Fully Automated Mikrosa Grinding Machine for High-Volume Shaft Production

Advanced centerless notch grinding automation for maximum throughput and consistent precision.

Iskra PRO developed and integrated a fully automated grinding system on the latest Mikrosa centerless notch grinding machine, designed specifically for high-volume shaft production. The solution handles feeding, orientation, grinding, inspection, and automated compensation — ensuring 100% quality control with minimal operator involvement.

This machine represents a significant technological leap from earlier Mikrosa installations at the facility — shifting from partial automation to full process automation.

The customer required a dedicated, high-throughput grinding solution capable of producing large batches of precision shafts with multiple setups in a single cycle. The system needed to:

Grind multiple workpieces simultaneously
Shorten cycle times without sacrificing accuracy
Perform orientation checks on unground parts before processing
Ensure complete post-process cleaning and quality verification
Compensate automatically for grinding wheel wear, drive wheel wear, and diamond dresser wear
Execute programmed alignment of grinding and drive wheels for consistent performance

The automation also had to seamlessly integrate into the customer’s existing production flow, allowing easy changeover between different shaft types.

“The integration of advanced measurement and auto-correction systems allows us to maintain consistent tolerance and finish, even in long production runs.”

Mikrosa automation of CNC grinding components by Iskra PRO

Project Implementation

Technical breakdown

1. Part Handling and Cleaning

Continuous loading of parts with precise positioning.
Orientation control ensures correct alignment before grinding.
Reduces downtime caused by misfeeds.

2. Optical Inspection for Orientation and Damage Prevention

Optical sensors verify correct part orientation.
Prevents part jams and grinding wheel damage.
Ensures process stability and component protection.

3. Simultaneous Grinding of Multiple Workpieces

Parallel processing of several parts for higher throughput.
Consistent surface quality across all pieces.
Shorter cycle times and improved productivity.

4. Enclosed Cleaning Chamber with Air Blow-Off and Dust Extraction

Automated air blow-off removes residual dust and particles.
Enclosed cleaning prevents contamination of other areas.
Maintains clean parts for subsequent operations.

5. Automated Demagnetization Unit

Neutralizes magnetic fields after grinding.
Prevents sticking or interference during handling.
Ensures safe downstream processing.

6. Precision Measurement Rings for Dimensional Verification

Integrated control of critical dimensions after grinding.
Ensures repeatability and compliance with tight tolerances.
Provides immediate feedback for correction if needed.

7. Automated Correction Functions

Compensates automatically for:
- Grinding wheel wear
- Drive wheel wear
- Diamond dresser wear
Maintains consistent accuracy and surface quality over time.