Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
  • B24B33/00—Honing machines or devices; Accessories therefor
  • B24B33/02—Honing machines or devices; Accessories therefor designed for working internal surfaces of revolution, e.g. of cylindrical or conical shapes
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
  • B24B27/00—Other grinding machines or devices
  • B24B27/0023—Other grinding machines or devices grinding machines with a plurality of working posts
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
  • B24B27/00—Other grinding machines or devices
  • B24B27/0069—Other grinding machines or devices with means for feeding the work-pieces to the grinding tool, e.g. turntables, transfer means
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
  • B24B27/00—Other grinding machines or devices
  • B24B27/0076—Other grinding machines or devices grinding machines comprising two or more grinding tools
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
  • B24B41/00—Component parts such as frames, beds, carriages, headstocks
  • B24B41/005—Feeding or manipulating devices specially adapted to grinding machines
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
  • B24B41/00—Component parts such as frames, beds, carriages, headstocks
  • B24B41/02—Frames; Beds; Carriages

Definitions

• the invention relates to a honing machine for performing honing operations on at least one bore in a workpiece, in particular for honing cylinder bores in a cylinder crankcase, according to the preamble of claim 1.
• Honing is a geometrically indeterminate cutting process in which a multi-bladed bonded cutting tool during a honing operation in the bore performs a two-component working movement resulting in a characteristic surface texture of the machined inner surface, typically with crossed machining marks.
• the transferred from a honing spindle of a honing machine on the honing tool working movement therefore usually consists of an axially reciprocating stroke movement and one of these superimposed rotational movement.
• cylinder surfaces ie inner surfaces of cylinder bores in a cylinder crankcase (ZKG) or in a cylindrical sleeve to be installed in a cylinder sleeve bearing surfaces for shafts, eg in a crankshaft bearing bore, or the cylindrical inner surfaces in connecting rods honing a submerged
• bearing surfaces on connecting rods, gears or components for other power and working machines, such as compressors, are often processed by honing.
• machining cylinder treads When machining cylinder treads, several different, successive honing operations are typically performed, e.g. a pre-honing to produce the required basic shape and a finish honing with which the surface structure ultimately required is generated. Measuring steps can be used to check the processing success.
• a honing plant may contain a plurality of honing machines in an arrangement linked by means of a conveyor system.
• the German Patent DE 10 2007 045 619 B4 describes a device for fine machining of workpieces, which can be set up in particular for honing and / or fine boring of cylinder bores in cylinder crankcases.
• a module with a substantially rectangular ground plan one or two horizontally displaceable machining units for honing and / or fine boring are provided on two opposite longitudinal sides.
• the processing units should be suitable for carrying out all honing processes and also for fine boring.
• a module is designed as a cabin with side walls along the two longitudinal sides.
• the processing units are mounted on horizontally movable carriages which run along linear guides which are attached to the mutually facing inner sides of the side walls.
• German patent application DE 10 2004 053 503 A1 discloses a honing machine for honing workpieces, which has a multiplicity of workstations which are each configured to carry out at least one work step on a workpiece, at least one part of the workstation being at least one honing station a honing operation is arranged on a workpiece.
• a conveyor system is used to convey workpieces to the workstations and workstations. Each work station is directly connected to the conveyor system.
• the Honstrom is controlled by a control device.
• the control device takes over the distribution of the workpieces as a function of the availability of the individual workstations and thus controls the workpiece flow through the honing system. If a workstation fails or during maintenance work, the workpiece flow can be diverted.
• a Such Honstrom is characterized by high availability of their processing capacity.
• the invention has for its object to provide a honing machine with the various honing operations and possibly other machining operations in short cycle times are possible on a workpiece.
• a honing machine is to be provided, with which complete machining of cylinder bores on cylinder crankcases is possible with the shortest possible non-machining times available for machining.
• the invention provides a honing machine with the features of claim 1.
• the machine base or the machine base of the honing machine carries in the edge region a plurality of vertical uprights, which in turn support a machine upper part, which is arranged at a vertical distance above the machine base. If the machine base has a substantially rectangular basic shape, the vertical uprights can be arranged in the corner areas of the rectangle. Other cross-sectional shapes of the machine base are possible. Between the machine base and the machine head, a working space of the honing machine is formed. The work space may be accessible to an operator in the areas between the uprights from the side.
• the rotary table arranged on the machine base forms a machine-internal transfer unit with which a quick transfer of the workpieces between the individual workstations can be realized.
• the machine-internal rotary table transfer makes it possible to use a single loading station for loading and unloading the workpiece holders. In contrast to transfer machines, it is thus possible for the workpieces to leave the honing machines at the same place where they were fed to the honing machine. This facilitates the loading and unloading and in particular the coupling of the honing machine to an external conveyor system. With the help of an external conveyor system, the honing machine can be linked as needed with other honing machines and / or with other processing machines to form a manufacturing plant.
• At least one honing unit is carried by the machine head.
• the honing unit is positioned or positioned so that a bore of a workpiece, which was transported by means of the rotary table in a working position or processing position of the honing station, can be processed by honing by means of a honing tool borne by the honing spindle.
• the honing spindle which is rotatable about a vertical spindle axis and movable parallel to the spindle axis, can project down into the working space, while some or all other components of the honing unit can be arranged outside the working space above the machine top.
• the gantry design can, inter alia, ensure that the lateral access to the working space is not hindered by components of the honing unit.
• the portal design turns out to be favorable for limiting machine vibrations during machining.
• the machine head can be designed so that it largely closes the working space upwards much like a lid. The arranged above the machine head components of the honing unit must then not be disguised, since they are protected to the working space through the machine head, for example against coolant splashes.
• the machine base has a rectangular cross-section with two opposite longitudinal sides and transverse sides perpendicular to each other, with an honing station disposed on each of the longitudinal sides.
• the belonging to the honing stations machining positions of the workpieces may be opposite to each other diametrically to the rotary table axis.
• the rotary table can be arranged centrally between the longitudinal sides, so that a symmetrical structure of the honing machine with good accessibility results from each of the longitudinal sides.
• each of the honing units has a single honing spindle, two successive honing units are available for processing a workpiece. It is also possible for at least one honing station to have two or more honing units which can work simultaneously or in parallel. At such an honing station, a parallel machining of two or more holes of a workpiece can take place. If there are two honing stations each with two honing units, there are a total of four honing units available, two of which can work simultaneously on the same workpiece. There is thus great flexibility with regard to the honing operations that can be carried out on a workpiece in the honing machine, which can be one-stage or multi-stage.
• the rotary table can be used to transport a workpiece from the region of one longitudinal side to the region of the opposite longitudinal side.
• the rotary table has a diameter that is greater than 60% or greater than 70% of a transversely measured width of the machine base.
• the diameter may be between about 75% and about 95% of this width.
• a honing unit is mounted on a carriage carried by the machine head.
• the carriage is preferably arranged on the upper side of the machine upper part, ie outside the working space.
• the carriage is preferably movable linearly along a travel direction, which runs tangentially to a reference circle lying centrally with respect to the rotary table axis.
• the radius (radius) of the reference circle can be the radial distance between the rotary table axis and a machined Corresponding hole in a workpiece that is received in a workpiece holder of the rotary table.
• the honing spindle of the honing unit can be positioned by moving the carriage coaxially to a bore to be machined, but also at tangentially offset positions.
• a workpiece holder for receiving a cylinder crankcase having a plurality of cylinder bores arranged in series with mutually parallel cylinder axes is formed such that all cylinder axes lie in a common tangent plane to the reference circle when the cylinder crankcase is positioned by the rotary table in a machining position is.
• Some embodiments are designed for automatic tool change in order to be able to quickly equip the honing units with different honing tools, if, for example, a tool change should be necessary when a honing tool is worn or when changing between different honing operations.
• some embodiments have a tool changing device with a tool magazine that can accommodate a plurality of machining tools.
• a tool changing device is arranged in the working region of the linearly movable carriage such that the honing unit can be moved for a tool change between the honing station and the tool changing device.
• One of the workstations is provided as loading stations for loading and unloading the workpiece holder. Due to the rotary table transfer, a single charging station is sufficient.
• the loading station is arranged in some embodiments on a transverse side of the machine base, so that a 90 ° rotation of the rotary table is sufficient to transport a workpiece from the loading station to a honing station or from a honing station to the charging station. This results in extremely short non-productive times for transport.
• a loading robot or a linear portal with transverse stroke is provided to perform the transfer between a workpiece holder on the rotary table and an external conveyor or in the reverse direction.
• the loading station is preferably associated with a shuttle which can be moved between an inner end position for loading and unloading the rotary table and an outer end position outside the working space of the honing machine defined by the machine base and the machine upper part.
• the pendulum slide for example, be linearly movable radially to the rotary table axis.
• a loading and unloading of the pendulum carriage can be performed from above, without the corresponding loading devices or gripping devices are disturbed by the machine head.
• a pendulum carriage can be loaded, for example, by means of a linear portal or by a robot, but optionally also manually.
• Fig. 1 shows a schematic front view of a honing machine according to an embodiment of the invention
• Fig. 2 is a plan view of the honing machine of Fig. 1;
• Fig. 3 shows a side view of a honing machine according to an embodiment with external gantry loader
• FIG. 4 shows a side view of a honing machine according to an embodiment with internal loading system
• FIG. 1 shows a schematic side view of a honing machine 100 according to an embodiment of the invention.
• Fig. 2 shows the honing machine of Fig. 1 in plan view.
• the honing machine has four independently controllable honing units and is adapted to machine the cylinder bores of workpieces in the form of cylinder crankcases 102 first by pre-honing and then by finish honing.
• the honing machine has a rectangular in plan machine base 1 10, which carries all the mechanical components of the honing machine.
• On the upper side of the machine base four vertical uprights 1 12A to 1 12D are fixed in the corner areas by means of screws.
• Each of the identically constructed stands has a square cross-section, is hollow on the inside and slightly offset inwardly from the nearest corner of the machine base, the distance to the corner being smaller than the side length of the square cross-section.
• the stands carry a horizontally oriented, torsion-resistant, plate-shaped machine upper part 120, which has a rectangular basic shape and rests with its underside 122 on the upper sides of the stand.
• the width of the machine base measured in the y direction of the machine coordinate system MKS in the example case is 2400 mm and is typically between 2000 mm and 2500 mm.
• the machine head has about the same width.
• the machine top In the longitudinal direction (parallel to the x-direction of the machine coordinate system), the machine top is shorter than the machine base with the rear transverse sides of the machine base and machine top vertically aligned, while on the opposite front the machine base extends beyond the leading edge of the machine top so that this projecting portion 1 14 free from above is accessible.
• the lying below the machine shell between this and the machine base cuboid area forms the working space 1 15 of the honing machine. This is largely completed by the top of the machine, while it is accessible from the sides in the areas between the stands 1 12A to 1 12D.
• a rotary table 130 On the machine base, a rotary table 130 is mounted, which is infinitely rotatable about a vertical rotary table axis 134 by means of a arranged below the rotary table rotary drive 132.
• workpiece holders 135 At the top of the rotary table four workpiece holders 135 are mounted at equal angular intervals of 90 ° to each other and at equal radial distances from the rotary table axis.
• Each workpiece holder has contact surfaces, Indexierimplantation and pneumatic support controls and serves to accommodate a single cylinder crankcase, which is firmly clamped in the workpiece holder.
• the cylinder crankcase is oriented so that the mutually parallel cylinder axes of the cylinder bores arranged in series lie in a common tangential plane 136 to a reference circle 135.
• a workpiece holder still has a pivoting device.
• the rotary table serves as a machine-internal transfer system in such a way that a recorded in a workpiece holder workpiece can be transported by rotation of the rotary table successively at different workstations of the honing machine.
• the honing machine is referred to in this application as "round table module”.
• the honing machine can in the chosen division of the rotary table with four workpiece holders a total of four Workstations are approached simultaneously by workpieces. In the configuration shown by way of example, only three workstations are used. Centered on the front transverse side is the charging station 140, whose facilities are intended to each transport a workpiece from outside the working space 15 to an empty workpiece holder on the rotary table and / or a workpiece to be unloaded from a workpiece holder in the interior of the working space to the outside transport.
• a horizontally movable pendulum slide (shuttle) 142 is provided which can be moved linearly back and forth between an inner end position in the region of a workpiece holder and an outer end position outside of the working space 15. Since the outer end position is outside the working space covered upwards by the machine upper part, it is possible to load and unload the pendulum carriage from above, for example by means of a portal gripper (compare FIG. 3).
• a picked-up tool is first transported to a processing position at a first honing station 150.
• This is located on a first longitudinal side 105 of the honing machine.
• a further rotation of 90 ° brings the workpiece to an unequaled empty station in the middle between the long sides.
• Further rotation through 90 ° brings a workpiece into a processing position in the region of a second honing station 160, which is located on the second longitudinal side 106 opposite the first longitudinal side.
• the processing positions at the two honing stations are opposite each other diagonally to the rotary table axis.
• Another 90 ° rotation then brings the workpiece back into the area of the charging station 140.
• the vacant station for example, Nachmess perceiveden, Bürstein pulp or the like.
• more tool holders and / or other devices may be attached on the rotary table.
• four more tool holders are each provided offset by 45 ° to the tool holders shown. They are designed to accommodate differently sized workpieces, so that two different types of workpieces can be clamped simultaneously and processed between loading and unloading.
• Each of the honing stations 150, 160 is equipped with two essentially identical honing units, which can be operated independently of each other at different times or at the same time.
• Each of the honing units has a single honing spindle, which is rotatable about a vertical spindle axis by means of a rotary drive and which can be moved back and forth parallel to the spindle axis by means of a lifting drive.
• a honing unit also comprises a delivery system for the radial delivery or for the radial retraction of honing elements, which are arranged on the circumference of a honing tool borne by the honing spindle. All honing units of the honing machine are carried by the machine upper 120. The construction of a honing unit is explained in more detail using the example of the honing unit 180 (in FIG. 1, right).
• the honing unit 180 comprises a headstock 182, which serves as a bearing for the honing spindle 184, which is guided with a vertical spindle axis in the headstock.
• the rotation of the honing spindle about the spindle axis is effected by a rotary drive 186 which is mounted adjacent to the headstock and acts on the honing spindle via a chain drive.
• a lifting drive 188 causes the vertical movements of the honing spindle parallel to the spindle axis during insertion of the honing tool 185 in the bore to be machined or when pulling the honing tool from this hole.
• the lifting drive can be controlled during the honing process so that the honing tool within the bore of the workpiece performs a vertical reciprocating motion according to the desired honing parameters.
• the honing unit has a feed system which comprises two independently operable feed devices in order to be able to control honing tools with double widening if necessary.
• a first feed device has a first expanding drive 192 with a servomotor, which acts on a centrally passing through the honing spindle push rod and can move it axially.
• This push rod is disposed within a hollow push rod coaxial with this and movable relative thereto.
• the hollow push rod belongs to an electromechanical second adjusting device with an electromechanical feed drive 194. Since the structure of double widening delivery systems is known per se, a detailed description is omitted here.
• the aforementioned components of the honing unit 180 are mounted on a carriage 200 carried by the machine head 120.
• the carriage 200 runs on a pair of guide rails 204, which run parallel to the x-direction of the machine coordinate system MKS with lateral distance from each other on the upper side of the machine upper part facing away from the working space 15. Between the guide rails is located in the machine upper part extending in the x-direction recess 124, through which the honing spindle or an attached thereto drive rod is guided down into the working space.
• the drive for the carriage movement via a servo motor which drives a parallel to the guide rails extending ball screw 206, on which a spindle nut sits, which is fixed to the underside of the base plate 202 of the carriage.
• the base plate extends extending horizontally beyond the sphere of the ball screw and thus serves as a cover for this.
• the carriage 200 carries two substantially identical honing units which can operate simultaneously.
• On the opposite longitudinal side of another carriage is provided, which also carries two identical honing units.
• the honing machine 100 has two honing stations, each with two honing units.
• the honing units with the vertical honing spindles contained therein can be moved by means of the carriage as a whole in the horizontal direction parallel to the x-axis of the machine coordinate system MKS. This direction is referred to herein as "longitudinal direction” or “direction of travel”.
• the honing spindles thereby move along a line which runs tangentially to a reference circle 137 running concentric with the rotary table axis 134.
• the travel paths are preferably designed so that each honing spindle can approach each bore of a workpiece.
• Horizontal longitudinal movements can also be used to move the honing units to a tool changing device 220 arranged in line with the longitudinal movement.
• a tool changing device with a rotary table magazine is provided with a plurality of tool holders.
• FIG. 3 an embodiment of a honing machine 100 'explained, in which the shuttle (shuttle) 142 via a gantry loader 300 is loaded and unloaded. This has a horizontal (parallel to the y-direction) and vertically (parallel to the z-direction) movable gripping arm 310, at the lower end of which gripping members 315 are arranged for gripping a respective cylinder crankcase. The gripper moves completely outside the working space 1 15 of the honing machine.
• the gripper arm can pick up a workpiece to be machined at an input station, not shown, convey horizontally to a position above the loading position 140 and then set down on the shuttle carriage 142. This then takes over the transport of the workpiece from outside into the working space 1 15 inside.
• the pendulum carriage has a lifting drive to deposit the workpiece from above into a tool holder on the rotary table or, after completion of the machining, lift it and then transport it to the outside.
• the honing machine 100 'in FIG. 3 has substantially the same construction as the honing machine 100 of FIGS. 1 and 2. However, only one honing unit 320 is mounted on one of the carriages movable along the longitudinal sides, so that the honing machine is a three-spindle honing machine is. The same applies to the variant in FIG. 4.
• the honing machine 100 "in Fig. 4 has an internal loading system 400 with which it is possible to pick up a workpiece directly from a pick-up station outside the working space 1 15 and set down on the rotary table 130 without the use of an intermediate pendulum carriage.
• the internal loading system 400 has a carriage 410 that can be moved horizontally parallel to the y-direction and that can be moved along guide rails of a linear guide device 420.
• the carriage 410 carries a vertically movable gripper unit 415.
• the linear guide device extends over the entire narrow side of the honing machine and on one of the longitudinal sides (or both longitudinal sides) beyond this longitudinal side to the outside.
• a removal station is provided in the interior of the working space 1 15 and the workpieces are initially brought to this removal station during loading from the outside, before they are then placed on the rotary table.
• the implementation between internal removal station and rotary table or vice versa can be done for example by means of a robot, a swivel arm or a Shahubtransfers.
• Honing machines of the type shown here allow a very flexible design of a variety of machining processes, which include one or more Honbearbeit Institute.
• a single honing machine usually has no more than four honing spindles and the internal rotary table transfer.
• the work space 1 15 below the machine top is accessible from at least three sides for an operator.
• the columns supporting the machine head practically do not obstruct the lateral accessibility.
• the honing spindles are each facing outwards, ie move in the vicinity of the respective longitudinal sides and are therefore very accessible from the side.
• the interior of the honing machine, ie the work space 1 15, must be entered by an operator neither during operation nor during maintenance.
• the machine concept is characterized by extremely short non-productive times for workpiece changes and tool changes.
• Modularly constructed honing machines of the type shown here i. Rotary table modules
• two or more honing machines of the type shown in FIGS. 1 to 4 with the longitudinal sides next to each other can be constructed such that the charging stations can be approached and operated by the same portal loader.
• an optimal distribution of workpieces and optimal utilization of the individual honing machines are possible.
• gantry loaders or even the internal loading systems can be used.
• the loading of the rotary table can take place parallel to the main time with the help of a loading shuttle.
• the pendulum carriage itself can be loaded with the help of a linear portal or also by a robot or manually. If a loading robot or a linear portal with transverse stroke is available, it is possible to load directly onto the rotary table without a shuttle. If necessary, the travel axis of the pendulum carriage can also be extended.
• the first honing station for a pre-honing operation and the second honing station for a finish honing operation can be set up by coupling corresponding honing tools.
• a workpiece to be machined which has been preprocessed, for example by means of precision boring, is first deposited on the pendulum carriage and deposited therefrom on a free workpiece holder.
• the workpiece is then first driven to the Vorhonstation, where two holes at the same time by Prehone be edited.
• the carriage is then moved by a corresponding path, so that the honing spindles can then machine the other pair of bores.
• the rotary table is indexed 180 ° until the pre-honed workpiece reaches the area of the opposite honing unit, where the finished honing takes place in a corresponding manner.
• the workpiece is moved back to the loading position by 90 ° rotation of the rotary table, where it is picked up by the pendulum carriage and transported to the outside.
• a carriage with two honing units is moved over a long travel path in the direction of the tool magazine, where an automatic tool change is performed before the honing process can be continued with new honing tools.

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• 2012
  • 2012-02-06 DE DE102012201730A patent/DE102012201730A1/de not_active Ceased
• 2013
  • 2013-01-31 EP EP13702991.4A patent/EP2812152B1/de active Active
  • 2013-01-31 DE DE202013012303.6U patent/DE202013012303U1/de not_active Expired - Lifetime
  • 2013-01-31 DE DE202013012445.8U patent/DE202013012445U1/de not_active Expired - Lifetime
  • 2013-01-31 WO PCT/EP2013/051913 patent/WO2013117482A1/de active Application Filing
  • 2013-01-31 JP JP2014555205A patent/JP6097312B2/ja active Active
  • 2013-03-31 DE DE202013012320.6U patent/DE202013012320U1/de not_active Expired - Lifetime

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