You have been hurting your brain for a new use, determining the best grinders and abrasives, because you have to discuss with the supplier of grinders and abrasive tools to determine the best grinding and feed rate, you have to be good Train operators. However, after a few days or weeks of starting work, your quality control manager tells you that this new machine cannot process qualified parts. At that time you must identify and identify the problem and identify the various variables that affect the grinding process. This is not an easy task.
To avoid this, more and more manufacturers are turning to measurements during the grinding process. This measurement strategy is called “online measurement†because it monitors the size of the part as it is being machined. Although this closed-loop process control method was available in the early 1950s, in recent years, the enhancement, durability, and simplicity of the online measurement system have become the practical choice for the shop.
On-line measurement allows the user to: control the grinding process; after the dressing of the grinding wheel, the machine can quickly return to “zeroâ€; adjust the cycle immediately according to the size of the part; obtain real-time feedback to speed up the processing of fault problems and process analysis.
Because the part is measured and compensated on a real-time basis, online measurement of the grinding process does not require statistical tracking. The actual control of the machine depends on the various conditions at which each part is machined.
In applications, the measuring head must be skin-skinned and able to withstand prolonged exposure to coolant with abrasive and abrasive debris. Leather is inevitably simple. Generally speaking, a simple measuring instrument has better thermal stability, and the fewer the number of parts of the measuring instrument, the better the maintenance and the faster the maintenance.
The principle of “the simpler is better†also applies to the interface of the measuring instrument. It should be highly visible and have icons for quick installation and reduce the chance of operator error.
In addition, the surface of the part to be ground is often intermittent, and the measurement system must be able to accurately measure its true size, even including the size of the discontinuous part of the measurement area. It is not uncommon for the error of the part to reach 3 μm. The results obtained by online measurement prove its usefulness. Note that a two-finger/dual-sensor grinder can achieve the highest measurement accuracy throughout the process, and because it allows you to look at each sensor separately, it can also be used as a process analysis.
When the operator sees the meter fluctuating, he may mistakenly believe that the meter has a problem. In fact, this fluctuation may be the first sign of some problem in the process. For example, if the material cutting rate is slowly decreasing, this indicates that the grinding wheel needs to be corrected, and the fluctuation in the measurement may also indicate the deformation of the part. This requires adding a center bracket to reduce the wheel pressure or correct the grinding wheel in different directions.
By monitoring and correcting the grinding process, on-line measurement eliminates quality problems early in the manufacturing process, rather than producing scrap and finding problems during the inspection phase and even during the assembly phase, so you don't make scrap. As a result, your quality assurance costs have been substantially reduced, which is called the concept of "quality leverage."
In summary, the concept of “quality leverage†is to modify or improve quality earlier in production, and the greater the benefits of determining the process and reducing costs. In the final stage of the production process, when the product is to be shipped to the user, it is costly to determine the quality problem at this stage. What is more, the process is no longer able to change the process to prevent recurrence.
The situation is different. In theory, in the initial stage of the production process, that is, the product technology preparation phase, the return on investment in quality will be 100:1 compared to when the product is shipped. In the manufacturing engineering phase (ie in the metalworking phase), the return on investment in closed-loop process control based on module measurement or probing is tens of times greater than the subsequent improvement in quality control (QC) or inspection. If you have to wait until the assembly phase to improve, there will be no return on investment. “Quality Leverage†clearly shows that the earlier the quality problem is determined in the production process, the greater the benefit and the lower the cost. The longer you wait, the smaller the benefit and the higher the cost.
You would rather use online measurements in the upstream of the production process than on the downstream, and downstream adoption to improve quality is not only costly, but also bug fixes, even powerless.
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