Technical Field The invention relates to an apparatus for checking the diameter of pins, rotating about a geometrical axis, in the course of the machining in a numerical control grinding machine including a worktable, defining said geometrical axis and a grinding wheel slide carrying a grinding wheel, with a measuring head including a Vee-shaped reference device for cooperating with the pins to be checked, a feeler for contacting the surfaces of the pins to be checked and a transducer for generating signals depending on the position of the feeler with respect to the Vee- shaped reference device, a support device, adapted to be coupled to the grinding wheel slide, including reciprocally movable coupling elements, for supporting the measuring head in a movable way, a control device for controlling automatic displacements of the measuring head from a rest position to a checking condition and vice versa, and a processing and display device connected to the measuring head for receiving and processing the signals provided by the transducer.

Background Art Apparatuses with these characteristics, for the diameter checking of crankpins rotating with orbital motion about a geometrical axis, are disclosed in international patent application published with No. WO-A-9712724.

The embodiments described in such international patent application guarantee excellent metrological results and small forces of inertia, and the standards of performance of the apparatuses with these characteristics, manufactured by the company applying for the present patent application,

confirm the extraordinary quality and the reliability of the applications.

Moreover, these known apparatuses provide remarkable flexibility of use, also thanks to the possibility of replacing-by performing simple operations-some components, as the Vee-shaped reference device for varying, for example, the measurement range of the head. However, these known apparatuses do not enable to check in an automatic and sequential way the machining of parts differing among each other insofar as their nominal dimensions are concerned (for example the crankpins and the main journals of a same crankshaft), as this would imply the need to replace the Vee-shaped reference devices in between a checking and a subsequent one or at least carry out a new head calibration on a suitable section of a master piece every time the nominal dimension changes.

Disclosure of the Invention Object of the present invention is to provide an apparatus for the checking of pins rotating in the course of the machining in a machine tool, for example during the in- process checking in a grinding machine for grinding crankpins rotating with an orbital motion and/or main journals rotating about their symmetry axis, that enables to check in a simple and rapid way pins having nominal diametral dimensions varying within a relatively wide range.

This object is achieved by a checking apparatus of the hereinbefore mentioned type, wherein the processing and display device includes a memory unit for storing compensation values or coefficients, the processing and display device being adapted to process the transducer signals and the compensation values or coefficients and provide measuring signals.

Thus, by compensating transducer errors, it is possible to

attain a wide transducer linearity range and corresponding measurement displacements of the feeler of a considerable entity. In this way, the choice for determining the appropriate angle defined by the sides of the Vee-shaped reference device, permitting the head to have a wide measurement range, is not substantially bound to the need of limiting the feeler displacements but it can be made by taking into due consideration other physical or functional characteristics of the application.

Moreover, wider feeler displacements enable to achieve, at an identical measurement range, an improved sensitivity of the head and a higher resolution of the apparatus.

Brief Description of the Drawings The invention is now described in detail with reference to a preferred embodiment, illustrated in the enclosed sheets of drawings, given by way of non-limiting example, wherein: Figure 1 is a side view of a measuring apparatus mounted on a grinding wheel slide of a machine for grinding crankshafts, shown in a working condition in the course of the checking of a crankpin; Figure 2 is a side view of the measuring apparatus of figure 1, shown in a working condition in the course of the checking of a main journal ; Figure 3 is a partial front view of the apparatus mounted on the grinding wheel slide of the grinding machine; Figure 4 is a partially cross-sectional view of the measuring system of the apparatus; Figures 5 and 6 are graphs showing a possible method for determining correction coefficients and values of the linearity error of the transducer; Figure 7 is a graph showing the variations-caused by thermal variations-in the output signal of the head of an apparatus according to the invention; and

Figure 8 is a circuit block diagram showing some components of a processing system according to the invention.

Best Mode for Carrying Out the Invention With reference to figures 1 to 3, the grinding wheel slide 1 of a computer numerical control ("CNC") grinding machine -for grinding a crankshaft 34 defining an axis of rotation 8-supports a spindle 2 that defines the axis of rotation 3 of grinding wheel 4. Above spindle 2 the grinding wheel slide 1 carries a support device including a support element 5 and a first rotating, coupling element 9 and a second rotating, coupling element 12. The support element 5, by means of a rotation pin 6 that defines a first axis of rotation 7 parallel to the axis of rotation 3 of grinding wheel 4 and the axis of rotation 8 of the crankshaft 34, supports the first rotating, coupling element 9.

In turn, coupling element 9, by means of a rotation pin 10, defining a second axis of rotation 11 parallel to the axis of rotation 3 of grinding wheel 4 and to the axis of rotation 8 of the crankshaft 34, supports the second rotating, coupling element 12. At the free end of coupling element 12 there is coupled a tubular-shaped guide casing 15 wherein there can axially translate a transmission rod 16 (figure 4) carrying a feeler 17 for contacting the surface of the pin to be checked, for example a crankpin 18 or a main journal 38 of the crankshaft 34, as shown in figures 1 and 2, respectively. The tubular-shaped casing 15, the rod 16 and the feeler 17 belong to a measuring, or checking, head 39, that also includes a support block 19, coupled to the lower end of the tubular guide casing 15, for supporting a Vee-shaped reference device 20, adapted for engaging the surface of the pin to be checked, by virtue of the rotations allowed by pins 6 and 10. The transmission rod 16 is movable along the bisecting line of

the Vee-shaped reference device 20.

Moreover, the support block 19 supports a guide device 21, that, as described in international patent application published with No. WO-A-9712724, has the purpose of guiding the reference device 20 to engage the pin to be checked and maintain contact with the pin while the reference device 20 moves away from the pin for limiting the rotation of the first 9 and the second 12 coupling elements about the axes of rotation 7 and 11 defined by pins 6 and 10.

The axial displacements of transmission rod 16 with respect to a reference position are detected by a measurement transducer, fixed to casing 15, for example a transducer 41 of the LVDT or HBT type (per se known), with fixed windings 40 and a ferromagnetic core 43 coupled to a rod 42, movable with the transmission rod 16 (figure 4). The axial displacement of the transmission rod 16 is guided by two bushings 44 and 45, arranged between casing 15 and rod 16 and a compression spring 49 urges rod 16 and feeler 17 towards the surface to be checked of crankpin 18 or main journal 38 or, in the absence of such surface, towards a rest position of feeler 17 defined by abutment surfaces not shown in the figures. A metal bellows 46, stiff with respect to torsional forces, having its ends fixed to rod 16 and casing 15, respectively, accomplishes the dual function of preventing rod 16 from rotating with respect to casing 15 (thus preventing feeler 17 from undertaking improper positions) and sealing the lower end of casing 15.

The support block 19 is secured to guide casing 15 by means of pairs of screws 47 passing through slots 48 and supports reference device 20, consisting of two elements 31 with sloping surfaces, whereto there are secured two bars 32.

The rest position of feeler 17 can be adjusted by means of screws 47 and slots 48.

The transducer 41 of the head 39 is connected to a processing and display device 22, in turn connected to the computer numerical control 33 of the grinding machine.

The crankshaft 34 to be checked is positioned on the

worktable 23, between a headstock and a tailstock, not shown, that define the axis of rotation 8, coincident with the main geometrical axis of the crankshaft 34. The crankpin 18 (shown in figure 1) and the main journal 38 (shown in figure 2) rotate about axis 8, the first of the two by describing an orbital trajectory.

Basically, the coupling elements 9 and 12 are linear arms with geometric axes lying in transversal planes with respect to the axis of rotation 8 of the crankshaft 34 and the axis of rotation 3 of grinding wheel 4. However, as shown in figure 3, that also illustrates the crankshaft 34, for avoiding any possible interference with elements and devices of the grinding machine, for example with component parts of a coolant plant for directing, by means of a nozzle, coolant towards the surface being machined, the coupling elements 9 and 12 include portions 36 and 37 that extend in a longitudinal direction and portions offset in a plurality of transversal planes.

A control device includes a double-acting cylinder 28, for example of the hydraulic type. Cylinder 28 is supported by grinding wheel slide 1 and includes a rod 29, coupled to the piston of the cylinder, carrying at the free end a cap 30. An arm 14 has one end coupled to element 9 and carries, at the other end, an abutment with an idle wheel 26. When cylinder 28 is activated for displacing the piston and the rod 29 towards the right (with reference to figures 1 and 2), cap 30 abuts against the idle wheel 26 to displace the checking apparatus to a rest position according to which reference device 20 is no longer in contact with the surface of the pin. An overhang 13 is coupled in a rigid way to support element 5, and a coil return spring 27 is coupled to overhang 13 and arm 14. When rod 29 retracts for enabling the apparatus to displace to the checking condition, and cap 30 disengages from the abutment, or idle wheel 26, support block 19 approaches crankpin 18 (or main journal 38) through rotations of the coupling elements 9, 12 and the apparatus reaches and maintains the checking

condition, substantially in the way described in the hereinbefore mentioned international patent application published with No. WO-A-9712724.

The cooperation between crankpin 18 (figure 1) or main journal 38 (figure 2) and the reference device 20 is maintained thanks to displacements of the components caused by the force of gravity. The action of coil spring 27, the stretching of which increases as the support block 19 lowers, partially and dynamically counterbalances, in the embodiment shown in figures 1 and 3, the forces due to the inertia of the component parts of the checking apparatus that displace by following the displacements of the crankpin 18. In this way it is possible, for example, to avoid high thrusts between the reference device 20 and the crankpin 18, at the lower position (identified by reference number 18"), that could cause the deformation of the Vee of the reference device 20. On the other hand, since during the raising displacement of the apparatus (due to the rotation of the crankpin towards the upper position 18') the pulling action of spring 27 decreases, the forces of inertia that, at the upper position 18', tend to release the engagement between the Vee-shaped reference device 20 and crankpin 18, can be properly counterbalanced. In this latter case it should be realized that the balancing action is achieved by diminishing the pulling force of spring 27.

In other words, return spring 27 does not cause any force between reference device 20 and crankpin 18, that mutually cooperate, as previously mentioned, simply owing to the force of gravity.

In the course of the checking phase, transducer 41 in head 39 sends signals to the processing and display device 22.

The signals are indicative of the position of feeler 17, the displacements of which are transmitted by transmission rod 16. In the device 22, also including a memory unit 24, the signals arriving from head 39 are processed and corrected on the basis of values or compensation coefficients stored in unit 24, and measuring signals are

displayed and transmitted to the computer numerical control 33. More specifically, the former values/coefficients can be utilized for compensating linearity errors of the signal output by transducer 41 and/or alterations of the latter as a consequence of thermal variations.

As far as the linearity errors are concerned, in the course of the calibration of transducer 41, before its assembly in head 39, and causing changes in the operative position (i) of core 43 within windings 40, a sequence of values yi relating to the signal output by transducer 41 is detected, as well as a sequence of values xi that identify corresponding positions of core 43, the latter values are obtained by utilizing specific testing equipment of a known type. These sequences xi and yi are stored, for example in a tabular form, in memory unit 24, in a known and herein not further illustrated way.

The processing unit 22 processes the former sequences, in order to determine correction coefficients and values for compensating the linearity errors of transducer 41.

A possible procedure for determining these coefficients and values is hereinafter described.

Starting from the sequences of values xi, yi, stored in memory unit 24, it is determined, by applying the least squares method, the regression straight line rregr of the values yi detected by transducer 41 with respect to those xi measured by means of the testing equipment. Figure 5 shows, in a plane X-Y, the points corresponding to pairs of values xi and yi detected in the course of the testing phase, the regression line rregr and the ideal line rid of equation y=x that would be obtained in the event the positions yi detected by the transducer were identical to those xi measured by means of the testing equipment. In general, owing to sensitivity errors of the transducer, the regression line rregr does not coincide with the line rid, but has a different gradient with respect to the latter.

The sensitivity error can be indicated as the difference between the angular coefficients of the regression line

rregr (kregr) and of the ideal line rid, the latter being equal to 1. Since Yid 1=yregr : kregr where Yid and yregr represent the ordinates y of points of the straight lines rid and rregrr respectively, corresponding to a same generic value x, for compensating the sensitivity error it is necessary to divide the value of ordinate y of every point of the regression line rregr by the angular coefficient kregr of the regression line rregr itself. This compensation can be represented as a rotation of the regression line rregr till it overlaps with the ideal line rid, as indicated by reference r'regr in figure 6.

In addition to compensating the sensitivity error, by dividing all the ordinates y of the regression line rregr by the angular coefficient kregr of the regression line rregr, it is also necessary to compensate the linearity errors represented by the distances of the points of co-ordinates Xi, yi from the regression line rregr. Consequently, in order to achieve the compensation, it is necessary to add, to the values detected by the transducer, the identical and opposite values of their associated linearity errors, as indicated by the arrows in figure 6.

The coefficients and the correction values determined in this way for a discrete number of points are memorized in memory unit 24, for example in a tabular form. In the course of the checking operations, the transducer 41 signal is corrected in processing unit 22 on the basis of such compensation coefficients and values. As these coefficients and values are indicative of the linearity errors at a discrete, although possibly high, number of reciprocal positions between core 43 and windings 40 of transducer 41, it is furthermore possible to process the values, in a known way, by interpolation, for compensating the output signal of transducer 41 in a substantially continuous way within the entire operation range of head 39.

As an alternative to the defining and the storing of the compensation values in a tabular form, the error values

detected during the calibration phase can be processed for obtaining a compensation curve, and the coefficients of its polynomial (typically of the 3rd degree) can be stored in memory unit 24.

The above described procedure enables to achieve, without modifying the mechanical characteristics of the transducer 41, a wider measurement range while accuracy remains substantially unaltered.

The compensation values or coefficients can be stored, for example, on the basis of detectings carried out in the course of the calibration of transducer 41 on testing equipment, before the assembly in head 39, as previously described. As an alternative, the values stored in unit 24 can be obtained by statistical processings of data detected during the testing of a certain number of sample transducers that belong to a same"family", in other terms that have common manufacturing characteristics (dimensions and other).

Another possible compensation regards the repeatability errors of head 39 generated by temperature variations that cause alterations of the characteristics of transducer 41.

More specifically, as schematically shown in figure 7, where axis s stands for the displacement of the feeler 17 and axis M indicates the measurement detected on the basis of the output signal of transducer 41, the straight line Mo represents the measurement detected as the displacement s varies at a reference temperature to, and straight line MT represents the same measurement at a reference temperature brother than to.

The straight lines are bound by the following equation: MT = M0 + [k1 (tT-t0)] + [Mo k2 (tz ~ to)] that does not consider terms of a higher order, which are generally negligible.

The term [kl (tT-to)], or"zero drift", indicates the measurement variation, as the temperature varies, at the

zero position of transducer 41 (s = 0) and is identified by reference Do in figure 7.

The term [k2 (tT-to)], or"sensitivity drift", indicates the measurement variation caused by variations in the transducer sensitivity as the temperature varies.

With reference to figure 7, it can be stated that the term [ki (tT-to)] indicates the distance between the two straight lines MT and Mo at s = 0, while [k2 (tT-to) indicates the angle formed by the two straight lines.

The values of the coefficients kl and k2, that enable to obtain the trend of the measurement MT when the reference straight line Mo and the temperature difference (tT-to) are known, are detected in an experimental way during the calibration of transducer 41. As already described with regard to the compensation of the linearity errors of transducer 41, in this case too the values of coefficients kl and k2 can be individually detected and employed for each single transducer 41, or detected on the basis of statistical processing-in particular as mean values of the data relating to a certain number of sample transducers that have common manufacturing characteristics-and are utilized for compensating any head (39) with any whatsoever transducer (41) provided with these characteristics. Both the methods provide worthy improvements in the repeatability of the heads 39, even though, obviously, the improvements provided in the first case are more evident.

In order to compensate the errors due to thermal variations, it is mandatory, as already mentioned, to detect the temperature variation (tT-to) with respect to a reference temperature. For this purpose it is possible to use a temperature sensor of a known type (for example, a "thermistor") inserted in head 39.

As an alternative, data relating to the temperature variation can be obtained by employing the components of the position transducer 41 for detecting variations in the electric resistance of the windings 40 and processing these variations with data that identify the characteristics of

the material from which the windings 40 are made. More specifically, the temperature variation can be calculated in the following way to)- (RT-Ro)/a where (RT-Ro) is the resistance difference of the windings 40 of the transducer 41 at temperature t, with respect to a reference temperature, and a is a constant that depends on the type of material.

Figure 8 schematically shows the power supply and processing circuits that can be utilized, in processing device 22, with transducer 41, the latter being, for instance, of the so-called"half bridge"type. Figure 8 shows a source of alternating voltage 50 and a source of direct voltage 51, an adder 52, a drive circuit 53 with a shunt resistance 54, an amplifier 55, a low pass filter 56, a second adder 57, and circuits 60 for conditioning the output signal of transducer 41.

An alternating voltage VAC for the power supply of the transducer and a direct voltage Vac are provided by sources 50 and 51, respectively, and added in adder 52. At point A the voltage is kept substantially constant by drive circuit 53. The variations in the value of resistance R of windings 40 as the temperature changes cause current variations and the consequent voltage drop at the ends of the shunt resistance 54 that is amplified (55) and filtered (56) to eliminate the alternating component. An offset voltage value Vos, obtained from the direct voltage generated by source 51, is subtracted (57,58) from the voltage so obtained.

The variations of the resistance R of the windings 40 as the temperature changes cause consequent changes in the voltage at point B: therefore by periodically detecting the latter voltage it is possible to calculate the resistance variation (RT-RO) with respect to a reference value and to get the temperature change with respect to a reference value to corresponding to resistance Ro.

The calculation (RT-Ro) made on the basis of the voltage difference detected at point B involves known quantities like the value of the offset voltage Vos, the gain of the circuits 53 and 55 and the value of resistance 54, according to equations herein not provided for the sake of simplicity.

The conditioning circuits 60 provide the output signal of the transducer 41 at point O and are of a known type herein not described in detail.

When a new crankpin 18 (or main journal 38) has to be machined, it is brought in front of grinding wheel 4, usually by displacing the worktable 23 (in the event of a grinding machine with a single grinding wheel), and the checking apparatus moves to a measuring position, i. e. the head 39 is displaced onto a new pin to be checked, as hereinbefore described.

Thanks to the compensation in the processing and display unit 22, in particular relating to the linearity errors of transducer 41, the measurement range of head 39 is particularly wide. In other words, it is wide the range of the possible displacements of feeler 17 that correspond to substantially linear variations of the measuring signals output by processing unit 22. This enables to program the sequential and automatic machining of pins that have different nominal dimensions (for example crankpin 18 shown in figure 1 and main journal 38 of figure 2) without there being the need to perform cycles for zero-setting the head 39 against master pieces with various nominal dimensions representing those of the various pins. Instead, an initial zero-setting on a piece with just a known dimension (obviously within the measurement range of head 39) is sufficient for enabling, thereafter, the machining-under the control of the computer numerical control 33-of pins with nominal dimensions that vary within the wide range of head 39. The proper mechanical cooperation between feeler 17 and the surface of pin (18 or 38) is provided by virtue of the Vee-shape of the reference device 20 and the

arrangement of the feeler 17 and the transmission rod 16, substantially along the bisecting line of the Vee-shaped reference device (or along a direction with a slight angular arrangement with respect to such bisecting line).

According to one of the various possible embodiments of the invention, a substantially linear measuring signal can be obtained, by means of transducer 41 and associated compensations in unit 22, within a range wider than 4mm.

This enables to check, in combination with the geometric characteristics of the Vee-shaped reference device 20, the. machining of pins with a nominal diameter varying within a range that can be wider than 20mm. Figure 4 clearly shows the ratio existing among the various positions of feeler 17 and the corresponding various dimensions of pins 18 and 38.

On the other hand, the wide linearity range of the measuring signal enables to achieve a wide measurement range of head 39 insofar as Vee-shaped reference devices 20 with considerably different opening angles are concerned.

In other words, it is possible to choose the opening angle of the Vee-shaped device 20 on the basis of various technical characteristics of the application without significantly affecting the measurement range of the head 39 that, even though it varies, in any case will remain definitely high.

Thus, the innovative aspects of an apparatus according to the invention are evident and basically regard the shape of the reference device 20 and the compensation of the linearity errors of transducer 41 and/or of errors due to temperature variations, which are characteristics that, although individually known, in combination enable to achieve a remarkable technical result.

Apparatuses according to the invention can include other manufacturing aspects with respect to what has been so far illustrated and described, among other things with regard to the component parts of the support device, that need not necessarily rotate, and the guide device 21, that can be left out or manufactured in a different way, so as to

include, for example, surfaces for cooperating with the coupling elements of the support device and not with the part to be checked.