A heat sink profile cutting and rotating processing integrated process

Abstract

The application discloses a heat radiator profile cutting and rotating processing integrated process and relates to the heat radiator profile processing technical field.The process comprises the following steps: S1, feeding; S2, clamping and positioning; S3, cutting; S4, reference detection and compensation; S5, boss processing; and S6, unloading.The cutting, reference detection and compensation and boss processing are integrated in the same station, the double steel saws are arranged in series, the non-contact sensor is used for on-line detection of the cutting end face, the rotating reference and the sawing starting position are compensated in real time, the profile cutting and the high-precision processing of the end boss are completed once clamping is achieved, the transfer link in the traditional segmented processing is eliminated, the workpiece bump damage is avoided, the processing precision and the good product rate are obviously improved through the closed-loop control mechanism, and the flexible processing of various boss shapes such as the circular shape and the polygonal shape can be adapted.

Description

Technical Field

[0001] This invention relates to the field of radiator profile processing technology, and in particular to an integrated process for radiator profile cutting and rotary processing. Background Technology

[0002] In the field of radiator profile processing, profile cutting and end boss processing are two key processes that directly affect the assembly accuracy and performance of the radiator. Currently, the industry commonly uses segmented processing, where two independent processing machines complete these two processes separately. Specifically, a dedicated cutting machine first cuts the long strip of radiator profile to a predetermined length, obtaining profile segments of the set length. Then, using manual or mechanical transfer, the cut profile segments are transferred to another end boss processing machine, which processes the ends of the profile segments to form the required end boss structure. This traditional processing method is currently the mainstream approach in the industry, basically meeting the processing requirements of radiator profiles and ensuring the basic structural integrity of the product.

[0003] However, the aforementioned traditional segmented processing model has a prominent technical problem: the transfer process between different devices is unavoidable. During this process, whether manual or mechanical transfer is used, it is difficult to completely prevent the profile segments from colliding and rubbing against the transfer devices, equipment tables, or other workpieces. This leads to scratches, dents, and other damage on the profile segment surface, and may even cause dimensional deviations in the machined boss areas, ultimately affecting the product yield. In existing technologies, practitioners have attempted to alleviate this problem by optimizing the buffer structure of the transfer device and improving the standardization of transfer operations. However, these methods can only reduce the probability of collisions to a certain extent and cannot eliminate the risk of collisions during the transfer process at its source, nor can they fundamentally solve the problem of yield being affected by transfer. Summary of the Invention

[0004] To overcome the above shortcomings, this invention provides an integrated process for cutting and rotating heat sink profiles, aiming to improve the defects of the existing technology where segmented processing requires cross-equipment transfer and is prone to collisions, thus affecting the product yield.

[0005] This invention provides the following technical solution: an integrated process for cutting and rotary machining of radiator profiles, comprising the following steps:

[0006] S1. Loading: Transport the heat sink profile to be processed to the processing station;

[0007] S2. Clamping and positioning: Start the clamp to clamp and fix the heat sink profile located at the processing station;

[0008] S3. Cutting: Control the first hacksaw to perform a cutting action, cut the clamped and fixed radiator profile, and form a profile segment with a cutting end face;

[0009] S4. Reference Detection and Compensation: Perform reference detection on the cut end face of the profile section to obtain its actual spatial position and attitude data, and based on the reference detection data, compensate and calibrate the rotation reference of the rotating device and the starting position of the lifting of the second hacksaw in the subsequent boss machining step;

[0010] S5. Boss Machining: Based on the compensated and calibrated reference, the clamping device cooperates with the rotating device to drive the profile section to rotate to a preset angle, and at the same time control the second hacksaw to perform a lifting and sawing operation, starting from the cut end face, removing part of the material, and machining the required boss structure on the profile section;

[0011] S6. Unloading: Control the fixture to release the machined profile section and move it out of the machining position.

[0012] By adopting the above technical solution: By integrating loading, clamping and positioning, cutting, reference detection and compensation, boss machining and unloading into the same process route, the integrated operation of profile cutting and end boss machining is achieved by one device, eliminating the transfer link in the traditional process and avoiding the transfer collision risk from the source. On this basis, by adding a reference detection and compensation step after cutting, using a non-contact sensor to obtain the cutting end face deviation data and compensating and calibrating the rotation reference and the starting position of lifting, the influence of cutting error on the subsequent machining accuracy is effectively eliminated; at the same time, by analyzing the rotation angle according to the boss shape and adopting a differential collaborative machining strategy, synchronous execution for circular bosses and step-by-step execution for polygonal bosses are adopted, realizing the flexible machining of various-shaped bosses by the same device. In addition, by arranging the first hacksaw and the second hacksaw in series, cutting, detection compensation, and boss machining are carried out in sequence at the same station, realizing seamless connection between processes and in-situ transfer of reference information, and avoiding the accumulation of positioning errors caused by station switching.

[0013] Preferably, in step S1, the loading further includes:

[0014] Pushing the radiator profile to be machined to a preset loading position through an automatic loading mechanism; performing position detection on the radiator profile reaching the loading position to ensure that it is in the correct clamping attitude.

[0015] Preferably, in step S2, the clamping and positioning further includes: Controlling the first fixture and the second fixture arranged side by side along the length direction of the radiator profile to act synchronously to clamp the parts of the radiator profile on both sides of the cutting trajectory of the first hacksaw.

[0016] Preferably, in step S3, the cutting further includes: Controlling the first hacksaw to perform a cutting operation perpendicular to the length direction of the radiator profile at a preset feed speed and cutting depth to form a flat cut end face.

[0017] Preferably, in step S4, the benchmark detection and compensation further includes:

[0018] Non-contact sensors are used to scan the cut end face and obtain its three-dimensional point cloud data;

[0019] The actual positional and angular deviations of the cut end face are calculated by comparing the 3D point cloud data with the preset standard end face model.

[0020] Based on the positional and angular deviations, compensation values ​​are generated for the rotational reference of the rotating equipment and for the starting position of the lifting of the second hacksaw.

[0021] Preferably, the step of generating compensation values ​​based on positional and angular deviations further includes:

[0022] Based on the positional deviation, the offset of the rotation center in the equipment coordinate system is calculated by coordinate system transformation, and used as the rotation reference compensation value.

[0023] Based on the projection component of the position deviation in the lifting direction, the offset of the starting height of the second hacksaw is calculated as the compensation value for the starting position of the lifting.

[0024] Preferably, in step S5, the step of driving the profile segment to rotate to a preset angle by the clamping device in conjunction with the rotating device further includes:

[0025] Based on the preset boss shape, one or more rotation angles that the profile segment needs to achieve during the processing are analyzed;

[0026] Before or during the sawing action of the second hacksaw, the rotating device linked with the clamp is driven to precisely rotate the profile segment held by it to the resolved rotation angle based on the compensated and calibrated rotation reference.

[0027] Preferably, in step S5, controlling the second hacksaw to perform the lifting and lowering sawing action further includes:

[0028] Based on the contour path of the boss shape, the saw blade of the second hacksaw is controlled to move up and down in a plane perpendicular to its sawing direction. The starting point of the up and down movement is determined based on the compensated and calibrated starting position of the up and down movement. In coordination with the rotational movement of the profile segment, the material is removed by sawing to form the boss structure.

[0029] Preferably, when the boss structure is circular, the drive profile segment rotates to a preset angle and the control of the second hacksaw to perform lifting and sawing actions are performed synchronously. That is, the rotating device drives the profile segment to rotate continuously at a uniform speed, while the second hacksaw maintains a fixed sawing depth, and together they saw out a circular boss.

[0030] When the boss structure is polygonal, the drive profile segment is rotated to a preset angle and the control of the second hacksaw to perform lifting and sawing actions are performed in steps. That is, the profile segment is first rotated to the angle required for the first processing surface, and then the second hacksaw is controlled to descend and saw. After processing one surface, the rotation and sawing actions are repeated until a complete polygonal boss is processed.

[0031] Preferably, the first hacksaw and the second hacksaw are arranged in series along the conveying direction of the radiator profile; steps S3, S4 and S5 are performed sequentially at the processing station.

[0032] The present invention has the following beneficial effects:

[0033] 1. In this invention, by integrating feeding, clamping and positioning, cutting, benchmark detection and compensation, boss processing and unloading into the same process route, a single machine can complete the integrated operation of profile cutting and end boss processing, eliminating the transfer links between different machines in the traditional process, avoiding the risk of collision during the transfer process from the source, and effectively improving the product yield.

[0034] 2. In this invention, by adding a reference detection and compensation step after the cutting step, a non-contact sensor is used to scan the cutting end face and calculate its actual position deviation and angle deviation. Based on the detection data, the rotation reference and the lifting start position are compensated and calibrated, so that the subsequent boss processing can accurately adapt to the current end face state and effectively eliminate the influence of cutting error on the boss processing accuracy.

[0035] 3. In this invention, by analyzing the rotation angle according to the shape of the boss and adopting a differentiated collaborative processing strategy, the circular boss is processed by rotating and sawing simultaneously, with uniform rotation and fixed cutting depth, while the polygonal boss is processed by step-by-step rotation and sawing, and splicing in a straight line instead of a curve, thus realizing flexible processing of bosses of various shapes on the same equipment.

[0036] 4. In this invention, by arranging the first hacksaw and the second hacksaw in series along the profile conveying direction, the three steps of cutting, benchmark detection and compensation, and boss processing are carried out sequentially at the same processing station, realizing seamless connection between processes and in-situ transmission of benchmark information, and avoiding the accumulation of positioning errors caused by station switching or secondary clamping.

[0037] 5. Based on the integrated process, this invention further introduces a closed-loop control mechanism of "detection-compensation-processing". Unlike traditional segmented processing or simple integration, this solution achieves dynamic correction of the processing benchmark by performing in-situ benchmark detection immediately after cutting and feeding the detection results back to the rotation and sawing motions of subsequent boss processing in real time. This mechanism not only eliminates the accumulation of errors caused by the cutting process, but also enables the boss processing to adaptively adapt to the actual state of the current end face, significantly improving consistency and yield. This processing method based on in-situ detection and motion trajectory linkage is not a simple superposition of existing technologies, but a fundamental improvement to the heat sink profile processing mode, with outstanding substantive features and significant progress. Attached Figure Description

[0038] Figure 1 This is a flowchart of an integrated process for cutting and rotating heat sink profiles proposed in this invention. Detailed Implementation

[0039] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0040] The overall structure of the integrated processing equipment for realizing this process is described in detail below:

[0041] This invention relates to an integrated process for cutting and rotating radiator profiles, which is achieved using a dedicated integrated processing equipment. All functional mechanisms of this equipment are integrated and fixed on the same horizontal equipment frame. Along the horizontal conveying direction of the radiator profile, i.e., the length direction of the profile, an automatic feeding mechanism, a clamping and positioning mechanism, a cutting processing mechanism, a reference detection mechanism, a boss processing mechanism, a rotating drive mechanism, and an unloading mechanism are arranged sequentially and coaxially from upstream to downstream. The equipment is also equipped with an integrated control system. All actuators and detection elements are electrically connected to and controlled by this control system, realizing fully automated closed-loop control.

[0042] The following provides a complete and detailed description of the structure, installation relationships, and coordination logic of each core component of the equipment. Those skilled in the art can directly reproduce the equipment structure based on the following description:

[0043] Equipment frame: The frame is made of integrally welded steel structure. The top surface of the frame is set with a high-precision installation reference surface that has been precision machined. All mechanisms are locked to this reference surface by positioning pins and bolts to ensure the coaxiality and installation accuracy of each mechanism. The inside of the frame is reserved with dedicated installation space for electrical wiring and hydraulic / pneumatic pipelines.

[0044] Automatic feeding mechanism: Used to achieve single-piece separation and directional feeding of profiles to be processed. This mechanism includes an inclined profile material bin, a servo-driven profile separation module, a servo push rod, and a feeding positioning table. The inclined profile material bin is fixed at the uppermost end of the frame and is used to stack and store profiles to be processed. A single-sided discharge port is set at the bottom of the bin. The profile separation module adopts a servo motor-driven feeding wheel structure and is installed at the discharge port. It can separate the stacked profiles into a horizontal discharge channel. The single rotation angle of the feeding wheel is controlled to ensure that only one profile enters the pushing station at a time. The servo push rod is slidably installed on the frame along the length of the profile. The pushing stroke of the push rod matches the length of the profile to be processed, and the pushing end corresponds to the preset feeding position of the feeding positioning table. The feeding positioning table is fixed on the frame and located downstream of the profile material bin. The positioning table is equipped with a V-shaped material support groove that matches the cross-section of the profile. The center line of the material support groove is completely coaxial with the clamping center line of the subsequent clamping positioning mechanism to ensure that the profile is in a standard clamping posture after being pushed into place.

[0045] Clamping and positioning mechanism: Used to achieve precise clamping and fixing of profiles and coordinated rotation drive. This mechanism includes a clamping mounting base, a first clamp, a second clamp, and two independent servo clamping drive modules. The clamping mounting base is fixed to the reference surface of the frame and located downstream of the loading and positioning stage. The first and second clamps are coaxially mounted side by side on the clamping mounting base along the length of the profile, with the clamping center lines of the two clamps completely overlapping and a coaxiality tolerance ≤0.02mm. A cutting gap of 15-30mm is reserved between the two clamps, and the center position of this cutting gap is the preset cutting trajectory position for the cutting process. The first clamp is fixedly installed on the upstream side of the clamp mounting base, and the second clamp is rigidly connected to the servo rotating spindle of the rotary drive mechanism through a rotary linkage flange. It can rotate 360° synchronously around the clamping center line with the servo rotating spindle. Both clamps adopt a V-shaped positioning jaw structure with anti-slip toothed surfaces on the inner side of the jaw. Each clamp is equipped with an independent servo clamping drive module. The servo clamping drive module is electrically connected to the control system and can control the two clamps to perform clamping / releasing actions synchronously. It can also adjust the clamping stroke separately based on the posture data of the loading detection to achieve torsional correction and precise positioning of the profile.

[0046] Rotary drive mechanism: This is the rotary equipment used in the process to drive the clamped profile segment to rotate precisely around the clamping centerline. The mechanism includes a servo rotary spindle, a spindle mounting base, and an absolute encoder. The spindle mounting base is fixed downstream of the fixture mounting base. The servo rotary spindle is coaxially mounted within the spindle mounting base via a high-precision bearing assembly. The rotation axis of the servo rotary spindle is completely aligned with the clamping centerlines of the two fixtures. The front end of the servo rotary spindle is rigidly connected to the clamping base of the second fixture via a rotary linkage flange, enabling the second fixture and the clamped profile segment to rotate synchronously without relative displacement or transmission backlash. The absolute encoder is built into the tail of the servo rotary spindle. The encoder resolution is ≥17 bits, achieving a rotation angle control accuracy of 0.001°. The encoder's signal output is electrically connected to the control system, providing real-time feedback of the rotation angle and position, enabling precise control and dynamic compensation of the rotation reference.

[0047] Cutting processing mechanism: Used to achieve vertical cutting of profiles. This mechanism includes a first hacksaw and a first hacksaw servo feed module. The first hacksaw servo feed module is a cross-shaped linear servo module, fixedly installed on the frame, with the cutting gap corresponding to the two sets of fixtures. It can drive the first hacksaw to make high-precision displacement along the horizontal feed axis perpendicular to the length of the profile and the lifting axis perpendicular to the reference plane of the frame, with a feed repeatability accuracy ≤0.01mm. The first hacksaw is installed at the execution end of the servo feed module. The hacksaw spindle has a built-in cutting force sensor. The sensor's detection signal is transmitted to the control system in real time to realize adaptive feed control based on cutting force feedback. The maximum cutting stroke of the first hacksaw covers the maximum cross-sectional size of the profile to be processed, ensuring that the entire profile can be completely cut off.

[0048] The reference detection mechanism is used to realize the three-dimensional reference detection and deviation calculation of the cutting end face. This mechanism includes a line laser profilometer and a three-axis high-precision linear module. The three-axis high-precision linear module is a precision servo linear module with a marble base, which is fixedly installed on the frame between the cutting processing mechanism and the boss processing mechanism. The X-axis of the module is set along the length of the profile, the Y-axis is set along the horizontal width of the profile, and the Z-axis is set along the vertical height of the profile. It can drive the line laser profilometer to move in the full range in three-dimensional space, and the scanning stroke covers the maximum cross-sectional size of the profile to be processed. The line laser profilometer is fixedly installed on the Z-axis slide of the three-axis high-precision linear module, with the detection end facing the cutting end face of the profile. The point cloud data output end of the profilometer is communicatively connected to the data processing module of the control system, which can transmit the collected three-dimensional point cloud data of the cutting end face in real time.

[0049] Boss processing mechanism: Used to saw and form the boss on the end face of the profile segment. This mechanism includes a second hacksaw and a second hacksaw servo lifting module. The second hacksaw servo lifting module is a high-precision servo linear module, fixedly installed on the frame and set corresponding to the cutting end face of the profile segment. It can drive the second hacksaw to make high-precision feed movements along the lifting axis perpendicular to the length direction of the profile, with a feed repeatability accuracy ≤0.01mm. The second hacksaw is installed on the execution end of the servo lifting module. The sawing plane of the hacksaw is parallel to the length direction of the profile, and the sawing feed direction is perpendicular to the rotation axis of the profile. It can cooperate with the rotation of the profile to remove material from the cutting end face to form the boss structure. The maximum sawing stroke of the second hacksaw covers the maximum processing height and depth of the boss.

[0050] Unloading Mechanism: Used to unload and store finished profile sections. This mechanism includes a three-axis unloading robot and a finished product bin. The three-axis unloading robot adopts a pneumatic clamping structure and is slidably installed on the crossbeam at the top of the frame. The crossbeam is set along the length of the profile. The robot's travel range covers the processing station and the finished product bin, enabling the grabbing, horizontal transfer, and unloading of finished products. The finished product bin is fixedly installed at the lowest end of the frame and is used to store all finished profiles that have been processed. The movement of the unloading robot is controlled by the control system, which automatically executes the unloading process after receiving the processing completion signal.

[0051] Integrated Control System: This system enables full-process logic control, data processing, and motion coordination. It includes a PLC control unit, a servo drive module, a data processing module, and a human-machine interface unit. The PLC control unit is the core of the control system, containing a built-in logic control program, coordinate transformation algorithm, and compensation value calculation program. The servo drive module is electrically connected to all servo motors and servo modules to execute motion commands issued by the PLC control unit. The data processing module is communicatively connected to all detection elements and sensors to receive and process point cloud data and detection signals, and to perform deviation calculations. The human-machine interface unit is used to set processing parameters, monitor equipment status, and perform manual operation.

[0052] All the above mechanisms are arranged in series and coaxially along the profile conveying direction within the same processing station of the same frame. Cutting, benchmark inspection, and boss processing are all completed sequentially within this processing station. The profile segment is always held by the second fixture throughout the entire processing process, without secondary clamping and transfer, thus realizing the in-situ transfer of processing benchmark and ensuring accuracy.

[0053] like Figure 1 As shown in the embodiments of the present invention, the present invention provides an integrated process for heat sink profile cutting and rotary processing, including the following steps:

[0054] S1. Loading: Transport the heat sink profile to be processed to the processing station;

[0055] Furthermore, the feeding process further includes:

[0056] The automatic feeding mechanism pushes the radiator profile to be processed to the preset feeding position; the position of the radiator profile that has reached the feeding position is detected to ensure that it is in the correct clamping posture.

[0057] Specifically, this step aims to transport the heat sink profile to be processed from the hopper or previous station to the processing station of this equipment, in preparation for subsequent clamping, cutting and boss processing.

[0058] Material feeding and pushing: The heat sink profiles to be processed are pushed to the preset feeding position by an automatic feeding mechanism. This automatic feeding mechanism usually adopts a cylinder-driven or servo motor-driven push rod structure, in conjunction with a profile-by-profile separation mechanism in the hopper, to ensure that only one profile is pushed to the designated position at a time. The feeding position must be set to ensure that the centerline of the profile roughly coincides with the centerline of the fixture, and that the end of the profile is within the preset range of the first hacksaw cutting trajectory.

[0059] The automatic feeding mechanism in this step is the same as the automatic feeding mechanism of the integrated processing equipment mentioned above. After the profile is pushed into place, it falls into the V-shaped material tray of the feeding and positioning table, completing the initial positioning. The position detection in this step uses non-contact sensors fixedly installed on the side and top surface of the feeding and positioning table, with the sensor's detection end facing the surface of the profile to be detected. The detection signal is transmitted in real time to the data processing module of the equipment control system, providing data input for the posture correction in the subsequent clamping step.

[0060] Position detection and attitude confirmation: After the profile reaches the loading position, it does not directly enter the clamping step, but needs to undergo position detection to confirm that it is in the correct clamping posture. To achieve accurate detection, a set of non-contact sensors, such as laser displacement sensors or machine vision cameras, are installed near the loading position. In this specific embodiment, two laser displacement sensors are used, one aligned with the side and the other with the top surface of the profile. By detecting the horizontal position deviation and torsional angle of the profile, a compensation basis is provided for subsequent clamping.

[0061] S2. Clamping and positioning: Start the clamp to clamp and fix the heat sink profile located at the processing station;

[0062] Furthermore, the clamping and positioning further includes: controlling the first clamp and the second clamp, which are arranged side by side along the length of the radiator profile, to move synchronously to clamp the parts of the radiator profile located on both sides of the first hacksaw cutting trajectory.

[0063] Specifically, this step aims to precisely clamp and fix the radiator profile that has arrived at the processing station, preparing it for subsequent cutting and rotation processing. The dual clamps are located on both sides of the first hacksaw cutting path, effectively resisting cutting forces and maintaining the stability of the cut end face. The clamps are driven by servo motors, enabling synchronous clamping and allowing for fine-tuning of the clamping force based on the posture data from the loading detection, actively correcting profile torsion.

[0064] The first and second clamps in this step refer to the two sets of clamps in the clamping and positioning mechanism of the integrated processing equipment mentioned above. The V-shaped jaws of the two sets of clamps enable automatic centering and positioning of the profile. Combined with the precise stroke control of the servo clamping drive module, the profile's torsional correction can be completed based on the torsion angle detected in the feeding step, through the differentiated clamping strokes of the two sets of clamps. This ensures that the axis of the profile after clamping is completely aligned with the rotation axis of the rotary drive mechanism. After the profile is clamped, the part to be cut is precisely within the cutting gap between the two sets of clamps, providing a stable clamping foundation for subsequent cutting processes.

[0065] S3, Cutting: Control the first hacksaw to perform the cutting action, cut the clamped and fixed radiator profile, and form a profile segment with a cut end face;

[0066] Furthermore, the cutting process further includes: controlling the first hacksaw to perform a cutting operation perpendicular to the length direction of the radiator profile at a preset feed speed and cutting depth, forming a flat cut end face.

[0067] Specifically, in this step, the first hacksaw moves along a direction perpendicular to the length of the profile, employing adaptive feed control based on cutting force feedback to adjust the feed speed in real time to maintain stable cutting force, thereby ensuring the flatness of the end face. After cutting, the profile segment remains held by the clamp, and the cut end face is in a fresh state.

[0068] The first hacksaw in this step refers to the first hacksaw of the cutting mechanism of the integrated processing equipment mentioned above. Driven by the first hacksaw servo feed module, it feeds along the direction perpendicular to the length of the profile. During the cutting process, the two sets of clamps remain clamped, effectively suppressing cutting vibration and ensuring the flatness of the cut end face. After cutting, the first hacksaw quickly retracts to the initial safe position. The remaining profile material is held by the first clamp, and the finished profile segment is held by the second clamp. The cut end face of the profile segment is precisely facing the detection direction of the reference detection mechanism, allowing it to directly enter the reference detection process without any displacement or transfer.

[0069] S4. Benchmark detection and compensation: Benchmark detection is performed on the cutting end face of the profile section to obtain its actual spatial position and posture data. Based on the benchmark detection data, the rotation benchmark of the rotating equipment and the lifting start position of the second hacksaw in the subsequent boss processing steps are compensated and calibrated.

[0070] Furthermore, the benchmark testing and compensation further include:

[0071] Non-contact sensors are used to scan the cut end face and obtain its three-dimensional point cloud data;

[0072] The actual positional and angular deviations of the cut end face are calculated by comparing the 3D point cloud data with the preset standard end face model.

[0073] Based on the positional and angular deviations, compensation values ​​are generated for the rotational reference of the rotating equipment and for the lifting and lowering starting position of the second hacksaw.

[0074] Furthermore, generating compensation values ​​based on positional and angular deviations further includes:

[0075] Based on the positional deviation, the offset of the rotation center in the equipment coordinate system is calculated through coordinate system transformation, and used as the rotation reference compensation value.

[0076] Based on the projection component of the position deviation in the lifting direction, the offset of the starting height of the second hacksaw is calculated as the compensation value for the starting position of the lifting.

[0077] Specifically, the implementation method of this step is as follows:

[0078] 1. Detection Device Configuration: In this specific embodiment, the non-contact sensor is a line laser profilometer, mounted on a high-precision linear module, capable of moving along the X, Y, and Z axes. Under the command of the control system, the sensor scans the cutting end face and acquires its three-dimensional point cloud data.

[0079] The line laser profilometer used in this step is the same line laser profilometer in the reference detection mechanism of the aforementioned integrated processing equipment. Driven by a three-axis high-precision linear module, it can move along the length of the profile to the front of the cutting end face, and then scan along the Y and Z axes to completely acquire the full-range three-dimensional point cloud data of the cutting end face. After scanning, it automatically returns to a safe position to avoid interference with subsequent boss processing procedures. The acquired point cloud data is transmitted in real time to the data processing module of the control system, providing basic data for subsequent deviation calculations.

[0080] 2. Point cloud data processing and deviation calculation: The acquired point cloud data set is represented as P={p1,p,...,p} n}, where p i =(x i ,y i ,z i The control system uses the least squares method to perform plane fitting on the point cloud data to obtain the plane equation of the actual cutting end face:

[0081] ax + by + cz + d = 0;

[0082] Where a, b, c are the unit normal vectors of the fitted plane, satisfying a 2 +b 2 +c 2 =1, where d is the distance parameter from the origin to the plane. The fitted actual plane is compared with a pre-defined standard end-face model. The standard end-face model is an ideal plane Π. std Its normal vector Perpendicular to the length of the profile and located at the theoretical design position.

[0083] Positional deviation Δp: defined as the directed distance from any point (x0, y0, z0) on the standard plane to the actual fitted plane, calculated using the following formula:

[0084] ;

[0085] Where: Δp represents the positional deviation of the cutting end face, i.e., the offset of the actual plane relative to the standard plane, in millimeters; (x0, y0, z0) represents the coordinates of any point on the standard plane Πstd, usually selected as the theoretical cutting point, in millimeters; a, b, c, d are the actual fitted plane Π act The equation coefficients are given by , where a, b, and c constitute the unit normal vector of the plane.

[0086] Angular deviation Δθ: defined as the actual plane normal vector and the normal vector of the standard plane The spatial angle between them. The calculation formula is:

[0087] ;

[0088] Where: Δθ represents the angular deviation of the cut end face, that is, the tilt angle of the actual plane relative to the standard plane, in radians or degrees; =(a,b,c) represents the unit normal vector of the actual fitted plane; The unit normal vector representing the standard plane, for a perpendicular cut, =(0,0,1) or defined according to the actual equipment coordinate system; Represents the dot product of two vectors; and These represent the magnitudes of the two vectors, with each value being 1 for a unit vector.

[0089] 3. Compensation value generation method:

[0090] The theoretical coordinates of the rotation center of the rotating equipment are (x rot ,y rot ,z rotBased on the positional deviation Δp and angular deviation Δθ, the offset components (Δx, Δy, Δz) of the rotation center are calculated through coordinate system transformation. The compensated coordinates of the rotation center are:

[0091] ;

[0092] The values ​​(Δx, Δy, Δz) are calculated by projecting the deviation values ​​onto the axes of the equipment coordinate system.

[0093] The theoretical starting height of the second hacksaw for lifting and lowering starting position compensation is h. lift Based on the projection component Δh of the position deviation Δp in the lifting direction, typically the Z-axis, the compensated starting height is:

[0094] = +Δh;

[0095] Where: h lift Indicates the theoretical initial height before compensation, in millimeters; The actual starting height after compensation is expressed in millimeters; Δh represents the projection component of the position deviation Δp in the lifting direction, also in millimeters. If the lifting direction is parallel to the profile length direction, then Δh = Δp; if an angle exists, a corresponding coordinate transformation is required.

[0096] Output and application of compensation data: Through the above calculations, the control system generates two sets of key compensation data: rotational reference compensation values ​​(Δx, Δy, Δz) and lifting start position compensation value Δh. These compensation values ​​will serve as direct inputs for the S5 boss machining steps.

[0097] The control system in this step is the integrated control system of the aforementioned integrated processing equipment. Its PLC control unit has a built-in coordinate transformation algorithm and compensation value calculation program. It can complete plane fitting, deviation calculation and compensation value generation based on the input point cloud data, and directly send the compensation value to the servo drive module for real-time compensation and calibration of the rotation reference of the rotary drive mechanism and the lifting start position of the second hacksaw servo lifting module. This eliminates the influence of the position and angle deviation of the cutting end face on the subsequent boss processing accuracy from the root.

[0098] S5. Boss processing: Based on the compensated and calibrated reference, the clamping device and the rotating equipment drive the profile segment to rotate to a preset angle, while controlling the second hacksaw to perform lifting and sawing actions. Starting from the cutting end face, part of the material is removed, and the required boss structure is processed on the profile segment.

[0099] Furthermore, the process of rotating the profile segment to a preset angle by the clamping device in conjunction with the rotating equipment further includes:

[0100] Based on the preset boss shape, one or more rotation angles that the profile segment needs to achieve during the processing are analyzed;

[0101] Before or during the sawing action of the second hacksaw, the rotating device linked with the clamp is driven to precisely rotate the profile segment held by it to the resolved rotation angle based on the compensated and calibrated rotation reference.

[0102] Furthermore, controlling the second hacksaw to perform the lifting and lowering sawing action further includes:

[0103] Based on the contour path of the boss shape, the saw blade of the second hacksaw is controlled to move up and down in a plane perpendicular to its sawing direction. The starting point of the up and down movement is determined based on the compensated and calibrated starting position of the up and down movement. In conjunction with the rotational movement of the profile segment, the material is removed by sawing to form the boss structure.

[0104] Furthermore, when the boss structure is circular, the drive profile segment rotates to a preset angle and the control of the second hacksaw to perform lifting and sawing actions are executed synchronously. That is, the rotating device drives the profile segment to rotate continuously at a uniform speed, while the second hacksaw maintains a fixed sawing depth, working together to saw out the circular boss.

[0105] Furthermore, when the boss structure is polygonal, the drive profile segment is rotated to a preset angle and the control of the second hacksaw to perform lifting and sawing actions are carried out in steps. That is, the profile segment is first rotated to the angle required for the first processing surface, and then the second hacksaw is controlled to descend and saw. After processing one surface, the rotation and sawing actions are repeated until a complete polygonal boss is processed.

[0106] Specifically, this step, based on the compensation data generated by S4, achieves boss machining through the coordinated movement of the rotating device and the second hacksaw. For circular bosses, continuous rotation and fixed cutting depth are performed simultaneously; for polygonal bosses, a combination of step-by-step rotation and straight-line sawing is used. Throughout the entire machining process, the profile segment is always held by the same set of fixtures, eliminating the need for secondary clamping.

[0107] The second hacksaw in this step refers to the second hacksaw of the boss processing mechanism of the aforementioned integrated processing equipment, and the rotating device refers to the rotating drive mechanism of the aforementioned integrated processing equipment. Before boss processing, the first clamp performs a release action to release the clamping of the profile material residue, avoiding interference with the rotation of the profile segment. The second clamp maintains the clamping state of the profile segment, and the servo rotating spindle drives the second clamp to rotate synchronously with the profile segment, realizing the profile segment's rotational processing without secondary clamping. During processing, the servo drive module, based on the compensated rotation reference and the lifting start position, synchronously controls the rotational action of the rotating drive mechanism and the lifting and feeding action of the second hacksaw. The two form interpolation collaboration to accurately form the preset boss contour. After processing, the second hacksaw returns to the initial safe position, and the rotating drive mechanism drives the second clamp to reset to the initial angle, preparing for the unloading process.

[0108] S6. Unloading: Control the fixture to release the finished profile section and remove it from the machining workpiece.

[0109] Specifically, after the clamps are released, the unloading robot grabs the profile segment and moves it to the finished product bin, and sends a workstation idle signal to start the next cycle.

[0110] This step involves the unloading robot and the finished product bin, which are the three-axis unloading robot and finished product bin of the aforementioned integrated processing equipment's unloading mechanism. After the profile segment completes all processing, the second clamp performs a release action. Under the command of the control system, the unloading robot moves to the clamping position of the profile segment. After the pneumatic gripper clamps the profile segment, it moves along the top crossbeam of the frame to the top of the finished product bin. The gripper is then released to place the finished product into the bin, completing the unloading process. After unloading, the unloading robot returns to its initial position and sends a station idle signal to the control system, triggering the next processing cycle.

[0111] Furthermore, the first hacksaw and the second hacksaw are arranged in series along the conveying direction of the radiator profile; steps S3, S4 and S5 are performed sequentially at the processing station;

[0112] Specifically, the first and second hacksaws are arranged in series along the conveying direction of the radiator profile, meaning they are positioned one after the other along the length of the profile. The first hacksaw is located upstream and is responsible for cutting, while the second hacksaw is located downstream and is responsible for machining the boss. A non-contact sensor is installed between them. This series arrangement allows for sequential operation of the process, achieving workstation reuse, fixture sharing, and space optimization, while ensuring the in-situ transmission of reference information.

[0113] The first hacksaw, the reference testing mechanism, and the second hacksaw are arranged sequentially along the profile conveying direction within the axial range of the same processing station. All processes are completed within this processing station. The profile segment is always held by the second clamp throughout the entire processing process, without secondary clamping and transfer, thus eliminating the cumulative reference error caused by multiple clamping from the root.

[0114] Through the above-mentioned integrated process, the present invention completes all the processing content that traditional solutions require two independent stations and multiple clamping and transfers in a single station, achieving true one-time clamping and completion, and significantly improving processing accuracy and efficiency.

[0115] This invention integrates cutting, benchmark detection, and boss rotation processing into a single workstation through an integrated equipment structure, achieving a deep match between the process and the equipment. Those skilled in the art can fully implement the technical solution of this invention without creative effort based on the equipment structure and process steps disclosed in this specification, solving the integrated forming requirement of radiator profile cutting and boss processing, and fully meeting the requirements of sufficient patent disclosure.

[0116] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An integrated process for cutting and rotary machining of radiator profiles, characterized in that, Includes the following steps: S1. Loading: Transport the heat sink profile to be processed to the processing station; S2. Clamping and positioning: Start the clamp to clamp and fix the heat sink profile located at the processing station; S3. Cutting: Control the first hacksaw to perform a cutting action, cut the clamped and fixed radiator profile, and form a profile segment with a cutting end face; S4. Benchmark detection and compensation: Benchmark detection is performed on the cutting end face of the profile section to obtain its actual spatial position and posture data. Based on the benchmark detection data, the rotation benchmark of the rotating equipment and the lifting start position of the second hacksaw in the subsequent boss processing steps are compensated and calibrated. S5. Boss processing: Based on the compensated and calibrated reference, the clamping device and the rotating equipment drive the profile segment to rotate to a preset angle, while controlling the second hacksaw to perform lifting and sawing actions. Starting from the cutting end face, part of the material is removed, and the required boss structure is processed on the profile segment. S6. Unloading: Control the fixture to release the finished profile section and remove it from the machining workpiece.

2. The integrated process for cutting and rotary machining of radiator profiles according to claim 1, characterized in that, In step S1, the feeding process further includes: The automatic feeding mechanism pushes the radiator profile to be processed to the preset feeding position; the position of the radiator profile that has reached the feeding position is detected to ensure that it is in the correct clamping posture.

3. The integrated process for cutting and rotary machining of radiator profiles according to claim 1, characterized in that, In step S2, the clamping and positioning further includes: controlling the first clamp and the second clamp, which are arranged side by side along the length of the radiator profile, to move synchronously to clamp the parts of the radiator profile located on both sides of the first hacksaw cutting trajectory.

4. The integrated process for cutting and rotary machining of radiator profiles according to claim 1, characterized in that, In step S3, the cutting further includes: controlling the first hacksaw to perform a cutting operation perpendicular to the length direction of the radiator profile at a preset feed speed and cutting depth, forming a flat cutting end face.

5. The integrated process for cutting and rotary machining of radiator profiles according to claim 1, characterized in that, In step S4, the benchmark detection and compensation further includes: Non-contact sensors are used to scan the cut end face and obtain its three-dimensional point cloud data; The actual positional and angular deviations of the cut end face are calculated by comparing the 3D point cloud data with the preset standard end face model. Based on the positional and angular deviations, compensation values ​​are generated for the rotational reference of the rotating equipment and for the starting position of the lifting of the second hacksaw.

6. The integrated process for cutting and rotary machining of radiator profiles according to claim 5, characterized in that, The step of generating compensation values ​​based on position and angle deviations further includes: Based on the positional deviation, the offset of the rotation center in the equipment coordinate system is calculated by coordinate system transformation, and used as the rotation reference compensation value. Based on the projection component of the position deviation in the lifting direction, the offset of the starting height of the second hacksaw is calculated as the compensation value for the starting position of the lifting.

7. The integrated process for cutting and rotary machining of radiator profiles according to claim 1, characterized in that, In step S5, the step of driving the profile segment to rotate to a preset angle by the clamping device in conjunction with the rotating device further includes: Based on the preset boss shape, one or more rotation angles that the profile segment needs to achieve during the processing are analyzed; Before or during the sawing action of the second hacksaw, the rotating device linked with the clamp is driven to precisely rotate the profile segment held by it to the resolved rotation angle based on the compensated and calibrated rotation reference.

8. The integrated process for cutting and rotary machining of radiator profiles according to claim 1, characterized in that, In step S5, controlling the second hacksaw to perform the lifting and lowering sawing action further includes: Based on the contour path of the boss shape, the saw blade of the second hacksaw is controlled to move up and down in a plane perpendicular to its sawing direction. The starting point of the up and down movement is determined based on the compensated and calibrated starting position of the up and down movement. In coordination with the rotational movement of the profile segment, the material is removed by sawing to form the boss structure.

9. The integrated process for cutting and rotary machining of radiator profiles according to claim 1 or 8, characterized in that, When the boss structure is circular, the drive profile segment rotates to a preset angle and the control of the second steel saw to perform lifting and sawing actions are executed synchronously. That is, the rotating device drives the profile segment to rotate continuously at a uniform speed, while the second steel saw maintains a fixed sawing depth, and together they saw out a circular boss. When the boss structure is polygonal, the drive profile segment is rotated to a preset angle and the control of the second hacksaw to perform lifting and sawing actions are performed in steps. That is, the profile segment is first rotated to the angle required for the first processing surface, and then the second hacksaw is controlled to descend and saw. After processing one surface, the rotation and sawing actions are repeated until a complete polygonal boss is processed.

10. The integrated process for cutting and rotary machining of radiator profiles according to claim 1, characterized in that, The first hacksaw and the second hacksaw are arranged in series along the conveying direction of the radiator profile; steps S3, S4 and S5 are performed sequentially at the processing station.

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