Multifunctional cutting base and cutting method for large casting of fan

Abstract

The invention discloses a multifunctional cutting base and a cutting method for a large fan casting, and relates to the technical field of casting cutting machining.The base comprises a self-adaptive supporting platform, a combined type damping assembly, a vibration control unit and a chip and oil mist recycling unit; the self-adaptive supporting platform is attached to the bottom of a casting through a plurality of spherical hinge universal planes with angles and heights adjusted hydraulically to form a profiling supporting face so as to achieve multi-point self-adaptive clamping. The combined type damping assembly conducts damping adjustment along with machining vibration dynamic response through the damping unit in cooperation with the vibration control unit, and the machining posture of the casting is stabilized. The cuttings and oil mist recovery unit is used for synchronously collecting and separating dust, metal cuttings and cooling oil liquid generated in the turning process through a liquid-solid separation module, a dust hood with a negative pressure suction function and a chip removal channel; the clamping stability and the machining precision of the large casting are effectively improved, the machining site environment is improved, and the problem that an existing large casting machining platform affects the casting machining state is solved.

Description

Technical Field

[0001] The present invention relates to the technical field of casting cutting and processing, in particular to a multifunctional cutting base and a cutting method for large-scale fan castings. Background Art

[0002] As one of the most important energy conversion devices in the current new energy sector, wind turbines require key structural components such as hubs, nacelle bases, and spindle connectors, all of which are large castings that carry the core functions of load bearing and transmission. These castings are generally characterized by thick walls, complex structures, high geometric precision requirements for assembly positions, and high unit weight. Their manufacturing process involves multiple key steps, including casting, rough machining, finishing, and heat treatment.

[0003] In the machining process of large fan castings, the traditional method is usually to hoist the casting onto a heavy-duty vertical machine tool or heavy-duty CNC milling machine for rough machining after the casting is completed and the nozzle is separated. The rough machining stage mainly completes the pre-machining of the main surfaces and installation datums to facilitate subsequent fine machining and positioning. However, due to the huge size and different structures of fan castings, a single type of general-purpose machine tool or milling machine is difficult to meet the multi-faceted machining needs of different castings in the fine machining stage. Therefore, fine machining often requires changing different types of machine tools or repeatedly hoisting them to different clamping fixtures, resulting in longer processing cycles, low process connection efficiency, and multiple clamping also introducing additional positioning errors.

[0004] During the finishing process, since large fan castings often have irregular internal and external contours, turning tools need to perform multi-axis linkage cutting along complex curved surfaces; in addition, the castings are heavy and the support rigidity is insufficient. Once the clamping stability is slightly lacking, it is easy to generate vibration during processing, aggravating cutting stress and thermal deformation, and directly affecting the flatness, smoothness and dimensional accuracy of the machined surface; especially in key areas such as high-precision mating surfaces and flange mounting surfaces, traditional clamping platforms are difficult to effectively suppress vibrations in the absence of vibration reduction and adjustable support structures, resulting in subsequent assembly errors and operating noise risks.

[0005] In addition, large castings usually require a large amount of processing, and the large amount of chips and dust generated during the cutting process is difficult to clean quickly. They are easily accumulated around the workpiece and on the guide rail slides, which not only affects the smoothness of the subsequent tool path, but also increases the wear of the guide rail components and reduces the service life of the equipment. At the same time, the dust environment at the processing site also places higher demands on the health of operators and the safety of equipment.

[0006] Although some existing improved turning workbenches have introduced adjustable support seats, hydraulic clamping systems or rotating base structures, they still generally have problems such as insufficient rigidity, narrow adaptation range, poor chip cleaning, and unfriendly processing environment. They are unable to meet the comprehensive requirements of stability, precision and efficiency in the finishing stage of large fan castings.

[0007] The existing technology has the following technical problems:

[0008] (1) The casting structure is complex and heavy, and the existing turning base is difficult to provide high rigidity support and precise positioning;

[0009] (2) When turning complex curved surfaces during the finishing stage, poor vibration control can easily lead to machining errors and affect accuracy;

[0010] (3) During the processing, a large amount of chips and dust accumulate, affecting equipment operation and environmental hygiene, and there is still a lack of efficient cleaning and collection solutions;

[0011] (4) The process switching and clamping efficiency are low, which limits the overall processing rhythm and production capacity.

[0012] In summary, it is found that the existing technology has at least the following technical problems:

[0013] Existing large-scale casting processing platforms are difficult to provide high-rigidity support and precise positioning for castings. There are also technical problems such as poor vibration control, difficulty in cleaning chips and dust during the processing, and low casting clamping efficiency. Summary of the Invention

[0014] The purpose of the present invention is to provide a multifunctional cutting base and cutting method for large fan castings, so as to solve the technical problems that the existing large casting processing platform is difficult to provide high-rigidity support and precise positioning for the castings, and also has poor vibration control, difficulty in cleaning chips and dust during the processing, and low casting clamping efficiency.

[0015] The various technical effects that can be produced by the preferred technical solutions among the various technical solutions provided by the present invention are described in detail below.

[0016] In order to solve the above technical problems, the present invention provides the following technical solutions:

[0017] The present invention provides a multifunctional cutting base for large-scale castings of wind turbines, comprising an adaptive support platform, provided with a plurality of hydraulic support units mounted on a base member, wherein a ball joint universal plane is mounted on the hydraulic support unit; the plurality of hydraulic support units are supported and connected to the bottom of the casting to be clamped via the ball joint universal plane, and the support height and orientation can be adjusted according to the shape of the bottom of the casting to form a contoured support surface that fits the bottom surface of the casting, thereby realizing multi-point adaptive clamping; and a composite shock-absorbing assembly, comprising a rigid connecting plate arranged on the upper layer, a vibration-absorbing unit in the middle, and a rigid base member in the lower layer; the vibration-absorbing unit is filled with magnetorheological fluid, the rigid connecting plate is connected to the base member of the adaptive support platform, and the rigid base member is connected to the working table of a CNC machine tool; and a vibration control unit, comprising a plurality of acceleration sensors and A damping regulator connected to the control valve of the magnetorheological fluid, the acceleration sensor is installed on the base component and electrically connected to the damping regulator; the damping regulator dynamically adjusts the flow resistance of the magnetorheological fluid based on the vibration signal fed back by the acceleration sensor, thereby realizing damping adjustment of the vibration reduction unit; and a chip and oil mist recovery unit, comprising an annular dust hood installed on the outside of the CNC machine tool spindle and capable of synchronously moving along the spindle feed direction, a chip removal channel and a liquid-solid separation module arranged in the adaptive support platform; the chip removal channel is arranged in the gap area between the ball joint universal planes of the hydraulic support unit, and is used to collect chips and cooling oil generated during the cutting process, and separate them through the liquid-solid separation module, and the dust hood maintains stable suction to dynamically recover dust and oil mist following the turning tool.

[0018] In one embodiment, the adaptive support platform is further provided with a hydraulic control unit, and the hydraulic control unit is connected to a plurality of the hydraulic support units for precisely controlling the extension and extension and supporting force of the hydraulic support units.

[0019] In one embodiment, the hydraulic support unit includes a hydraulic cylinder, a ball joint universal joint, a pressure sensor and a distance sensor; both ends of the hydraulic cylinder of the hydraulic support unit are connected between the base component and the ball joint universal plane through the ball joint universal joint to form an adjustable hydraulic contour support; the pressure sensor is installed on the hydraulic cylinder to collect the oil pressure data in the cylinder in real time, and the oil pressure in the cylinder transmits the data to the hydraulic control unit for accurately controlling the supporting force of the hydraulic cylinder; the distance sensor is installed on the hydraulic cylinder, and the detection direction is toward the telescopic end of the hydraulic cylinder, and the detection direction is parallel to the telescopic path of the hydraulic cylinder, and the telescopic length data of the telescopic end of the hydraulic cylinder is collected in real time, and the telescopic length data is transmitted to the hydraulic control unit for accurately measuring the telescopic length of the hydraulic cylinder.

[0020] In one embodiment, three of the hydraulic support units are connected to one of the ball joint universal planes to form a contouring group, and the multiple contouring groups are distributed in a ring or matrix around the axis of the base component, and each of the contouring groups is independently controlled to independently adjust the support angle and height of the ball joint universal plane of each group.

[0021] In one embodiment, the vibration reduction unit is composed of a plurality of independent magnetic fluid chambers, and the damping regulator independently controls each of the magnetic fluid chambers to achieve multi-region dynamic vibration compensation of the adaptive support platform.

[0022] In one embodiment, the chip and oil mist recovery unit also includes a negative pressure device, a liquid collection container and a chip collection container; the negative pressure end of the negative pressure device is respectively connected to the dust hood and the chip removal channel, the discharge end is connected to the feed end of the liquid-solid separation module, the liquid outlet end of the liquid-solid separation module is connected to the liquid collection container, and the solid discharge end is connected to the chip collection container; a plurality of negative pressure sensors are provided in the negative pressure device for monitoring the negative pressure adsorption working status of the dust hood and the chip removal channel, and adjusting the suction force in real time according to the negative pressure data feedback from the negative pressure sensor to maintain the negative pressure of the dust hood and the chip removal channel constant.

[0023] In one embodiment, an interface module and a central controller are installed on the rigid base member, and the interface module includes multiple communication interfaces and is electrically connected to the central controller, the hydraulic control unit, the vibration control unit and the chip and oil mist recovery unit; the central controller receives data input from the CNC system of the CNC machine tool, and controls the operation of the hydraulic control unit, the vibration control unit and the chip and oil mist recovery unit in a linkage manner according to the processing status, and realizes coordinated control, parameter feedback and dynamic response of the entire processing process.

[0024] A cutting method is also provided, comprising the following steps: S1, working condition identification: an interface module receives the spindle operating status, feed speed and program segment signal of the CNC system and transmits them to a central controller;

[0025] S2, Adaptive clamping: The central controller controls the hydraulic support unit to enter the contour adjustment mode, and adjusts the support angle and height according to the preset support force threshold, pressure sensor and distance sensor feedback to complete the clamping of the casting;

[0026] S3. Dynamic vibration reduction: During the operation of the CNC machine tool's spindle, the central controller dispatches the damping regulator to determine the vibration state based on real-time acceleration data, thereby adjusting the viscosity of the magnetorheological fluid and regulating the damping of the vibration reduction unit in real time to achieve multi-zone vibration reduction control.

[0027] S4, chip suction linkage: After the CNC system's cutting start signal is triggered, the negative pressure device is activated, the dust hood moves with the spindle, and the negative pressure is synchronized with the chip removal channel to capture and collect chips and cooling oil, liquid dust and oil mist respectively;

[0028] S5. Reset processing: After the processing is completed, the interface module receives the reset signal of the CNC system and feeds it back to the central controller. The central controller controls the hydraulic control unit, the vibration control unit and the chip and oil mist recovery unit to automatically exit the operation mode and return to the standby state.

[0029] In one embodiment, an oil mist concentration sensor is provided in the liquid-solid separation module, and the oil mist concentration sensor monitors the oil mist particle concentration in the gas entering the liquid-solid separation module in real time; the negative pressure device adaptively adjusts the suction speed according to the pressure difference data fed back by the oil mist concentration sensor and the negative pressure sensor to maintain the stability of the negative pressure attraction.

[0030] In one embodiment, the central controller is configured with a collaborative algorithm module for fusing and processing the data from the pressure sensor and the acceleration sensor, and then outputting a joint control instruction so that the movements of the hydraulic support unit and the vibration reduction unit are synchronously adjusted during the processing, thereby enhancing the vibration reduction effect and improving the posture stability of the casting during the cutting process.

[0031] Compared with the prior art, the multifunctional cutting base provided by the present invention has the following beneficial effects:

[0032] Improved casting clamping rigidity and positioning accuracy: The present invention connects the spherical joint universal plane by arranging multiple hydraulic support units with spherical joint universal adjustment capabilities. The multiple spherical joint universal planes form an adaptively adjustable contoured support surface, which can accurately match the bottom contour of large and complex castings, thereby achieving high-rigidity, fitted, multi-point support clamping of castings, significantly improving the clamping stability and clamping efficiency of castings.

[0033] Improved machining vibration control capabilities and increased machining accuracy: This invention uses a composite vibration reduction structure filled with magnetorheological fluid, and sets an acceleration sensor and a damping regulator to form a closed-loop control system. This can adjust the damping in real time according to the dynamic vibration during milling or turning, achieving active vibration suppression, effectively reducing contour errors and surface roughness problems caused by machining vibration, and significantly improving cutting accuracy.

[0034] Optimize the machining environment and chip removal efficiency: The vacuum hood is linked to the machine spindle in a negative pressure vacuum setting. Combined with the negative pressure reference setting of the chip removal channel set inside the base and the liquid-solid separation module, it can effectively capture and collect dust, oil mist and metal chips during the cutting process, and separate the coolant for recycling, significantly improving the working environment, reducing manual cleaning, and improving cutting efficiency and equipment cleanliness.

[0035] Good CNC system compatibility and intelligent control capabilities: Each functional module of the multifunctional cutting base of the present invention can be linked with the CNC system of the CNC machine tool for control, with good system integration, can adapt to the needs of automated and intelligent processing, and improve the stability, intelligence and industrial adaptability of the overall processing system;

[0036] Therefore, the present invention systematically solves the core problems such as unstable clamping, vibration interference, environmental pollution and low efficiency in the cutting process of large castings by integrating the system of contour support, dynamic vibration reduction, dust and chip removal and the linkage control unit of the central controller, and has significant practical value and promotion prospects. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] In order to more clearly illustrate the technical solution of the present invention, the following briefly introduces the drawings required for use in the implementation. Obviously, the drawings described below are only some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0038] Figure 1 It is a side view structural diagram of the multifunctional cutting base of the present invention;

[0039] Figure 2 It is a schematic flow chart of the turning method adapted to the multifunctional cutting base of the present invention.

[0040] The accompanying drawings are numerals as follows:

[0041] 1. Adaptive support platform; 11. Hydraulic support unit; 111. Hydraulic cylinder; 112. Ball joint universal joint; 113. Pressure sensor; 114. Distance sensor; 12. Ball joint universal joint plane; 13. Base member;

[0042] 2. Composite shock-absorbing assembly; 21. Rigid connecting plate; 22. Vibration-absorbing unit; 221. Magnetorheological fluid chamber; 23. Rigid base member; 24. Acceleration sensor;

[0043] 3. Imitation group;

[0044] 4. Chip and oil mist recovery unit; 41. Dust hood; 42. Chip removal channel; 43. Negative pressure device; 44. Liquid-solid separation module; 45. Liquid collection container; 46. Chip collection container;

[0045] 5. Interface module;

[0046] 6. Central controller;

[0047] 7. Castings;

[0048] 8. CNC machine tool spindle. DETAILED DESCRIPTION

[0049] The technical solutions in the embodiments of the present invention will be described clearly and completely below with reference to the accompanying drawings in the embodiments of the present invention.

[0050] In a specific embodiment, a multifunctional cutting base and cutting method for large fan castings are provided, which base includes an adaptive support platform, a composite shock-absorbing component, a vibration control unit and a chip and oil mist recovery unit; the adaptive support platform is fitted with the bottom of the casting through a ball joint universal plane with multiple hydraulically adjustable angles and heights to form a contoured support surface to achieve multi-point adaptive clamping; the composite shock-absorbing component uses the vibration damping unit to cooperate with the vibration control unit to adjust the damping according to the dynamic response of the processing vibration to stabilize the processing posture of the casting; the chip and oil mist recovery unit uses a liquid-solid separation module and a dust collection hood with negative pressure suction and a chip removal channel to synchronously collect and separate dust, metal chips and cooling oil generated during the turning process; it effectively improves the clamping stability and processing accuracy of large castings, improves the processing site environment, and effectively solves the technical problems that the existing large casting processing platform is difficult to provide high-rigidity support and precise positioning for castings, and still has poor vibration control, difficult to clean chips and dust during processing, and low casting clamping efficiency.

[0051] The first embodiment of the multifunctional cutting base is as follows Figure 1As shown, it includes an adaptive support platform 1, which is provided with a plurality of hydraulic support units 11 installed on a base member 13, and a ball joint universal plane 12 is installed on the hydraulic support unit 11; the plurality of hydraulic support units 11 are supported and connected to the bottom of the casting 7 to be clamped through the ball joint universal plane 12, and the support height and direction can be adjusted according to the shape of the bottom of the casting 7 to form a contoured support surface that fits the bottom surface of the casting 7, thereby realizing multi-point adaptive clamping; and a composite shock-absorbing component 2, including a rigid connecting plate 21 arranged on the upper layer, a vibration-absorbing unit 22 in the middle and a rigid base member 23 in the lower layer; the vibration-absorbing unit 22 is filled with magnetorheological fluid, the rigid connecting plate 21 is connected to the base member 13 of the adaptive support platform 1, and the rigid base member 23 is connected to the working table of the CNC machine tool; and a vibration control unit, including a plurality of acceleration sensors 24 and The control valve of the magnetorheological fluid is connected to the damping regulator, and the acceleration sensor 24 is installed on the base component 13 and electrically connected to the damping regulator; the damping regulator dynamically adjusts the flow resistance of the magnetorheological fluid based on the vibration signal fed back by the acceleration sensor 24, thereby realizing the damping adjustment of the vibration reduction unit 22; and the chip and oil mist recovery unit 4, including an annular dust collection hood 41 installed on the outside of the CNC machine tool spindle 8 and capable of synchronously moving along the spindle feed direction, a chip removal channel 42 and a liquid-solid separation module 44 arranged in the adaptive support platform 1; the chip removal channel 42 is arranged in the gap area between the ball joint universal plane 12 of the hydraulic support unit 11, and is used to collect the chips and cooling oil generated during the cutting process, and separate them through the liquid-solid separation module 44, and the dust collection hood 41 maintains a stable suction force to dynamically recover dust and oil mist following the turning tool.

[0052] The technical advantages of the multifunctional cutting base provided by the present invention are: improving the clamping rigidity and positioning accuracy of the casting 7: the present invention provides multiple hydraulic support units 11 with ball joint universal adjustment capabilities connected to the ball joint universal plane 12, and the multiple ball joint universal planes 12 form an adaptively adjustable contoured support surface, which can accurately match the bottom contour of large and complex castings 7, thereby achieving high-rigidity, fitted, multi-point support clamping of the casting 7, significantly improving the clamping stability and clamping efficiency of the casting 7;

[0053] Improved machining vibration control capabilities and enhanced machining accuracy: The present invention adopts a composite vibration damping structure filled with magnetorheological fluid, and sets an acceleration sensor 24 in conjunction with a damping regulator to form a closed-loop control system. This can adjust the damping in real time according to the dynamic vibration during milling or turning, achieving active vibration suppression, effectively reducing contour errors and surface roughness problems caused by machining vibration, and significantly improving cutting accuracy.

[0054] Optimize the processing environment and chip removal efficiency: The vacuum hood 41 is set to move in conjunction with the machine tool spindle, and the negative pressure reference setting of the chip removal channel 42 set inside the base and the liquid-solid separation module 44 can effectively capture and collect dust, oil mist and metal chips during the cutting process, and separate the coolant for recycling, which significantly improves the working environment, reduces manual cleaning, and improves cutting efficiency and equipment cleanliness.

[0055] Possessing good CNC system compatibility and intelligent control capabilities: Each functional module of the multifunctional cutting base of the present invention can be linked with the CNC system of the CNC machine tool for control, with good system integration, can adapt to the needs of automated and intelligent processing, and improve the stability, intelligence and industrial adaptability of the overall processing system;

[0056] Therefore, the present invention systematically solves the core problems such as unstable clamping, vibration interference, environmental pollution and low efficiency in the cutting process of large castings 7 by integrating the system of contour support, dynamic vibration reduction, dust and chip removal and the central controller 6 linkage control unit, and has significant practical value and promotion prospects.

[0057] As one optional implementation method:

[0058] Regarding the mechanism for controlling the hydraulic support units 11 , the adaptive support platform 1 is further provided with a hydraulic control unit, which is connected to a plurality of hydraulic support units 11 for precisely controlling the extension and extension and supporting force of the hydraulic support units 11 .

[0059] During application, the hydraulic control unit integrates a proportional valve module, a closed-loop pressure control module and a main control PLC communication module; the proportional valve module adjusts the oil inlet and outlet of each hydraulic cylinder 111 in real time according to the control signal sent by the central controller 6 to achieve fine support force adjustment; the closed-loop pressure control module collects the oil pressure value feedback from each pressure sensor 113 in real time, calculates the error with the set support force, and automatically corrects the output control instruction, so that the hydraulic support unit 11 maintains a stable clamping force during the clamping process of the casting 7, prevents the clamping from loosening due to local unloading or reaction force, and solves the problems of insufficient rigidity and posture offset of the existing clamping support.

[0060] Regarding the composition of the above-mentioned hydraulic support unit 11, the hydraulic support unit 11 includes a hydraulic cylinder 111, a ball head universal joint 112, a pressure sensor 113 and a distance sensor 114; both ends of the hydraulic cylinder 111 of the hydraulic support unit 11 are connected between the base component 13 and the ball joint universal plane 12 through the ball head universal joint 112 to form an adjustable hydraulic contour support; the pressure sensor 113 is installed on the hydraulic cylinder 111, and collects the oil pressure data in the cylinder in real time, and transmits the oil pressure data in the cylinder to the hydraulic control unit for accurately controlling the supporting force of the hydraulic cylinder 111; the distance sensor 114 is installed on the hydraulic cylinder 111, and the detection direction is toward the telescopic end of the hydraulic cylinder 111, and the detection direction is parallel to the telescopic path of the hydraulic cylinder 111, and collects the telescopic length data of the telescopic end of the hydraulic cylinder 111 in real time, and transmits the telescopic length data to the hydraulic control unit for accurately controlling the telescopic length of the hydraulic cylinder 111.

[0061] During application, the maximum adjustment angle of the ball head universal joint 112 used in the hydraulic cylinder 111 is ±20°, which can adapt to the angle adjustment of the irregular curved bottom of the large casting 7; the distance sensor 114 adopts laser displacement or LVDT linear detection form, and the measurement accuracy is better than 0.1mm, ensuring the accuracy of the extension length control of the hydraulic cylinder 111; through the dual feedback adjustment combining pressure data and length data, the hydraulic control unit can achieve balanced support under the conditions of different mass centers and non-uniform thicknesses of the casting 7, thereby improving the fit and clamping reliability of the contoured clamping, and solving the problem that the traditional point support system is prone to displacement during the clamping of heavy castings 7.

[0062] Regarding the specific structure of the profiling group 3 composed of the above-mentioned multiple hydraulic support units 11, three hydraulic support units 11 are connected to a ball joint universal plane 12 to form a profiling group 3, and multiple profiling groups 3 are distributed in a ring or matrix around the axis of the base component 13, and each profiling group 3 is independently controlled to independently adjust the support angle and height of the ball joint universal plane 12 of each group.

[0063] During application, each profiling group 3 is allocated an independent PID control channel through the central controller 6 for regional control. The layout of the profiling groups 3 can be switched to a ring (suitable for disc-type workpieces) or a matrix (suitable for special-shaped base-type workpieces) arrangement according to the bottom shape of the casting 7 to be processed; the ball joint universal plane 12 of each profiling group 3 is hingedly installed with the hydraulic cylinder 111, and has a limited anti-slip structure, which can withstand a point load of not less than 2000kg, effectively improving the adaptive support capability of large and complex-shaped castings 7.

[0064] Regarding the structure and function of the above-mentioned vibration reduction unit 22, the vibration reduction unit 22 is composed of multiple independent magnetic fluid chambers 221. The damping regulator independently controls each magnetic fluid chamber 221 to achieve multi-region dynamic vibration compensation for the adaptive support platform 1.

[0065] During application, multiple magnetorheological fluid cavities 221 are distributed on the circumference of the vibration damping unit 22, on the key vibration path between the rigid connector and the rigid base 23 under the adaptive support platform 1, and each cavity corresponds to an independent electromagnetic excitation control channel; during the turning process, the acceleration sensors 24 in different areas transmit real-time vibration signals to the damping regulator, and the damping regulator adjusts the viscosity and flow resistance of the magnetorheological fluid in the corresponding area, thereby constructing a multi-zone asynchronous response damping layer; the damping control system can effectively reduce the secondary oscillation caused by local vibration coupling, effectively avoid tool path drift and cutting ripple generation, and improve the stability of the complex contour processing process of the casting 7.

[0066] Regarding the specific structure and function of the above-mentioned chip and oil mist recovery unit 4, the chip and oil mist recovery unit 4 also includes a negative pressure device 43, a liquid collection container 45 and a chip collection container 46; the negative pressure end of the negative pressure device 43 is respectively connected to the dust hood 41 and the chip removal channel 42, and the discharge end is connected to the feed end of the liquid-solid separation module 44, the liquid outlet end of the liquid-solid separation module 44 is connected to the liquid collection container 45, and the solid discharge end is connected to the chip collection container 46; a plurality of negative pressure sensors are provided in the negative pressure device 43 for monitoring the negative pressure adsorption working status of the dust hood 41 and the chip removal channel 42, and adjusting the suction force in real time according to the negative pressure data feedback from the negative pressure sensor to maintain the negative pressure of the dust hood 41 and the chip removal channel 42 constant.

[0067] Specifically, the negative pressure device 43 discharges air, solids and liquids from the negative pressure end to the discharge end, and the liquid-solid separation module 44 filters from the feed end through a cyclone separator and a filter element, and discharges the separated dust, chips and other solids to the solid discharge end, and discharges the separated cooling oil, oil mist and other liquids to the liquid outlet end.

[0068] During application, the negative pressure device 43 is equipped with a two-stage wind pressure regulation system. The air volume is controlled by an electronically controlled speed-regulating fan in the first stage, and a local negative pressure chamber is constructed by a variable channel throttle valve in the second stage to achieve dynamic negative pressure maintenance of the dust hood 41 and the chip removal channel 42; in conjunction with multiple negative pressure sensors and the feedback signal of the liquid-solid separation module 44, a real-time monitoring feedback closed-loop control is formed to ensure constant suction output and adapt to changes in the concentration of chips, cooling oil, dust and oil mist under different working conditions; the liquid-solid separation module 44 adopts a two-stage combination structure of a cyclone separator and a filter element, and the solid-liquid separation efficiency is higher than 98%; the liquid collection container 45 includes an automatic liquid return pump group and a coolant storage tank. The automatic liquid return pump group is connected to the liquid outlet of the liquid-solid separation module 44, and the automatic liquid return pump group is connected to the coolant storage tank to avoid the problem of separation failure caused by the accumulation of liquid in the liquid-solid separation module 44 due to untimely storage and extraction of cooling oil.

[0069] Regarding the structure for coordinated control of the above-mentioned hydraulic control unit, vibration control unit and chip and oil mist recovery unit 4, an interface module 5 and a central controller 6 are installed on the rigid base part 23. The interface module 5 includes multiple communication interfaces and is electrically connected to the central controller 6, the hydraulic control unit, the vibration control unit and the chip and oil mist recovery unit 4; the central controller 6 receives data input from the CNC system of the CNC machine tool, and controls the operation of the hydraulic control unit, the vibration control unit and the chip and oil mist recovery unit 4 in a coordinated manner according to the processing status, and realizes coordinated control, parameter feedback and dynamic response of the entire processing process.

[0070] Specifically, the communication interface includes an interface with an industrial communication protocol such as MODBUS (MODBUS protocol), EtherCAT (Ethernet Control Automation Technology, EtherCAT) or PROFIBUS (Open Fieldbus Standard, Process Field Bus).

[0071] During application, the collaborative algorithm module of the central controller 6 makes a comprehensive judgment on the CNC machine tool status information, pressure sensor 113 data, distance sensor 114 data and acceleration sensor 24 data based on multi-source fusion logic, and implements dynamic support and dynamic damping coordinated control according to the set processing rhythm; each communication interface of the interface module 5 complies with the industrial Ethernet communication protocol, supports external host computer control, has high real-time performance, redundant protection and breakpoint resumption control functions, and improves the industrial adaptability of the system.

[0072] Based on the above embodiment of the multifunctional cutting base, a cutting method is provided, such as Figure 2 The turning method flow chart includes the following steps: S1, working condition identification: the interface module receives the spindle operation status, feed speed and program segment signal of the CNC system and transmits them to the central controller;

[0073] S2, Adaptive clamping: The central controller controls the hydraulic support unit to enter the contour adjustment mode, and adjusts the support angle and height according to the preset support force threshold, pressure sensor and distance sensor feedback to complete the clamping of the casting;

[0074] S3. Dynamic vibration reduction: During the operation of the CNC machine tool's spindle, the central controller dispatches the damping regulator to determine the vibration state based on real-time acceleration data, thereby adjusting the viscosity of the magnetorheological fluid and regulating the damping of the vibration reduction unit in real time to achieve multi-zone vibration reduction control.

[0075] S4, chip suction linkage: After the CNC system's cutting start signal is triggered, the negative pressure device is activated, the dust hood moves with the spindle, and the negative pressure is synchronized with the chip removal channel to capture and collect chips and cooling oil, liquid dust and oil mist respectively;

[0076] S5. Reset processing: After the processing is completed, the interface module receives the reset signal of the CNC system and feeds it back to the central controller. The central controller controls the hydraulic control unit, vibration control unit and chip and oil mist recovery unit to automatically exit the operation mode and return to the standby state.

[0077] When applying, the operation is carried out in the order of steps S1 to S5, and the operation process of each submodule of steps S1 to S5 is synchronized with the CNC system in real time, and supports visualization of processing process parameters and abnormal prompts; for example, in the dynamic vibration reduction of step S3, if the vibration abnormality exceeds the limit threshold, the central controller 6 will output a cutting pause instruction to the CNC system of the CNC machine tool, and automatically adjust the damping value to the highest gear to avoid further aggravation of the vibration; in the chip suction linkage of step S4, the position of the dust hood 41 follows the movement of the spindle to ensure effective coverage of the dust collection range; the entire process can set the operation mode through the human-machine interface (HMI), including the complete cycle of "adaptive clamping + processing collaboration + intelligent recycling".

[0078] Regarding monitoring the operating status of the above-mentioned liquid-solid separation module 44, and coordinating with the negative pressure device 43 to adjust the strength of the negative pressure suction, so as to maintain the collection efficiency of the dust hood 41 and the chip removal channel 42 for chips, cooling oil, dust and oil mist during the collection of chips and cooling oil, and maintain the separation efficiency of liquid and solid in the liquid-solid separation module 44. The specific operating status monitoring mechanism and setting method of the liquid-solid separation module 44 are as follows: an oil mist concentration sensor is provided in the liquid-solid separation module 44, and the oil mist concentration sensor monitors the oil mist particle concentration in the gas entering the liquid-solid separation module 44 in real time; the negative pressure device 43 adaptively adjusts the suction speed according to the pressure difference data fed back by the oil mist concentration sensor and the negative pressure sensor to keep the negative pressure attraction stable.

[0079] During application, the oil mist concentration sensor adopts the light scattering measurement principle with an accuracy better than 5ppm, and can monitor the oil mist saturation level in real time; the negative pressure device 43 forms a dynamic suction control closed loop by receiving the joint feedback of the sensor and the negative pressure sensor, and automatically adjusts the suction of the dust hood 41 and the chip removal channel 42 to prevent the dust hood 41 and the chip removal channel 42 from insufficient suction or over-suction to produce local turbulence, thereby ensuring the complete capture of chips, dust and oil mist, and effectively improving the processing environment quality and equipment maintenance convenience of the workshop CNC machine tools.

[0080] The specific control method for the central controller 6 to control the coordinated movement of the hydraulic support unit 11 and the vibration reduction unit 22 during the cutting process of the casting 7 so that the posture of the casting 7 is more stable during the processing is that the central controller 6 is configured with a collaborative algorithm module for fusing and processing the data from the pressure sensor 113 and the acceleration sensor 24, and then outputting a joint control instruction so that the movement of the hydraulic support unit 11 and the vibration reduction unit 22 is synchronously adjusted during the processing, thereby enhancing the vibration reduction effect and improving the posture stability of the casting 7 during the cutting process.

[0081] During application, the collaborative algorithm module adopts a feedforward + feedback joint control model. After initial clamping, it establishes a center of gravity-support-vibration response model of the casting 7 based on the current state data of the casting 7, predicts the vibration trend caused by the structural deformation trend that may occur during the processing, and synchronously instructs the hydraulic cylinder 111 to adjust the support force distribution and the shock absorber to adjust the local damping to offset the displacement error caused by stress release or temperature rise deformation, thereby realizing the coupled stabilization mechanism of "intelligent support + active vibration reduction", significantly improving the dimensional consistency and surface quality of heavy special-shaped castings 7 in high-precision cutting.

[0082] The technical features of the above embodiments may be combined arbitrarily. To simplify the description, not all possible combinations of the technical features in the above embodiments are described.

Claims

1. A multifunctional cutting base for large fan castings, characterized in that: The invention comprises an adaptive support platform, which is provided with a plurality of hydraulic support units mounted on a base member, and a ball joint universal plane is mounted on the hydraulic support unit; the plurality of hydraulic support units are connected to the bottom of the casting to be clamped via the ball joint universal plane, and the support height and direction can be adjusted according to the shape of the bottom of the casting to form a contoured support surface that fits the bottom surface of the casting, thereby realizing multi-point adaptive clamping; and a composite shock-absorbing assembly comprising a rigid connecting plate disposed on an upper layer, a vibration-absorbing unit in the middle, and a rigid base member in the lower layer; the vibration-absorbing unit is filled with magnetorheological fluid, the rigid connecting plate is connected to the base member of the adaptive support platform, and the rigid base member is connected to the work surface of the CNC machine tool; and a vibration control unit comprising a plurality of acceleration sensors and a damping regulator connected to the control valve of the magnetorheological fluid, wherein the acceleration sensors are mounted on the base member and electrically connected to the damping regulator; the damping regulator dynamically adjusts the flow resistance of the magnetorheological fluid based on vibration signals fed back by the acceleration sensors, thereby achieving damping adjustment of the vibration reduction unit; And a chip and oil mist recovery unit, including an annular dust hood installed on the outside of the CNC machine tool spindle and capable of synchronously moving along the spindle feed direction, a chip removal channel and a liquid-solid separation module arranged in the adaptive support platform; the chip removal channel is arranged in the gap area between the ball joint universal planes of the hydraulic support unit, and is used to collect the chips and cooling oil generated during the cutting process, and separate them through the liquid-solid separation module, and the dust hood maintains stable suction to dynamically recover dust and oil mist following the turning tool.

2. The multifunctional cutting base according to claim 1, characterized in that: The adaptive support platform is further provided with a hydraulic control unit, which is connected to a plurality of the hydraulic support units for precisely controlling the extension and extension and supporting force of the hydraulic support units.

3. The multifunctional cutting base according to claim 2, characterized in that: The hydraulic support unit includes a hydraulic cylinder, a ball joint universal joint, a pressure sensor and a distance sensor; both ends of the hydraulic cylinder are connected between the base component and the ball joint universal plane through the ball joint universal joint to form an adjustable hydraulic contour support; The pressure sensor is installed on the hydraulic cylinder to collect the oil pressure data in the cylinder in real time, and transmits the oil pressure in the cylinder to the hydraulic control unit for accurately controlling the supporting force of the hydraulic cylinder; The distance sensor is installed on the hydraulic cylinder, and the detection direction is toward the telescopic end of the hydraulic cylinder. The detection direction is parallel to the telescopic path of the hydraulic cylinder. The telescopic length data of the telescopic end of the hydraulic cylinder is collected in real time, and the telescopic length data is transmitted to the hydraulic control unit for accurately measuring the telescopic length of the hydraulic cylinder.

4. The multifunctional cutting base according to claim 3, characterized in that: A contouring group is formed by connecting three hydraulic support units to one ball joint universal plane. Multiple contouring groups are distributed in a ring or matrix around the axis of the base component, and each contouring group is independently controlled to independently adjust the support angle and height of the ball joint universal plane of each group.

5. The multifunctional cutting base according to claim 4, characterized in that: The vibration reduction unit is composed of a plurality of independent magnetic fluid chambers, and the damping regulator independently controls each magnetic fluid chamber to achieve multi-region dynamic vibration compensation of the adaptive support platform.

6. The multifunctional cutting base according to claim 5, characterized in that: The chip and oil mist recovery unit also includes a negative pressure device, a liquid collection container and a chip collection container; The negative pressure end of the negative pressure device is connected to the dust hood and the chip removal channel respectively, the discharge end is connected to the feed end of the liquid-solid separation module, the liquid outlet end of the liquid-solid separation module is connected to the liquid collection container, and the solid discharge end is connected to the chip collection container; The negative pressure device is provided with a plurality of negative pressure sensors for monitoring the negative pressure adsorption working status of the dust hood and the chip removal channel, and adjusting the suction force in real time according to the negative pressure data fed back by the negative pressure sensor to maintain a constant negative pressure in the dust hood and the chip removal channel.

7. The multifunctional cutting base according to claim 6, characterized in that: An interface module and a central controller are mounted on the rigid base member, wherein the interface module includes a plurality of communication interfaces and is electrically connected to the central controller, the hydraulic control unit, the vibration control unit, and the chip and oil mist recovery unit; The central controller receives data input from the CNC system of the CNC machine tool, and controls the operation of the hydraulic control unit, the vibration control unit and the chip and oil mist recovery unit in a linkage manner according to the machining status, thereby realizing coordinated control, parameter feedback and dynamic response of the entire machining process.

8. A cutting method for the multifunctional cutting base according to claim 7, characterized in that: The following steps are involved: S1. Working condition identification: The interface module receives the spindle operating status, feed speed and program segment signals of the CNC system and transmits them to the central controller; S2, Adaptive clamping: The central controller controls the hydraulic support unit to enter the contour adjustment mode, and adjusts the support angle and height according to the preset support force threshold, pressure sensor and distance sensor feedback to complete the clamping of the casting; S3. Dynamic vibration reduction: During the operation of the CNC machine tool's spindle, the central controller dispatches the damping regulator to determine the vibration state based on real-time acceleration data, thereby adjusting the viscosity of the magnetorheological fluid and regulating the damping of the vibration reduction unit in real time to achieve multi-zone vibration reduction control. S4, chip suction linkage: After the CNC system's cutting start signal is triggered, the negative pressure device is activated, the dust hood moves with the spindle, and the negative pressure is synchronized with the chip removal channel to capture and collect chips and cooling oil, liquid dust and oil mist respectively; S5. Reset processing: After the processing is completed, the interface module receives the reset signal of the CNC system and feeds it back to the central controller. The central controller controls the hydraulic control unit, the vibration control unit and the chip and oil mist recovery unit to automatically exit the operation mode and return to the standby state.

9. The cutting method according to claim 8, characterized in that: The liquid-solid separation module is provided with an oil mist concentration sensor, which monitors the oil mist particle concentration in the gas entering the liquid-solid separation module in real time; the negative pressure device adaptively adjusts the suction speed according to the pressure difference data fed back by the oil mist concentration sensor and the negative pressure sensor to maintain the stability of the negative pressure attraction.

10. The cutting method according to claim 9, wherein: The central controller is equipped with a collaborative algorithm module for fusing and processing the data from the pressure sensor and the acceleration sensor, and then outputting a joint control instruction so that the movement of the hydraulic support unit and the vibration reduction unit are synchronously adjusted during the processing, thereby enhancing the vibration reduction effect and improving the posture stability of the casting during the cutting process.

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