This invention relates to an abrading machine of the type wherein a closed loop abrasive coated belt is oscillated back and forth laterally to the direction in which the belt is translated longitudinally while performing an abrading operation on a work piece.
The invention is particularly concerned with automatically equalizing the time intervals that elapse while the belt is being oscillated laterally in each direction.
A well-known purpose for oscillating the belt bilaterally is to obtain the smoother sanding or abrading that results when there is some relative lateral component of motion between the abrasive belt and the work piece, while steering the belt places it in the correct average position.
In abrading machines of this type, an abrasive belt runs on a pair of cylindrical rolls. One of the rolls is driven for translating the belt and another roll on which the belt runs may serve as an idler. The idler is mounted for being rocked through a small angle about an axis that is normal to the rotational axis of the roll. This causes the belt to shift back and forth laterally on the rolls so that the desirable lateral component of abrading is combined with the dominant longitudinal component. A fluidic circuit controlled steering and oscillating system for achieving bilateral belt motion is shown in U.S. Pat. No. 3,745,717 which is issued to the present applicant and is incorporated herein by reference.
Having a belt driving mechanism which produces lateral oscillations of constant amplitude does not necessarily result in the belt being moved at the same speed in opposite directions. The reason is that abrading belts often have nonuniform characteristics such as slightly different lengths as measured along their edges in the longitudinal direction and nonuniform tensile qualities across the width of the belt and belts may be affected unevenly by humidity changes. This results in variable internal stresses in the belt which cause it to move laterally at different speeds because in one direction the belt stresses may tend to assist lateral movement and in the other direction oppose it. The present invention is for assuring that the belt moves laterally in both directions in equal and constant time intervals. This negates the effects of permanent and temporary nonuniform characteristics and automatically trims the belt for ideal tracking behavior without operator intervention.
Summary of the Invention
In accordance with a preferred embodiment of the invention, a fluidic logic oscillator and correction circuit determines if the time taken for the belt to be oscillated or moved to each lateral limit is greater than a predetermined time interval which is initiated coincidentally with a fluid driven oscillator receiving the beginning of a continuing signal to begin and maintain a belt oscillation in a lateral direction opposite to the direction of the next previous oscillation. If the predetermined time interval expires while the oscillation signal still endures for the same direction of oscillation, it means that the belt is moving toward its lateral limit too slowly in the direction being tested. The oscillator, which rocks one roll on which the belt runs through opposite angles to cause lateral belt shift, is then trimmed in response to the detected time error, to change the average tilt angle of the roll in the appropriate direction so opposite lateral movement times will be equal. The distance which the belt moves between limits is unchanged.
A detailed description of the new apparatus for compensating or equalizing the time which the abrasive belt spends oscillating in one lateral direction with the time that it spends oscillating in the other direction will be set forth in reference to the drawing.
Description of the Drawing
The single FIGURE drawing is a schematic view of an abrading belt, its supporting rolls, sensing and control mechanism for driving the basic oscillator and the new additional controls for equalizing oscillation intervals.
Description of a Preferred Embodiment
In the drawing, an abrading machine to which the new control system is applicable comprises a closed loop belt 10 which runs on a cylindrical drive roll 11 and an idler roll 12. The drive mechanism for roll 11 is not shown. The belt opposite the side that runs on the rolls is coated with abrasive, and the lower run of the belt bears on a work piece, not shown.
Idler roll 12 is journaled for rotation on a yoke 13 which has an arm 14 extending from it. The yoke 13 and, hence, roll 12 are supported for oscillating or rocking, in a vertical plane as shown, about an axis represented by the dashed line 15. This axis is preferably perpendicular to the rotational axis of roll 12. A suitable structure for supporting the yoke 13 for rocking or oscillating through opposite angles may be seen in the above-cited U.S. Pat. No. 3,745,717.
To facilitate rocking roll 12 and to make belt 10 shift back and forth laterally on the rolls, arm 14 of the yoke carries an actuator including base 17 and cylinder 16 through which piston rods 19, 20 carrying piston 18 extends. A pneumatic system is preferred. The actuator 16-20 is of the double acting type. A pair of tubes 31 and 32 connect to opposite ends of the actuator cylinder 16 above and below the piston 18, as shown. These tubes are sequentially pressurized and depressurized for driving the actuator cylinder 16 in opposite directions with respect to piston 18 and connecting rod 19, 20 to make roll 12 oscillate about axis 15 in successively opposite angular directions. Thus, when driving roll 11 translates belt 10 longitudinally at high speed as it does during machine operation, the actuator slightly rocks yoke 13 and idler roll 12 about axis 15 to cause the belt to ride toward corresponding ends of the rolls 11 and 12 and then back toward opposite corresponding ends.
Piston 18 does not move to actuate belt oscillation but establishes a neutral position from which cylinder 16 moves to rock yoke 13 on axis 15. The position of piston 18 is adjusted to the correct neutral position by moving piston rod 19, 20. As illustrated, piston rod 19 is connected through universal joint 34 to lead screw 35 which is threaded through nut 36 gimballed on yoke 37 pivoted to a fixed surface 38. Preferably lead screw 35 also carries knob 39 for manual positioning. Turning lead screw 35 moves piston 18 axially to a new neutral position. Yoke 37 and universal joint 34 allow for movement of the parts to oscillate belt 10.
Automatic adjustment of the neutral position is accomplished by attaching reversible motor 26 to piston rod 20, for instance by a collar 23 which may have a splined connection 21, 22 to the piston rod and set screw 24 engaging motor shaft 25. Other appropriate connections may be used. Motor 26 is reversible and preferably electric with leads 28, 29 for current to drive it in respective directions of rotation and common line 30 to complete the connection to d.c. current source 74 as later described. Motor 26 is desirably supported on a base illustrated as 27 connected to arm 14.
The limits to which the belt is shifted laterally in each direction are established by use of a control bar 45 which has a curved upper surface on which the inside surface of belt 10 slides. The structural and functional details of control bar 45 are described in U.S. Pat. No. 3,745,717 and need not be repeated here. It is sufficient to point out that the control bar has one or more orifices such as those marked 46 and 47 at opposite ends. These orifices are used to interact with the timing circuit by initiating timing signals to determine the limits of belt movement in each lateral direction by beginning oscillation in the opposite direction. As explained in the patent, there are sensors or tubes 48, 49 in the control bar which have ports aligned with selected orifices 46 and 47. A segment is omitted in the drawing of sensor tubes 48, 49 for the sake of simplifying it. These sensors sense pressure changes when the orifices 46 and 47 are alternately covered and uncovered by one or the other of the belt edges. The sensed pressure signals are delivered in a known way to the previously mentioned known type of belt-oscillating fluidic circuit symbolized by the block which has that legend and the reference numeral 33. The belt oscillating circuit 33 responds to the signals from the sensors by applying fluid pressure to one side of the piston 18 through one of tubes 31 and 32 while pressure on the other side of the piston is relieved for the moment through the other such tube. Sensing pressure change at the sensor 48, 49 at the other end of bar 45 causes belt oscillating circuit 33 to switch the pressures in tubes 31, 32. This moves cylinder 16 and yoke 13, 14 on axis 15 in the oscillating mode.
The new control for equalizing the times for the belt 10 to travel between opposite fixed limits will now be considered in detail.
Equalization is obtained by employing two similar control loops described below and comprising fluidic logic elements in the preferred embodiment, to develop signals indicative of an error in lateral travel time for the belt, and then using the signals to trim the pneumatic oscillator so it will effect appropriate changes in the angles through which the yoke 13 and, hence, the roll 12 is tilted to bring about lateral travel time equality by the belt 10.
Considering one control loop first, NOR gate 51 transmits pressure to its output port 52 until the cylinder volume on one side of piston 18 is pressurized and this sustained pressure is received on the input port 50 of the NOR gate 51 at which time this NOR gate turns off and its output line 52 is unpressurized. The pressure present on the output port 52 of the gate 51 while it is turned on is transmitted to a storage chamber 58 through a check valve 59 which prevents reverse flow from the storage chamber back to NOR gate 51 when its output pressure is terminated. The storage chamber 58 has a controlled orifice 60 which allows fluid to bleed out of storage chamber 58 at a predetermined rate such that a time constant is determined which represents the elapsed time between fully pressurizing the storage chamber 58 and the time when discharge through the orifice 60 lowers the pressure in the chamber to a predetermined level. In other words, closure of the check valve 59 coincides with initiation of the measurement of the predetermined reference time interval and bleeding down to a predetermined minimum pressure coincides with the end of the time interval. The pressure condition in storage chamber 58 is transmitted through a tube 61 to the logic signal input port 62 of a fluid amplifier which is symbolized by the block marked 63.
Amplifier 63 has the previously mentioned signal pressure input port 62 and an output port 64. It also has a pressurized fluid supply input port 65 which is coupled by means of a header tube 66 to the source air pressure tube 57. An amplifier with suitable functional features is described in greater detail in the cited patent. The amplifier 63 is normally closed. A minimum pressure at 62 is required to trigger amplifier 63 to its conductive or open state. While storage chamber 58 is discharging down to the minimum triggering pressure for the amplifier 63, a signal is thus passing through the amplifier to its output port 64 which is coupled to the input port 67 of another normally open NOR gate represented by the block 68. When storage chamber 58 has discharged to a pressure below the triggering pressure of the amplifier 63, a signal to the NOR gate 68 input port 67 no longer exists, so NOR gate 68 turns on or begins to conduct, pressurizing output port 69. Output port 69 of NOR gate 68 is coupled by means of a tube 70 to the input port 71 of a pressure controlled electric switch 72. This switch has a set of contacts, not visible, which are open when there is no pressure on its input port 71 and which close in response to pressure on its input port. The switch (and corresponding switch 85 in the second loop) has a d.c. input line 73, and has the previously mentioned output line 28 which is one of the inputs to reversible trimming motor 26. The motor is supplied through the contacts of pressure operated switch 72 from a d.c. source indicated by the reference numeral 74. The other source line is the previously mentioned common line 30 to the windings of reversible motor 26. Thus, when the contacts of pressure operated switch 72 close, a circuit is completed through motor 26 and it runs slowly in one direction to trim the neutral position of the oscillator actuator by moving piston rod 19, 20, carrying piston 18, to a new axial position by means of parts 34-39.
If the pressure that is supplied to oscillator cylinder 16 until the belt reaches a lateral limit and to the input port 50 of the first NOR gate 51 disappears because the limit is reached while the storage device 58 is timing out, the first NOR gate 51 will change state and a new charge of pressure will be supplied to storage chamber 58. In such case, there will be no change of state on the input 62 of amplifier 63 nor to the input port 67 of the last NOR gate 68 in the first control loop in which case pressure responsive switch 72 will not be operated and motor 26 will not run to trim the oscillator piston 18 neutral position.
Whenever the time for a full lateral oscillation of belt 10 exceeds the predetermined reference time interval set by discharge rate or time constant of storage device 58, the tilt angle for steering roll 12 on axis 15 will be changed in the direction that will result in the belt taking less time and, in effect a constant time to reach its limit in the one lateral direction to which the control loop relates.
Stated in another way, the storage device 58 provides a predetermined time interval with which the signal to cylinder 16 for oscillation of the belt in one direction is compared. If the oscillator input signal to one side of piston 18 is too long, the storage device 58 will have timed out while the oscillation signal still continues, and the motor 26 will be driven in a direction which will slowly change the roll 12 oscillation or tilt angle. If the signal from oscillation circuit 33 to the oscillator cylinder 16 prevails for a time which is too short, no change in the first control loop which is now under consideration will be made since the input port 50 to the first NOR gate 51 will go low earlier and storage device 58 will be quickly recharged to full pressure in which case the pressure operated switch 72 will not be operated.
The second control loop constantly tests and corrects any error in belt travel time in the other lateral direction and comprises a first previously mentioned NOR gate 54 port 52, a check valve 80, a storage chamber device 81 having a timing orifice 82, an amplifier 83, a second NOR gate 84 and a pressure operated switch 85, all comparable to like parts in the first control loop. The input port 53 of the first NOR gate 54 in the second control loop receives a signal comparable to the signal provided to the lower side of the piston 18 in cylinder 16 when the oscillator circuit triggers the oscillator to angulate the roll 12 to an opposite angle so the belt 10 will shift toward the other lateral limit. The pressure operated switch 85 also has a set of normally open contacts, not visible, in circuit with the d.c. supply line 73 coming from d.c. source 74. The switch has previously mentioned output line 29 which runs to a second input of reversible motor 26. When the contacts in pressure operated switch 85 close, a circuit is completed through electric line 29 and the common return line 30 to d.c. source 74. This drives motor 26 in the opposite direction from which it is driven when the contacts of pressure switch 72 in the first control loop are closed. When pressure switch 85 closes its contact, motor 26 turns piston rod 19, 20 carrying lead screw 35 in a direction which moves actuator piston 18 to change the roll 12 angulation for obtaining a lateral belt oscillation which does not exceed the predetermined reference time interval set by the discharge time of the second storage device 81. The orifice 82 of storage device 81 and the orifice 60 of the other storage device 58 are adjusted or chosen so that the respective storage devices will produce an identical predetermined time interval. Thus, they will always cause an adjustment of the actuator piston which will restore the signals for oscillation from oscillating circuit 33 to the actuator toward durations equal to the predetermined time. Hence, regardless of the abrasive belt 10 tending to use more time to move in one direction than in the other for any reason, the oscillation times will always be automatically set toward equality.
The belt travel time equalizing system described above can be simplified in the interest of reducing costs by substituting visual displays, such as indicator lamps, not shown, for the oscillation time trimming or correcting motor 26. In other words, instead of having the motor run, lamps could be connected between d.c. correction signal output line 29 and the common line 30 and line 28 and common 30, which would provide the machine attendant with a visual indication that the oscillation times in each direction had been indicated by the two control loops to be unequalized. A simple pneumatic indicator could replace the electric circuit. A manual correction could then be made such as by manually turning trimming lead screw 35 to adjust the position of the actuator piston 18. Other mechanical adustment means could also be used.
Another alternative is to use a pneumatic motor, not shown, in place of reversible motor 26. However, an electric motor is preferred because pneumatic motors tend to require too much air volume and too much air pressure to operate reliably. A rotatable electric motor 26 and a lead screw 35 are preferred as compared with other means for trimming the adjustment of the actuator cylinder stroke and, hence, the angles through which the yoke 13 oscillates, because a screw gives a very rigid adjustment and provides a solid base for operation of the actuator which causes the belt 10 to oscillate. A motor driven screw also makes the system more immune to errors which might result from inherent vibrations of the machine.
The idea of checking the time of each lateral belt oscillation and providing an oscillator trimming signal to obtain time equalization can, of course, be implemented in ways other than by what is contemplated to be the preferred way as described herein. For example, instead of referencing the durations of the oscillator drive signals from oscillating circuit 33 for alternate oscillations against a fixed predetermined time intervals independent of each other, signals equivalent to the successive signals to the first NOR gates in the loop could be stored for one oscillation cycle. Pairs of alternate signals could then be compared using programmable processors to produce an error or difference signal and using appropriate output devices to control a compensating servo motor to run in a direction depending on the positive or negative magnitude of the error signal.
It will be appreciated that in actual operation of the abrading machine, it is desirable to check the time of each lateral shift by the belt as described herein, but adjusting the neutral position of piston 18 for every oscillation cycle will not ordinarily be necessary. It is primarily a matter of correcting for drift in belt oscillation speed and moving the angulation equilibrium of the yoke. Hence, a relatively low speed trimming motor 26 can be used.
It will also be evident that the illustrative pneumatic logic devices in the individual control loops could be implemented with digital electronic logic devices. For instance, an electronic logic NOR gate could be substituted for fluidic NOR gate 51 whose output 52 goes low when its control signal input 50 goes high. An electric signal corresponding with the oscillator driving pressure signal on input line 50 to the first NOR gate could be replaced by a pressure responsive switch, not shown, in line 50 and having the output of this switch constitute one logic input to an electronic NOR gate. A diode, not shown, would be the analog of check valve 59. A capacitor and a resistor, not shown, for providing an RC time constant, would be analogs of storage device 58 and its bleeder orifice 60, respectively. An electronic amplifier could e substituted for pneumatic amplifier 63 and an electronic logic NOR gate, not shown, could be substituted for pneumatic NOR gate 68. In an electronic logic system, of course, a relay or controlled rectifier could be used in place of pressure responsive switch 72.
Although a fluidic logic system using two control loops for equalizing oscillation time of an abrasive belt has been described in considerable detail, such description is intended to be illustrative rather than limiting, for the invention may be variously embodied and is to be limited only by interpretation of the claims which follow.