Wind power casting processing management system and method based on 3D numerical control simulation

Abstract

The present invention discloses a wind power casting processing management system and method based on 3D numerical control simulation, which belongs to the field of processing management. The wind power casting processing management system based on 3D numerical control simulation includes a simulation drive module and a processing production module; the output end of the simulation drive module is connected to the input end of the processing production module. At the same time, a wind power casting processing management method based on 3D numerical control simulation is also provided, which can predict the impact of subsequent production on the modification of the wind power casting production process after 3D numerical control simulation, improve production efficiency and the integrity of wind power castings, and meet the ever-changing market and customer demand application scenarios of wind power casting production based on processing management decisions.

Description

Technical Field

[0001] The present invention relates to the field of processing management, and in particular to a wind power casting processing management system and method based on 3D numerical control simulation. Background Art

[0002] The working environment and conditions of wind power generation equipment are relatively harsh. The material properties of wind power castings need to meet special requirements and have very high requirements for product quality. It takes a long time to master the production process and form a stable batch production capacity. The expansion of production capacity also requires a lot of funds and professional workers. Casting production has high requirements for technology and production experience accumulation. All links need to use the long-term accumulated production technology and experience. Enterprises must not only have strong independent innovation capabilities, but also quickly develop new products that can adapt to the market and meet customer needs according to the ever-changing market and customer needs, and have mature product technology management capabilities and sophisticated on-site management levels.

[0003] However, due to the high requirements and precision of wind power castings, a small mistake in the actual production process of wind power castings may affect the smooth output of the entire production line. Therefore, the management of wind power casting processing is an indispensable part of the entire wind power casting production. Summary of the invention

[0004] The purpose of the present invention is to provide a wind power casting processing management system and method based on 3D numerical control simulation to solve the problems raised in the above background technology.

[0005] In order to solve the above technical problems, the present invention provides the following technical solutions:

[0006] A wind power casting processing management system based on 3D CNC simulation, the system includes: a simulation drive module and a processing production module;

[0007] The simulation drive module uses the working principle of VERICUT to create a simulation machine tool that is consistent with the actual machine tool, creates a project file according to the customer's processing model, compiles NC program files and processing technology, simulates the cutting process, and performs optimization processing; the processing production module performs actual processing on wind power castings based on simulation-driven simulation processing, builds risk analysis management in the actual processing process, provides guarantees for wind power casting production, and predicts the impact of modifications to wind power casting products during the production process;

[0008] The output end of the simulation driving module is connected to the input end of the processing and production module.

[0009] According to the above technical solution, the driving module includes a coordinate setting unit, a program compilation unit and a program optimization unit;

[0010] The coordinate setting unit is used to load the processing three dimensions into the project file according to the actual processing placement method, and set the processing coordinate system; the program compilation unit is used to compile the processing program in the VERICUT software, create the tool, and simulate the cutting of the parts according to the processing process route; the program optimization unit is used to optimize and modify the program to make it safe and reliable according to the overcut feedback generated during the simulated cutting process of the parts in the program compilation unit; the output end and the input end of the coordinate setting unit are respectively connected to the input end and the output end of the program compilation unit; the input end of the program optimization unit is connected to the output end of the program compilation unit.

[0011] According to the above technical solution, the processing and production module includes a production execution unit and a risk analysis unit;

[0012] The production execution unit is used to export a part processing program for the simulated cutting process in the optimization program unit in the driving module, and directly processes the parts in the simulated cutting process in the optimization program unit after loading; the risk analysis unit is used to predict the risks of production content that needs to be modified and the impact on later production during the production process of the production execution unit; the input end of the production execution unit is connected to the output end of the program optimization unit in the simulation driving module; the output end of the production execution unit is connected to the input end of the risk analysis unit.

[0013] A wind power casting processing management method based on 3D numerical control simulation, the method comprising the following steps:

[0014] S1. Load the processing 3D into the project file according to the actual processing placement method and set the processing coordinate system;

[0015] S2. Compile machining programs in VERICUT software, create tools, and simulate cutting of parts according to the machining process route;

[0016] S3. Optimize and modify the machining program based on the overcutting feedback generated during the cutting process;

[0017] S4, the machine tool imports the processing program to carry out actual processing;

[0018] S5. Build risk analysis management during the processing to improve production efficiency.

[0019] According to the above technical scheme, in S1, the processing three-dimensional is loaded into the project file according to the actual processing placement method, and the processing coordinate system is set to provide an environment for machine tool simulation and lay the foundation for achieving a complete and detailed simulation effect. The processing three-dimensional is a virtual simulation of a three-axis vertical machine tool. The Y and Z axes are located inside the root node of the machine body, the X axis is located in the Y axis node, and the fixture is located inside the X node. The design model is located inside the node of the fixture, that is, the design model is attached to the fixture, and the fixture moves with the X axis. Similarly, the X axis is placed on the Y axis, the tool is attached to the fixture, and the fixture is attached to the Z axis, reflecting that the tool moves with the Z axis driven by the spindle. Therefore, the setting of the coordinate system reflects the mutual dependence and constraint relationship between the coordinate axis, spindle, tool and fixture, reflects the most basic kinematic structure of the machine tool, and is the basis for machine tool modeling.

[0020] According to the above technical solution, in S2, the modeling function in the VERICUT software is used to establish the geometric model of each component in the component tree, and the various parts are assembled together through coordinates. Complex models can be established using other CAD software and then imported into the VERICUT system to form a solid model of the machine tool. The program management function of VERICUT is used to call in the part CNC machining program generated by the external CAM software. The system can automatically recognize the G code and perform the tool movement according to it to complete the part machining process. In this process, the user can see the linkage between the axes of the virtual machine tool like observing the actual machine tool machining, see the real-time image of the tool cutting off the rough material to form the part, and use the virtual three-axis milling machine established in the previous article to perform machining on a certain part. From the interface of machining simulation, we can see that VERICUT provides different views to simultaneously display the overall operation of the machine tool and the cutting status of the parts. It displays both machining details and overall effects, reflecting the superiority of the VERICUT system in machining display, which is something that other similar CNC simulation software cannot do. The VERICUT system can also be used to perform operations such as pause or single-step execution, rotate, zoom, and translate the view to better observe the simulation effect. If overcutting, collision, or interference between machine tool components occurs during the machining process, the system will highlight it in red to remind the user, and automatically record the error phenomenon and the program line where it is located in the report file to facilitate user query and modification.

[0021] According to the above technical solution, in S2, the creation of tools is to realize virtual processing, and matching tools should also be established. In the existing technology of VERICUT software, a tool management module is provided to realize this function. With this module, users can complete the modeling of tools of any shape. The tool modeling includes two parts: the tool rod (cutting part) and the tool handle (clamping part). For cutting edges and tool handles of common shapes, users can directly use the model provided by the system to establish them. For cutting edges with complex shapes, users can draw them by themselves through the CAD drawing function inside the system. Users can establish several tools to form a tool library that is the same as the actual machine tool.

[0022] According to the above technical solution, in S5, the risk analysis module is constructed during the wind power casting processing to predict the impact range of the wind power casting processing in the later stage according to the modification in the actual wind power casting processing. The algorithm of the topological structure can be used to achieve:

[0023] N ij =N i ∪N j

[0024] The coverage range of a modified node refers to the range that the modified node can directly affect, that is, the set of neighbor nodes, N i and N j All belong to the neighbor set of modified node i, N ij Indicates modifying the coverage of the node. i <N j , when the modified node is located at N i When the actual wind power casting processing is in the middle, the impact degree is N i , when the modified node is located at N j When the actual wind power casting processing is in the middle, the impact degree is N i +N j ; Similarly, if N i >N j , when the modified node is located at N i When the actual wind power casting processing is in the middle, the impact degree is N i +N j , when the modified node is located at N j When the actual wind power casting processing is in the middle, the impact degree is N j .

[0025] Compared with the prior art, the beneficial effects achieved by the present invention are:

[0026] 1. Predicting the impact of modifications in the mid-term production process of wind power castings after 3D CNC simulation can improve production efficiency and the integrity of wind power castings. Predicting product modifications in the production process reduces labor costs to a certain extent, predicts the possibility of production rework in advance, and meets the ever-changing market and customer demand application scenarios of wind power casting production based on processing management decisions.

[0027] 2. Simulation processing can simulate the actual processing of parts on the computer, verify the correctness of the CNC program, replace the trial cutting of parts, shorten the design and manufacturing cycle of parts, and has very important practical significance. It is also an inevitable trend in the development of modern manufacturing technology. Most of the simulation processing software used today can only reflect the processing process of the tool cutting part. Users cannot establish machine tools and tool models suitable for their own conditions, and can only passively select the simulation environment provided by the software, so they cannot achieve complete CNC processing simulation and virtualization. VERICUT software can establish a complete virtual machine tool, which not only makes the simulation effect more realistic, but also can realize virtual manufacturing of the entire process. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings:

[0029] Figure 1 It is a schematic diagram of the module composition of the wind power casting processing management system based on 3D numerical control simulation of the present invention;

[0030] Figure 2 It is a schematic diagram of the steps of the wind power casting processing management method based on 3D numerical control simulation of the present invention. DETAILED DESCRIPTION

[0031] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0032] See also Figure 1-Figure 2 , the present invention provides the following technical solutions: a wind power casting processing management system based on 3D numerical control simulation, the system comprising: a simulation drive module and a processing production module;

[0033] The simulation drive module uses the working principle of VERICUT to create a simulation machine tool that is consistent with the actual machine tool, creates project files according to the customer's processing model, compiles NC program files and processing technology, simulates the cutting process, and performs optimization processing; the processing production module performs actual processing of wind power castings based on simulation-driven simulation processing, builds risk analysis management in the actual processing process, provides guarantees for wind power casting production, and predicts the impact of modifications to wind power casting products during the production process;

[0034] The output end of the simulation driving module is connected to the input end of the processing and production module.

[0035] The simulation drive module includes a coordinate setting unit, a program compilation unit and a program optimization unit;

[0036] The coordinate setting unit is used to load the processing three dimensions into the project file according to the actual processing placement method, and set the processing coordinate system; the program compilation unit is used to compile the processing program in the VERICUT software, create the tool, and simulate the cutting of the parts according to the processing process route; the program optimization unit is used to optimize and modify the program to make it safe and reliable according to the overcut feedback generated during the simulated cutting process of the parts in the program compilation unit; the output end and the input end of the coordinate setting unit are respectively connected to the input end and the output end of the program compilation unit; the input end of the program optimization unit is connected to the output end of the program compilation unit.

[0037] The processing and production module includes a production execution unit and a risk analysis unit;

[0038] The production execution unit is used to export the part processing program for the simulated cutting process in the optimization program unit in the driving module, and directly processes the parts in the simulated cutting process in the optimization program unit after loading; the risk analysis unit is used to predict the risks of production content that needs to be modified and the impact on later production during the production process of the production execution unit; the input end of the production execution unit is connected to the output end of the program optimization unit in the simulation driving module; the output end of the production execution unit is connected to the input end of the risk analysis unit.

[0039] A wind power casting processing management method based on 3D numerical control simulation, the method comprising the following steps:

[0040] S1. Load the processing 3D into the project file according to the actual processing placement method and set the processing coordinate system;

[0041] S2. Compile machining programs in VERICUT software, create tools, and simulate cutting of parts according to the machining process route;

[0042] S3. Optimize and modify the machining program based on the overcutting feedback generated during the cutting process;

[0043] S4, the machine tool imports the processing program to carry out actual processing;

[0044] S5. Build risk analysis management during the processing to improve production efficiency.

[0045] According to the above technical scheme, in S1, the processing three-dimensional is loaded into the project file according to the actual processing placement method, and the processing coordinate system is set to provide an environment for machine tool simulation and lay the foundation for achieving a complete and detailed simulation effect. The processing three-dimensional is a virtual simulation of a three-axis vertical machine tool. The Y and Z axes are located inside the root node of the machine body, the X axis is located in the Y axis node, and the fixture is located inside the X node. The design model is located inside the node of the fixture, that is, the design model is attached to the fixture, and the fixture moves with the X axis. Similarly, the X axis is placed on the Y axis, the tool is attached to the fixture, and the fixture is attached to the Z axis, reflecting that the tool moves with the Z axis driven by the spindle. Therefore, the setting of the coordinate system reflects the mutual dependence and constraint relationship between the coordinate axis, spindle, tool and fixture, reflects the most basic kinematic structure of the machine tool, and is the basis for machine tool modeling.

[0046] According to the above technical solution, in S2, the modeling function in the VERICUT software is used to establish the geometric model of each component in the component tree, and the various parts are assembled together through coordinates. Complex models can be established using other CAD software and then imported into the VERICUT system to form a solid model of the machine tool. The program management function of VERICUT is used to call in the part CNC machining program generated by the external CAM software. The system can automatically recognize the G code and perform the tool movement according to it to complete the part machining process. In this process, the user can see the linkage between the axes of the virtual machine tool like observing the actual machine tool machining, see the real-time image of the tool cutting off the rough material to form the part, and use the virtual three-axis milling machine established in the previous article to perform machining on a certain part. From the interface of machining simulation, we can see that VERICUT provides different views to simultaneously display the overall operation of the machine tool and the cutting status of the parts. It displays both machining details and overall effects, reflecting the superiority of the VERICUT system in machining display, which is something that other similar CNC simulation software cannot do. The VERICUT system can also be used to perform operations such as pause or single-step execution, rotate, zoom, and translate the view to better observe the simulation effect. If overcutting, collision, or interference between machine tool components occurs during the machining process, the system will highlight it in red to remind the user, and automatically record the error phenomenon and the program line where it is located in the report file to facilitate user query and modification.

[0047] According to the above technical solution, in S2, the creation of tools is to realize virtual processing, and matching tools should also be established. In the existing technology of VERICUT software, a tool management module is provided to realize this function. With this module, users can complete the modeling of tools of any shape. The tool modeling includes two parts: the tool rod (cutting part) and the tool handle (clamping part). For cutting edges and tool handles of common shapes, users can directly use the model provided by the system to establish them. For cutting edges with complex shapes, users can draw them by themselves through the CAD drawing function inside the system. Users can establish several tools to form a tool library that is the same as the actual machine tool.

[0048] According to the above technical solution, in S5, the risk analysis module is constructed during the wind power casting processing to predict the impact range of the wind power casting processing in the later stage according to the modification in the actual wind power casting processing. The algorithm of the topological structure can be used to achieve:

[0049] N ij =N i ∪N j

[0050] The coverage range of a modified node refers to the range that the modified node can directly affect, that is, the set of neighbor nodes, N i and N j All belong to the neighbor set of modified node i, N ij Indicates modifying the coverage of the node. i <N j , when the modified node is located at N i When the actual wind power casting processing is in the middle, the impact degree is N i , when the modified node is located at N j When the actual wind power casting processing is in the middle, the impact degree is N i +N j ; Similarly, if N i >N j , when the modified node is located at N i When the actual wind power casting processing is in the middle, the impact degree is N i +N j , when the modified node is located at N j When the actual wind power casting processing is in the middle, the impact degree is N j .

[0051] Embodiment 1: Load the processing three dimensions into the project file according to the actual processing layout and set the processing coordinate system, compile the processing program in the VERICUT software, create the tool, and simulate the cutting of the parts according to the processing route. According to the overcut feedback generated during the cutting process, optimize and modify the processing program, and import the processing program into the machine tool for actual processing. No modification operation is performed during the actual processing, which will have no impact on the later production process.

[0052] Embodiment 2: Load the processing 3D into the project file according to the actual processing placement mode and set the processing coordinate system, compile the processing program in the VERICUT software, create the tool, and simulate the cutting of the parts according to the processing route. According to the overcut feedback generated during the cutting process, optimize and modify the processing program, import the processing program into the machine tool for actual processing, find problems during the actual processing process, predict the impact of the modification on the wind power casting products in the production process, and judge the coverage range directly affected by the nodes that need to be modified, that is, use N ij Indicates the coverage of the modified node, N i and N j All belong to the neighbor set of modified node i. If N i <N j , when the modified node is located at N i When the actual wind power casting processing is in the middle, the impact degree is N i ; When the modified node is located at N j When the influence on the actual wind power casting processing is N i +N j , you can determine the impact of the modified node on the neighbor set. If there is no impact, production can continue; if there is an impact, the production cycle and production schedule need to be modified and adjusted.

[0053] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0054] 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 aforementioned embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or replace some of the technical features therein by equivalents. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. Wind power casting processing management system based on 3D CNC simulation, characterized by: The system includes: a simulation drive module and a processing and production module; The simulation drive module uses the working principle of VERICUT to create a simulation machine tool that is consistent with the actual machine tool, creates a project file according to the customer's processing model, compiles NC program files and processing technology, simulates the cutting process, and performs optimization processing; the processing production module performs actual processing on wind power castings based on simulation-driven simulation processing, builds risk analysis management in the actual processing process, provides guarantees for wind power casting production, and predicts the impact of modifications to wind power casting products during the production process; The output end of the simulation driving module is connected to the input end of the processing and production module; The driving module includes a coordinate setting unit, a program compilation unit and a program optimization unit; The coordinate setting unit is used to load the processing three-dimensional into the project file according to the actual processing placement mode, and set the processing coordinate system; the program compilation unit is used to compile the processing program in the VERICUT software, create the tool, and simulate the cutting of the parts according to the processing process route; the program optimization unit is used to optimize and modify the program to make it safe and reliable according to the overcut feedback generated during the simulated cutting process of the parts in the program compilation unit; the output end and the input end of the coordinate setting unit are respectively connected to the input end and the output end of the program compilation unit; the input end of the program optimization unit is connected to the output end of the program compilation unit; The processing and production module includes a production execution unit and a risk analysis unit; The production execution unit is used to derive a part processing program for the simulated cutting process in the optimization program unit in the driving module, and the machine tool directly processes the parts in the simulated cutting process in the optimization program unit after loading; the risk analysis unit is used to predict the risks of production content that needs to be modified and the impact on later production during the production process of the production execution unit; the input end of the production execution unit is connected to the output end of the program optimization unit in the simulation driving module; the output end of the production execution unit is connected to the input end of the risk analysis unit; The risk analysis module is used to predict the impact of modifications on the later stage of wind power casting processing during the actual wind power casting processing, and is implemented according to the algorithm of the topological structure: N ij =N i ∪N j The coverage range of a modified node refers to the range that the modified node can directly affect, that is, the set of neighbor nodes, N i and N j All belong to the neighbor set of modified node i, N ij Indicates modifying the coverage of the node; if N i <N j , when the modified node is located at N i When the actual wind power casting processing is in the middle, the impact degree is N i , when the modified node is located at N j When the actual wind power casting processing is in the middle, the impact degree is N i +N j ; Similarly, if N i >N j , when the modified node is located at N i When the actual wind power casting processing is in the middle, the impact degree is N i +N j , when the modified node is located at N j When the actual wind power casting processing is in the middle, the impact degree is N j .

2. A wind power casting processing management method based on 3D numerical control simulation is applied to the wind power casting processing management system based on 3D numerical control simulation as claimed in claim 1, characterized in that: The method comprises the following steps: S1. Load the processing 3D into the project file according to the actual processing placement method and set the processing coordinate system; S2. Compile machining programs in VERICUT software, create tools, and simulate cutting of parts according to the machining process route; S3. Optimize and modify the machining program based on the overcutting feedback generated during the cutting process; S4, the machine tool imports the processing program to carry out actual processing; S5. Build risk analysis management during processing to improve production efficiency; In S1, the processing three-dimensional is loaded into the project file according to the actual processing placement mode, and the processing coordinate system is set. The processing three-dimensional is a virtual simulation of a three-axis vertical machine tool. The Y and Z axes are located inside the root node of the machine body, the X axis is located in the Y axis node, and the fixture is located inside the X node. The design model is located inside the node of the fixture, that is, the design model is attached to the fixture, and the fixture moves with the X axis. Similarly, the X axis is placed on the Y axis, the tool is attached to the fixture, and the fixture is attached to the Z axis, reflecting that the tool moves with the Z axis driven by the spindle; In S2, the modeling function in VERICUT software is used to build the geometric model of each component in the component tree, and the parts are assembled together through coordinates. Complex models are built using other CAD software and then imported into the VERICUT system to form a solid model of the machine tool.

3. The wind power casting processing management method based on 3D numerical control simulation according to claim 2 is characterized in that: In S2, tools are created to realize virtual machining, and matching tools should also be established. The tool management module is provided in VERICUT software to realize this function. With this module, users can complete tool modeling of any shape.

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