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One machining process that developed as a precision process (fixed abrasive) ahead of turning is grinding which was followed by lapping and polishing which may be considered as a high-precision loose abrasive grinding process There are various types of conventional grinding operations available today, some of which are summarized in Figure 414 In general, grinding operations are carried out on the external and internal surfaces of workpieces by using vertical or horizontal spindle grinding machines The development of hardened steel in the latter part of the 19th century created a need for a machine that was capable of finishing work pieces, which were as hard as cutting tools This led to the development of grinders, which over the years were improved and modified to become the highprecision grinders of today Surface grinding operations are commonly used for grinding flat surfaces depending on the workpiece size and shape Reciprocating and rotating tables, which have an electromagnetic holding surface, are usually employed for holding the workpiece The vertical spindle surface grinder with a reciprocating table grinds the face of the wheel and is capable of taking heavy cuts This is a good example of full immersion grinding where the grinding wheel grinds 16 workpiece surfaces at a time The main advantage of full immersion grinding is the uniqueness in the dimension and the final surface finish Cylindrical and centreless grinding operations are used to grind the outside diameters of round surfaces (Figure 414 (d, f )) These surfaces may be straight, stepped or tapered In cylindrical grinding, the workpiece is held between centres, which are rotated at a much lower speed in a direction opposite to that of the grinding wheel However, in centreless grinding operations, the workpiece is held between the grinding wheel and a regulating wheel and a work rest blade By tilting the rotational axis of the regulating wheel with respect to the grinding wheel, the workpiece is given a longitudinal force, creating movement or through feed, that is helpful for automation The fundamental difference between centreless grinding and most other forms of grinding is that the workpiece is not firmly held either on a magnetic chuck or between centres or in a vice, but rather it moves across the rim under.



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to be tuned to match a specific problem. While the formulas are reasonably generic, the gain factors need to be adjusted to get the best control. Now for one of those complexities that we ignored earlier. What are the units we are generating for Z Right now, Z is in terms of the input. If the inputs X and Y were scaled to the range [0. . .1] by dividing them by their maximum values, the output is then in terms of percent power. This can then be converted into a power level for a motor or other mechanism.

Fig 414: Example of products using specific grinding operations [30]





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A PID or other reflexive control is fine for the most low-level tasks. There are times, however, when you want your machine to perform a series of actions, one after the other. Industrial robots don t need intelligence, per se, but do need to have predictable behavior. These robots will consist of some low-level reflexes and a bunch of simple commands to execute, one after another. For another example, in a competition you need to might need to follow a path for a certain distance, retrieve an object, and then return to the start. A Mars explorer may be given a set of tasks by the ground control and it must then carry them out, one at a time, until it is done. A smart Mars explorer would even be able to skip a task if it found itself unable to complete it. There is not much to say on the topic of serial behaviors, though there are some subtleties to be aware of when implementing them. The first is, how does the robot know when to stop one behavior and start the next behavior You could do something simple like drive forwards for 10 seconds or turn this wheel 100 times, but those are special cases that are only useful in a controlled environment. If you are a Mars explorer, how do you know when you are next to that funny-looking rock If you are driving over rough or slippery ground, how do you know when you have gone 100 feet Some of these questions might

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Fig 415: A vertical surface grinder [31]

the combined action of the grinding wheel, the regulating wheel and the blade The grinding pressure is generated dynamically by the difference in the wheel velocity between the regulating and grinding wheels

be answered by specialized sub-programs that can recognize such a poorly defined situation This is difficult, one of those hard to define tasks like recognizing faces Animals do it all the time, robots have to work really hard on the problem Even when you have a situation where it is easy to tell when to switch tasks, such as when you have crossed a black line on the ground, you have bumped into a wall, or perhaps wandered into a shadow, you still don t know exactly where you are.

Fig 416: One of the special external centreless grinding operations is the grinding of the balls of ball bearings

In this process, the grinding wheel is fed against the roughing wheel Balls tend to rest on formed rests [32]

You may have crossed a line, but at what angle How far did you roll over it before you came to a stop If the next step in the task relies on the robot being in a particular position or situated next to something just right, you will probably need a bit of code to align the robot before it really transitions Everything a robot, or any other machine, does has error in it Some errors are well behaved, like the backlash of gears The error stays within a known range and doesn t grow over time Other kinds of error get worse over time If you have a slipping drive belt between a motor and actuator on your robot, that slippage will make the error in position grow worse over time Mobile robots have this problem no matter how they are built.

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