by mounting the above configuration on, e.g., an industrial robot. In this case, with regard to the above-described configuration that uses gravity, it becomes possible to perform an operation that does not depend on the attitude of the machined surface by using a known pressurization unit such as a hydraulic cylinder.
The present invention is not limited to the above embodiment, and needless to mention, the present invention includes even design change within a scope including various modifications and revisions readily conceivable by a person having ordinary knowledge in the field of the present invention and so without departing from the gist of the present invention.
Number | Date | Country | Kind |
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2016-046541 | Mar 2016 | JP | national |
This application is a continuation application of International Application. No. PCT/JP2017/005749, filed on Feb. 16, 2017 and designated the U.S., the entire contents of which are incorporated herein by reference. Further, this application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2016-046541, filed on Mar. 10, 2016, the entire contents of which are incorporated herein by reference.
Number | Date | Country | |
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Parent | PCT/JP2017/005749 | Feb 2017 | US |
Child | 16126854 | US |