Numerical control type steel drilling and cutting production method, software and system

Abstract

The present application relates to data processing system or method, specifically related to numerical control type steel drilling and cutting production method, software and system, numerical control type steel drilling and cutting production method, including the following steps: extracting the process information for drilling and cutting operation of the type steel from the DSTV file, the process information includes the component length and quantity; according to the component length, quantity and the length of raw material, automatic nesting combination is carried out, the automatic nesting material combination refers to that nc1 parts corresponding to a plurality of DSTV files are combined into a specified length of raw material, and raw material processing data is generated; according to the raw material processing data, the type steel is drilled and cut, and the automatic blanking treatment of numerical control type steel drilling and cutting is realized.

Description

Technical Field

[0001] This invention relates to a data processing system or method, specifically to a CNC steel drilling and cutting production method, software, and system. Background Technology

[0002] Currently, when processing U-shaped or H-shaped steel, operations such as drilling, engraving, cutting, and locking are required. These operations are automated by industrial control computers. However, the drilling, cutting, and locking systems are independent of each other and need to be operated separately. When processing large quantities of steel, it is impossible to form an assembly line operation, resulting in low efficiency. Furthermore, given the known processing target data, it is impossible to automatically plan the processing of raw materials, requiring manual calculation. Summary of the Invention

[0003] The purpose of this invention is to generate raw material processing data by using an automatic nesting and combination method based on the obtained component length, quantity and raw material length, and to realize automated production line processing of steel profiles based on the raw material processing data. Therefore, a CNC steel profile drilling and cutting lock production method, software and system are proposed.

[0004] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0005] The CNC steel drilling and cutting production method includes the following steps:

[0006] Extract the process information for drilling and cutting the steel profiles from the DSTV file. The process information includes the length and quantity of the components.

[0007] Automatic nesting and assembly is performed based on the length and quantity of the components and the length of the raw materials. The automatic nesting and assembly refers to combining multiple NC1 parts corresponding to DSTV files into a raw material of a specified length and generating raw material processing data.

[0008] Drilling and cutting operations are performed on the steel profiles based on the raw material processing data.

[0009] As a preferred embodiment, the automatic nesting assembly includes the following steps:

[0010] The process information of the main profiles of the same components is placed in an array;

[0011] The component lengths in the array are sequentially superimposed to obtain the total length. When the total length is greater than or equal to the length of the raw material, a set of workpieces is completed and a PNC file is generated.

[0012] As a preferred embodiment, the length of the raw material is equal to the actual length of the raw material plus the processing allowance.

[0013] As a preferred option, process information for drilling and cutting operations on the steel profiles is extracted from the DSTV file, specifically including:

[0014] Read CNC machining files generated by the steel structure design software TEKLA;

[0015] The CNC machining file is opened in text format, and key data is extracted to obtain process information.

[0016] As a preferred embodiment, the extracted key data includes an array of external contours for cutting, hole diameter length and hole diameter coordinate data for drilling, and data for drawing lines;

[0017] The extraction of key data includes the following steps:

[0018] Locate the outline array from the Nc1 file; the outline array includes length information, width information, and chamfer information.

[0019] From the length and width information, the two rows of data before and after the data mutation are extracted and processed; based on the data of the mutation part, the parameters required for cutting are obtained;

[0020] If chamfer information exists in the row data of the mutation, the rounded corners should be cut; if there is no chamfer information, there are no rounded corners, and they should be cut directly.

[0021] As a preferred embodiment, the method also includes generating a graphical display corresponding to the raw material processing data, the display content of which includes: a rectangle corresponding to the length of the raw material, cutting lines, and the lengths of the components segmented from the raw material.

[0022] As a preferred option, it also includes real-time monitoring during drilling and cutting operations on the steel profiles, including real-time monitoring of the 3D drilling machine, the cutting machine, and the locking machine.

[0023] As a preferred option, the data for real-time monitoring of 3D drilling includes:

[0024] The 3D drill magazine includes 3D position parameters, laser alignment reference, web height detection reference, engraving font, support duration, tool mode, drill diameter, drill length, tip compensation, feed rate, spindle speed, chip breaking depth, spindle retraction height, chip breaking time, engraving depth, and engraving speed.

[0025] As a preferred option, the real-time monitoring data of the cutting machine includes:

[0026] Maximum robot speed, maximum robot movement speed, deviation between laser detection and TCP point 3D coordinates, distance between photoelectric beam and host zero position, plasma arc initiation height, plasma cutting speed, plasma arc transition distance, and plasma kerf compensation.

[0027] Based on the same concept, a CNC steel drill cutting lock production software was also proposed, including a data import module, an automatic nesting and assembly module, and a raw material processing data output module.

[0028] The data import module extracts the process information for drilling and cutting the steel profiles from the DSTV file. The process information includes the length and quantity of the components.

[0029] The automatic nesting and assembly module automatically nests and assembles components based on their length, quantity, and the length of the raw material. The automatic nesting and assembly refers to assembling multiple NC1 parts corresponding to DSTV files into a raw material of a specified length and generating raw material processing data.

[0030] The raw material processing data output module outputs the raw material processing data to the industrial control computer that controls the drilling and cutting operations of the steel profile.

[0031] Based on the same concept, a CNC profiled steel drill and cutter lock production system was also proposed, including the aforementioned CNC profiled steel drill and cutter lock production software, a three-dimensional drilling system for profiled steel drill operation, and a cutting system for profiled steel cutting operation.

[0032] The CNC steel drilling and cutting software transmits the raw material processing data to the three-dimensional drilling system and the cutting system respectively.

[0033] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0034] This invention proposes a CNC steel section drilling and cutting production method, software, and system. Based on the obtained component length, quantity, and raw material length, it performs automatic nesting and combination to generate raw material processing data, and realizes automated production line processing of steel section based on the raw material processing data. Attached Figure Description

[0035] Figure 1 This is a flowchart of the CNC steel drilling and cutting production method in Embodiment 1 of the present invention;

[0036] Figure 2 This is a diagram of the main interface of the software in Embodiment 2 of the present invention;

[0037] Figure 3 This is a diagram of the customized component combination interface of the software in Embodiment 2 of the present invention;

[0038] Figure 4This is an example diagram of the customized component assembly interface in Embodiment 2 of the present invention, which combines 5 components from 12m of raw material;

[0039] Figure 5 This is an interface diagram of the automatic component assembly in Embodiment 2 of the present invention;

[0040] Figure 6 This is the automatic component assembly interface in Embodiment 2 of the present invention. Figure 2 ;

[0041] Figure 7 This is the automatically optimized calculation result diagram of the nesting in Embodiment 2 of the present invention;

[0042] Figure 8 This is an example Excel spreadsheet diagram of the components in Embodiment 2 of the present invention;

[0043] Figure 9 This is a graphical display interface diagram in Embodiment 2 of the present invention;

[0044] Figure 10 This is Example 2 of the graphical display interface diagram in Embodiment 2 of the present invention;

[0045] Figure 11 This is the production scheduling interface in Embodiment 2 of the present invention;

[0046] Figure 12 This is a diagram of the real-time monitoring interface for three-dimensional drilling in Embodiment 2 of the present invention;

[0047] Figure 13 This is a diagram of the real-time monitoring interface of the cutting machine in Embodiment 2 of the present invention;

[0048] Figure 14 This is the three-dimensional drilling parameter setting interface in Embodiment 2 of the present invention;

[0049] Figure 15 This is a diagram of the three-dimensional drill bit setting interface in Embodiment 2 of the present invention;

[0050] Figure 16 This is a diagram of the cutting machine parameter setting interface in Embodiment 2 of the present invention;

[0051] Figure 17 This is a diagram of the production schedule download interface in Embodiment 2 of the present invention;

[0052] Figure 18 This is the PLC data template diagram in Embodiment 2 of the present invention;

[0053] Figure 19 This is a schematic diagram of the operation panel and indicator lights of the CNC steel drilling and cutting lock production system control panel in Embodiment 3 of the present invention;

[0054] Figure 20This is a flowchart of the CNC steel drilling and cutting lock production system in Embodiment 3 of the present invention. Detailed Implementation

[0055] The present invention will now be described in detail with reference to the accompanying drawings.

[0056] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0057] Example 1

[0058] The CNC steel drilling and cutting production method, flowchart as follows: Figure 1 As shown, it includes the following steps:

[0059] Extract the process information for drilling and cutting the steel profiles from the DSTV file. The process information includes the length and quantity of the components.

[0060] Automatic nesting and assembly is performed based on the length and quantity of the components and the length of the raw materials. The automatic nesting and assembly refers to combining multiple NC1 parts corresponding to DSTV files into a raw material of a specified length and generating raw material processing data.

[0061] Drilling and cutting operations are performed on the steel profiles based on the raw material processing data.

[0062] As a preferred embodiment, the automatic nesting assembly includes the following steps:

[0063] The process information of the main profiles of the same components is placed in an array;

[0064] The component lengths in the array are sequentially superimposed to obtain the total length. When the total length is greater than the length of the raw material, a set of workpieces is completed and a PNC file is generated.

[0065] As a preferred embodiment, the length of the raw material is equal to the actual length of the raw material plus the processing allowance.

[0066] As a preferred approach, process information for drilling and cutting operations on structural steel is extracted from the DSTV file, specifically including:

[0067] Read CNC machining files generated by the steel structure design software TEKLA;

[0068] The CNC machining file is opened in text format, and key data is extracted to obtain process information.

[0069] As a preferred embodiment, the method also includes generating a graphical display corresponding to the raw material processing data, the display content of which includes: a rectangle corresponding to the length of the raw material, cutting lines, and the lengths of the components segmented from the raw material.

[0070] As a preferred option, it also includes real-time monitoring during drilling and cutting operations on the steel profiles, including real-time monitoring of the 3D drilling machine, the cutting machine, and the locking machine.

[0071] The reference side data includes three-dimensional position parameters of the three-dimensional drill bit library, laser alignment reference, web height detection reference, engraving font, support duration, tool mode, drill diameter, drill length, tool tip compensation, feed rate, spindle speed, chip breaking depth, spindle retraction height, chip breaking time, engraving depth, and engraving speed.

[0072] As a preferred option, the real-time monitoring data of the cutting machine includes:

[0073] Maximum robot speed, maximum robot movement speed, deviation between laser detection and TCP point 3D coordinates, distance between photoelectric beam and host zero position, plasma arc initiation height, plasma cutting speed, plasma arc transition distance, and plasma kerf compensation.

[0074] Example 2

[0075] The CNC steel drilling and cutting production software includes a data import module, an automatic nesting and assembly module, and a raw material processing data output module.

[0076] The data import module extracts process information for drilling and cutting operations on steel profiles from the DSTV file. This process information includes the length and quantity of the components. It can automatically recognize DSTV files (.nc1) generated by TEKLA software and automatically extract drilling and cutting process information from them.

[0077] The automatic nesting and assembly module automatically nests and assembles components based on their length, quantity, and the length of the raw material. This automatic nesting and assembly refers to combining multiple NC1 parts corresponding to DSTV files into a single raw material of a specified length and generating raw material processing data. Automated nesting is preferred, as it optimizes the nesting of components on 12m raw materials; manual nesting is also supported.

[0078] The raw material processing data output module outputs the raw material processing data to the industrial control computer that controls the production of steel drill and cut locks.

[0079] The software's operating system is WinXP / Win7 / Win10. The main interface of the software is as follows: Figure 2 As shown, the main interface includes the following parts:

[0080] The top is the menu bar, and below it is the corresponding shortcut toolbar;

[0081] The lower left corner is the program directory selection area and folder selection area: select the directory where the workpiece file is located;

[0082] The upper right corner displays the production schedule list and the component combination list, which respectively list the production schedule order and the component combination list;

[0083] The lower right corner is the graphic preview area: displaying the basic graphics of the selected workpiece file;

[0084] The menu includes:

[0085] Component assembly:

[0086] Manual component assembly: Enter the manual component assembly interface

[0087] Automatic Component Assembly: Enter the Automatic Component Assembly interface

[0088] Graphical display:

[0089] Single component graphic display: Select an nc1 file to display its graphic;

[0090] Component assembly graphic display: Select a PNC file (assembly component) to display its graphic;

[0091] Production schedule:

[0092] Production schedule generation: Enter the production schedule generation interface, where you can schedule production for task orders;

[0093] Production schedule download: Select a production schedule (pst file) in the production schedule list, click the production schedule download or the corresponding toolbar to download it to the PLC data area;

[0094] Real-time monitoring:

[0095] Full-line real-time monitoring: Enter the full-line real-time monitoring interface;

[0096] 3D Drilling Real-time Monitoring: Enter the 3D Drilling Standalone Real-time Monitoring Interface;

[0097] Cutting machine real-time monitoring: Enter the single-machine real-time monitoring interface of the cutting machine;

[0098] Locking machine real-time monitoring: Enter the locking machine single-machine real-time monitoring interface;

[0099] Parameter settings:

[0100] 3D Drilling Parameter Settings: Enter the 3D drilling single-machine parameter settings interface;

[0101] 3D Drill Tool Settings: Enter the 3D Drill Single Machine Tool Parameter Settings Interface;

[0102] Cutting machine parameter settings: Enter the single-machine parameter setting interface of the cutting machine;

[0103] Locking machine parameter settings: Enter the locking machine single-machine parameter settings interface;

[0104] Exit: Exit the program

[0105] The software's custom component assembly interface, such as Figure 3 As shown, the custom component assembly interface is used for manual component assembly.

[0106] On the main interface, click the toolbar corresponding to the "Manual Component Assembly" menu to enter the custom component assembly interface. The main function of this interface is to assemble multiple NC1 parts into a raw material of a specified length.

[0107] Click "File 1 Selection," select and open the file with the extension ".nc1" in the file dialog box, and extract relevant data, such as the component length, web height, flange height, web thickness, flange thickness, etc. (This data serves as the basis for the assembled component; if the selected component does not conform to this basic data, it cannot participate in the assembly). The nc1 file will then open in text format, with corresponding paragraph markers added in the background and displayed in the right-hand text editing box. Subsequently open "File 2 Selection," "File 3 Selection," and so on, appending data to the right-hand text box until the set raw material length is exceeded. Finally, click "Generate Assembly Program" to generate a machining program with the extension ".pnc."

[0108] Extracting relevant data from a ".nc1" file specifically includes the following steps:

[0109] First, import the ".nc1" file into the text box. This text box contains the outer contour data of the component, which includes the three-dimensional coordinates and radius of the points on the contour.

[0110] Secondly, the length of the component is calculated based on the outer contour data.

[0111] The Nc1 file defines its own parameter definitions and formats. According to the predefined parameters, the file name, material, specifications, component length, web height, flange height, web thickness, and flange thickness are read sequentially.

[0112] Then, the part starting with AK represents the outline array, AK v represents the web outline array, AK O represents the outline data of one side flange, AK U represents the outline data of the other side flange (the outline array is the data needed by the cutting machine), and BO represents the drilling data group. Each row of the drilling data group includes the x coordinate, y coordinate, and hole diameter length (these data are also used by 3D drilling).

[0113] Taking the outline array as an example, the first column is the length information (data in the y direction), the second column is the width (data in the x direction), and the third column is the chamfer R-angle data. In the first column of length information, the part less than half of the length is the material head data, and the part greater than half is the material tail data. If only the material tail information is used for cutting, only the material tail data needs to be extracted.

[0114] In the data at the tail of the material, look at the second column (data in the x-direction). If there is a sudden change in the second column (significant variation between the data above and below in the same column), the two rows of data before and after the change are the key information (i.e., the two rows of data where the change occurs are the critical values ​​of the contour data; the geometric information of the component to be processed can be obtained from these critical values, thus facilitating cutting). If there is a chamfered R-angle transition at the point of change, a rounded corner needs to be cut; otherwise, it can be cut directly. Similarly, in the data at the head of the material, it is also necessary to extract and process the two rows of data before and after the change; based on the data at the point of change, the parameters required for cutting can be obtained.

[0115] The KO data includes x, y, and z coordinates, which are used to draw lines. One KO array represents one drawn line.

[0116] The following points should be noted:

[0117] 1) The length of the raw material and the inter-process allowance must be entered first. The inter-process allowance refers to the cutting allowance between any two parts.

[0118] 2) Components 1-15 must be components of the same specification (only the length is different), otherwise an error will be reported.

[0119] 3) Each raw material can be combined into a maximum of 15 components.

[0120] 4) It is recommended to arrange components 1 to 15 in order of increasing length.

[0121] 5) An alarm will be automatically triggered when the combined length exceeds the length of the raw material, indicating overload.

[0122] An example of a custom component assembly interface for combining 5 components from 12m raw materials is shown below. Figure 4 As shown. Figure 4 The text on the right side of the interface explains: The original data comes from CNC machining files generated by the steel structure design software TEKLA, with the extension .nc1. The text box on the right opens the file in text format and allows extraction of key data. The method for extracting key data is the same as the steps described above for extracting relevant data from ".nc1" files. Multiple nc1 files have been merged and reorganized into a single text file for easier subsequent processing of machining data.

[0123] Click "File 1-5 Selection" to select the corresponding nc1 file. The text box on the right will then display text composed of multiple nc1 files. Clicking the "Generate Assembly Program" button will generate a component assembly file (.pnc), which represents a raw material processing program. Multiple processing programs can be generated sequentially using the above method.

[0124] Automatic component assembly interface, such as Figure 5 As shown, the automatic component assembly interface is used for automatic component assembly.

[0125] On the main interface, click the "Automatic Component Assembly" menu or the corresponding toolbar to enter the Automatic Component Assembly interface. The main function of this interface is to assemble all nc1 parts from the Excel spreadsheet into the raw material. The operation is as follows:

[0126] 1) The client shall provide an EXCEL spreadsheet in the specified format, which lists all the parts that need to be processed, including specifications, model, length, name, quantity, etc. Based on the specifications, model, length, name, and quantity, the corresponding component length, web height, flange height, web thickness, flange thickness, etc. can be obtained.

[0127] 2) Copy the table and all nc1 files into a directory.

[0128] 3) Click "Import Excel File", such as... Figure 6 As shown, the top left list displays a list of all the parts to be processed in this Excel spreadsheet.

[0129] 4) After importing the data, enter the raw material length and processing allowance in the nesting settings, and then click "Start Automatic Nesting". The system will automatically calculate the optimal nesting result. For example... Figure 7 As shown:

[0130] Summary information: Specifications and quantities of raw materials required for processing all parts, that is, the raw materials that the manufacturer needs to prepare to process these parts.

[0131] Nesting results – the optimal nesting arrangement for processing all parts. Each raw material represents a program, and each program includes its component combinations. The utilization rate of raw materials indicates the nesting efficiency.

[0132] At this point, the nesting results have been generated, and we will proceed to the next step.

[0133] 5) Click "Generate Files and Reports" to automatically generate PNC files. For each numbered raw material in the nesting results, a PNC program will be generated and automatically named according to the following naming convention: Specification + Number. A Worklist.dat report file will also be generated, which describes the component names included in each program.

[0134] The algorithm for automatic component assembly is:

[0135] When a large number of components require nesting and assembly, manually customizing component combinations becomes extremely inefficient. To address this issue, this automatic nesting module was developed based on data exported from the client's actual production design. The client will provide an Excel spreadsheet containing all components for each project. An example of the spreadsheet content is shown below. Figure 8 As shown.

[0136] Using this as the initial import data, the program first imports this Excel spreadsheet, forming an array. Then, this array is categorized and screened, placing components of the same specifications into a new array, ultimately forming a two-dimensional array. One dimension represents the specifications, and the other represents the number of components. For each component of the same specification, nesting is performed. The general algorithm is as follows: the pointer starts filtering from 0, placing component 0 into the raw materials and marking it as used. Then the pointer is incremented by 1, selecting component 1 and placing it into the raw materials. If it still does not exceed the length of the raw materials, it is marked as used, and the pointer is incremented by 1 again. If it exceeds the length of the raw materials, the pointer is incremented by 1 again, searching downwards, repeating the above process until all components have been traversed. If it still exceeds the length of the raw materials, then one nesting workpiece is completed, generating a PNC file for processing. The pointer is reset, and the algorithm continues to complete the second nesting workpiece according to the above rules, until all components are marked as used.

[0137] As a preferred solution, when performing nested material combination, the determination of the first component is random. After obtaining the first component, the length of the first component and the length of the raw material are known. The remaining length that can be arranged is obtained by subtracting the length of the first component from the length of the raw material. Then, one or more components that satisfy the remaining length that can be arranged are found in the array, so that the raw material is cut according to the combination and the expected value is minimized, so that each raw material is the optimal combination.

[0138] For example, if a raw material is 12 meters long, and the first component to be used in the layout is randomly selected (e.g., 4 meters), then the remaining possible lengths are 8 meters. In this case, we can find the component with the closest length of 8 meters in the array, or find multiple components in the array whose combined length is 8 meters.

[0139] As a preferred embodiment, a graphical display interface is also included, as shown in the figure below. Figure 9 As shown. In the main interface menu bar, clicking "Graphic Display" will enter the submenu "Single Component Graphic Display," which displays the graphic of each nc1 file. This allows users to easily view the graphic of each part, providing a reference for assembling and combining components. After entering the graphic display interface, clicking "Enter File Dialog Box" will open the file dialog box, where you can select the corresponding nc1 file.

[0140] In the component assembly list, select any PNC file, and then click "Graphic Display" to enter the submenu "Component Assembly Graphical Display" or the specified button in the toolbar to display the graphics of each assembled PNC file; you can zoom in, zoom out, or pan to display graphic details. Example 2 of the graphical display interface is shown below. Figure 10 As shown.

[0141] The raw material processing data output module generates raw material processing data, which is then output to the industrial control computer controlling the production of the steel drill and cutter lock in the form of a production schedule. The production scheduling interface is as follows: Figure 11 As shown.

[0142] To access the production scheduling interface, click "Production Schedule" in the main menu, then click "Generate Production Schedule" or the corresponding shortcut toolbar.

[0143] In the production scheduling interface, simply drag and drop the pre-assembled PNC file into the text box on the right to generate a processing sequence. This sequence is saved as a production schedule with the extension .pst. A production schedule must contain at least one PNC file.

[0144] It is recommended to divide a project into several production schedules according to specifications and models to facilitate management and production scheduling.

[0145] After the production schedule is generated, it can be seen in the "Production Schedule List" box on the main interface. Select a production schedule and click "Production Schedule Download" or the shortcut toolbar to download it to the PLC.

[0146] As a preferred option, the software also includes a real-time monitoring interface. On the main interface, clicking on "Real-time Monitoring" in the menu bar, followed by "Full-line Real-time Monitoring," "3D Drilling Real-time Monitoring," "Cutting Machine Real-time Monitoring," and "Sealing Machine Real-time Monitoring," will take you to the respective monitoring interface. The 3D drilling real-time monitoring interface is shown in the image below. Figure 12 As shown in the figure, the real-time monitoring interface of the cutting machine is as follows. Figure 13 As shown.

[0147] The monitoring interface allows you to view the status of each machine tool in real time, including coordinate values, alarm information, execution steps, current program number, and other information.

[0148] As a preferred option, the software also includes a system parameter setting interface for the machine tool. On the main interface, clicking on "Parameter Settings" in the menu bar, followed by "3D Drilling Parameter Settings," "3D Drilling Tool Settings," "Cutting Machine Parameter Settings," and "Sealing Machine Parameter Settings," will take you to the respective parameter setting interface. The 3D drilling parameter setting interface is shown below. Figure 14 As shown in the figure, the three-dimensional drill tool settings interface is as follows: Figure 15 As shown in the figure, the parameter setting interface of the cutting machine is as follows. Figure 16 As shown. Before blanking, the system parameters of the machine tool, such as "3D drilling parameter settings", "3D drilling tool settings", and "cutting machine parameter settings", need to be initialized before blanking production can be completed.

[0149] In the parameter settings interface, to modify the parameters, you must first click "Read Online", then click "Modify", and finally click "Write Online".

[0150] In the 3D drilling parameter setting interface, the parameters in the three list boxes—Reference Side (LF), Upper Element (Web), and Moving Side (RF)—are 3D drill library parameters, as detailed below:

[0151] Tool(X): Indicates the tool magazine's position on the X-axis.

[0152] Tool(Y): Indicates the position of the tool magazine on the Y-axis.

[0153] Tool(Z): Indicates the tool magazine's position on the Z-axis.

[0154] Other parameters:

[0155] Laser alignment reference: indicates the distance of the laser alignment from the principal axis X=0;

[0156] Abdominal height detection benchmark: indicates the distance between the abdominal plate detection probe and the end face of the upper unit spindle;

[0157] Engraving font: Indicates the font size for the engraving; two sizes are available.

[0158] Support duration: Indicates the time delay of the web support lifting up.

[0159] The parameters in the 3D drill tool settings interface are defined as follows:

[0160] Mode: Function selection for tools T1-T4. Mark indicates marking / scribing tool; Drill indicates drilling tool; Test indicates the tool is used for dot testing; Tapping indicates tapping tool; Slot indicates the tool is used for milling slotted holes;

[0161] Drill bit diameter: The diameters of cutting tools T1-T4 cannot be the same.

[0162] Drill bit length: This setting must be accurate, as this parameter determines the position from rapid advance to working feed.

[0163] Tool tip compensation: Drilling depth equals workpiece thickness plus tool compensation value.

[0164] Feed rate: The speed at which drilling is performed.

[0165] Spindle speed: The spindle speed during drilling.

[0166] Chip breaking depth: Chip breaking depth per feed, spindle pause time for chip breaking. Set to 0 if chip breaking is not required.

[0167] Spindle retraction height: The height at which the drill bit exits the workpiece after drilling is completed.

[0168] Chip breaking time: The pause time during chip breaking.

[0169] Carving depth: The depth (force) of the cut when carving words / lines.

[0170] Engraving speed: The feed rate for engraving / scribing.

[0171] The parameters in the cutting machine parameter setting interface are defined as follows:

[0172] Robot maximum speed: Sets the maximum operating speed of the robot's joint axis during idle travel;

[0173] Maximum robot movement speed: Sets the maximum lateral movement speed of the robot;

[0174] Laser Detection and TCP X-axis Distance: Sets the displacement deviation value between the laser detection point and the TCP point in the X-axis direction;

[0175] Laser detection and TCP Y-axis distance: Set the displacement deviation value between the laser detection point and the TCP point in the Y direction;

[0176] Laser detection and TCP Z-axis distance: Set the displacement deviation value between the laser detection point and the TCP point in the Z-axis;

[0177] Photoelectric beam distance from the host: Set the distance between the photoelectric beam switch and the zero position of the X-axis of the robot workpiece coordinate system;

[0178] Plasma arc initiation height: Sets the cutting distance between the plasma torch head and the workpiece surface;

[0179] Plasma cutting speed: The plasma cutting speed is set according to the thickness of the workpiece;

[0180] Plasma arc ignition transition distance: (Internal parameter, no modification required);

[0181] Plasma kerf compensation: The kerf compensation is determined based on the radius of the plasma flame.

[0182] Example 3

[0183] The CNC steel drilling and cutting lock production system includes the aforementioned CNC steel drilling and cutting lock production software, a three-dimensional drilling system for steel drilling operations, a cutting system for steel cutting operations, and a locking machine for steel locking. The CNC steel drilling and cutting lock production software transmits the raw material processing data to the three-dimensional drilling system, the cutting system, and the locking machine, respectively.

[0184] The data exchanged between the CNC steel drill cutting lock production software and the 3D drilling system, cutting system, and lock machine is mainly the production schedule.

[0185] On the main interface, select a production schedule (pst file) and click "Download Production Schedule" to send the production schedule to each machine tool. The production schedule download interface is shown in the image below. Figure 17 As shown, the data processing procedure is as follows: Open the PST file and parse it line by line. Each line represents a PNC file. Open each PNC file sequentially and parse it according to the TEKLA rules and protocol to extract the processing data. For example, the BO field represents drilling information, containing drilling coordinate values; the AK field represents the outline information, which can be used for cutting data; the KO field represents scribing data, etc. The above data is extracted in coordinate form and converted into hexadecimal data. Combined with the Siemens S7 communication protocol, it is packaged into frame-by-frame communication data and sent to the PLC's data template area. The PLC executes this template data sequentially to complete the processing. The PLC data template is as follows: Figure 18 As shown, the PLC data template includes:

[0186] WorkPieceLength: Workpiece length

[0187] WorkPieceHeight: Workpiece height

[0188] WorkPieceWidth: Workpiece width

[0189] WorkPieceThickness: Workpiece flange thickness

[0190] Workpiece web thickness

[0191] WorkPieceID: Workpiece Number

[0192] WorkPieceFlag: Workpiece type flag

[0193] FeedPStep: number of feeds

[0194] PartName (0-14): Names of components contained in the workpiece

[0195] PartLength (0-14): The length of the components contained in the workpiece.

[0196] FixData (0-1199): Reference side machining data area

[0197] MovData (0-1199): Mobile side processing data area

[0198] TopData (0-1199): Data area processed by the previous unit

[0199] FeedData (0-299): Feed data area.

[0200] For ease of operation, a control cabinet and operating console are also incorporated into the CNC steel drill cutting lock production system. This requires a 100KVA AC 380V power supply, which enters the control cabinet via the main power switch QF1. The AC 380V power supply powers the spindle motor, servo motor, oil pump motor, and chip conveyor motor, etc.; the AC 380V is converted to AC 220V control power by a control transformer, supplying the control circuitry, DC 24V switching power supply, spindle fan, and electrical cabinet air conditioning, etc. Two DC 24V switching power supplies are provided: one for solenoid valves, air valves, and lighting; and the other for servo drives, PLC, indicator lights, and proximity switches.

[0201] The control panel includes an industrial PC and a Siemens MCP483C standard control panel. The industrial PC is used for workpiece programming and real-time machine tool monitoring, while the Siemens control panel enables all machine tool operations. Both are connected to the control system via an Ethernet bus, interacting with the main control system through communication.

[0202] The control panel and indicator lights on the control panel, such as Figure 19 As shown, the functions of the indicator lights are described below:

[0203] 1. DC24V: When this light is on, it indicates that the control system of this device is powered on and started.

[0204] 2. Spindle Safety: When this light is on, it indicates that the three spindles have exited the drilling position and entered the safe standby position.

[0205] 3. Fault Alarm: When this light is on, it indicates that there is a fault in the system. At this time, please refer to the specific fault information on the monitoring interface and press the Reset button to reset the alarm.

[0206] 4. 3D Drill Emergency Stop (Red Mushroom Head Button): This button is for emergency stop of the 3D drill machine only. It is used to quickly stop the 3D drill machine in an emergency. When this button is pressed, the 3D drill will enter the stop state. This button is a self-locking button; it will not automatically spring back after being pressed. You need to manually rotate the mushroom head clockwise to make it spring back (return to its original position). Note that this button cannot cause a full-line emergency stop.

[0207] 5. Manual tool selection: This switch selects the tool number to be used when manually changing tools.

[0208] The functions of the buttons on the control panel are as follows:

[0209] 1. Emergency Stop for the Entire Line (Red Mushroom Head Button): This button is used for rapid shutdown in an emergency situation for the entire line; when this button is pressed, all equipment on the entire line will enter the shutdown state; this button is a self-locking button, and it will not automatically spring back after being pressed. It is necessary to manually rotate the mushroom head clockwise to make it spring back (return to its original position).

[0210] 2. System Start (Key Switch): Connects the system control power supply.

[0211] 3. JOG: Select the operation mode as manual. In this mode, you can manually move each axis, manually drill holes, and manually change tools. F4 can perform manual band positioning operation.

[0212] 4. TEACH IN: Select the operation mode as teaching operation. You can use the handwheel to move each axis, pull / release the tool, etc. F4 can perform continuous manual positioning operation.

[0213] 5. MDA: Select the semi-automatic operation mode, that is, the 3D drilling will operate automatically on its own and will not be associated with other equipment.

[0214] 6. AUTO: Select the fully automatic operation mode. When the automatic start conditions are met, the entire line will start automatically with one click.

[0215] 7. One-button start for peripheral equipment: Start / stop all peripheral equipment, including hydraulic systems, chip removal systems, etc. Indicator lights will illuminate when starting.

[0216] 8. REF.: Used for internal debugging at the manufacturer's origin.

[0217] 9. Initial position of 3D drilling: (Reserved for future reference)

[0218] 10. Pause / Restart 3D Drilling: (Keep this function for future reference)

[0219] 11. Initial position of the cutting machine: (Reserved for future reference)

[0220] 12. Cutting machine pause / restart: (Reserved for future use)

[0221] 13. Initial position of the locking machine: (Reserved for future reference)

[0222] 14. Pause / Restart Locking Machine: (Reserved for future use)

[0223] 15. RESET: Alarm reset button. If the fault light is on, it indicates that there is a fault in the system. In this case, please refer to the specific fault information on the monitoring interface and press this button to reset the alarm.

[0224] 16. Breakpoint Memory: This button saves the breakpoint pointer. During automatic operation, if the program is interrupted due to power failure, malfunction, maintenance, or other reasons, pressing this button will automatically save the breakpoint. The corresponding indicator light will illuminate. When the device restarts, simply press "Auto Start," and the device will automatically resume from the breakpoint. After the device restarts, press this button again to disable automatic breakpoint memory.

[0225] 17. CYCLE STOP: The indicator light flashes to indicate that the system is in automatic mode and paused. Press this button to stop the equipment during automatic processing.

[0226] 18. CYCLE START: When the indicator light is on, it means that the equipment is ready to start automatically. Pressing the button will allow the equipment to enter the automatic processing step. When this light is off, it means that the equipment is not ready to start automatically and cannot perform the automatic processing step. When the indicator light is flashing, it means that the system is in automatic operation.

[0227] 19. Cooling pump: Manually start / stop the cooling system; indicator light illuminates when starting.

[0228] 20. Booster Pump: Manually start / stop the chip conveyor coolant return motor; the indicator light will illuminate when starting.

[0229] 21. Lighting: Manually turn on the machine tool lighting system.

[0230] 22. Reference Side Drilling / Cancel: In manual mode, operate the reference side unit (LF) power head by pressing this button to alternately perform drilling / cancel drilling actions; in automatic mode, cancel the current drilling.

[0231] 23. Upper Unit Drilling / Cancellation: In manual mode, operate the upper unit (W) power head by pressing this button to alternately perform drilling / cancellation drilling actions; in automatic mode, cancel the current drilling.

[0232] 24. Moving Side Drilling / Cancel: In manual mode, operate the moving side unit (RF) power head by pressing this button to alternately perform drilling / cancel drilling actions; in automatic mode, cancel the current drilling.

[0233] 25. Horizontal pressing: Manually control the horizontal pressing.

[0234] 26. Horizontal release: Manually control the horizontal material release.

[0235] 27. Vertical pressing: Manually control the vertical pressing.

[0236] 28. Vertical release: Manually control the vertical release of the pressure material.

[0237] 29. Web support extension: Manually control the web support to rise / fall (BDMH750 does not have this device).

[0238] 30. F4 Material Ejection: Manually control the F4 material ejection / drop.

[0239] 31. Trolley clamping: Press this button manually to clamp the trolley and the indicator light will illuminate. Press it again to release and the indicator light will turn off.

[0240] 32. Side Push: In manual mode, press this button to push the material to the side of the feed channel.

[0241] 33. Detection system: Turn on / off the abdominal width and abdominal height detection function.

[0242] 34. Reference Side Selection: Selects the reference side unit operation, serving as the master switch for selecting all manual operations on the reference side.

[0243] 35. Upper Unit Selection: Selects the upper unit operation, serving as the master switch for selecting all manual operations in the upper unit.

[0244] 36. Mobile Side Selection: Selects the mobile side unit operation, serving as the master switch for selecting all manual operations on the mobile side.

[0245] 37. X: In manual mode, combine with the gating unit button to select the X-axis of the corresponding unit.

[0246] 38. Y: In manual mode, combine with the gating unit button to select the Y-axis of the corresponding unit.

[0247] 39. Z: In manual mode, use the gating unit button to select the Z-axis of the corresponding unit.

[0248] 40. Cart Feeding: In manual mode, select the forward and reverse axes of the feeding trolley.

[0249] 41. Cart Up / Down: In manual mode, select the up / down axis of the feeding trolley clamp.

[0250] 42. Web support movement: In manual mode, select the web support movement axis.

[0251] 43. F4 Lateral Channel: Select F4 lateral movement axis in manual or teach mode.

[0252] 44. Discharge longitudinal channel: In manual mode, select the inlet / outlet channel for the finished workpiece.

[0253] 45. Manual tool change: In manual mode, the tool change is manually started by selecting the corresponding strobe unit. When changing the tool, first put the tool on the spindle back into the tool magazine, and then take the tool selected by the tool selection knob.

[0254] 46. ​​-: In manual mode, move the selected axis in the direction of decreasing coordinate.

[0255] 47. RAPID: (Reserved for future use)

[0256] 48. +: In manual mode, move the selected axis in the direction of increasing coordinate.

[0257] 49. Spindle Override: (Keep for future reference)

[0258] 50. FEED OVERRIDE: Adjusts the percentage of feed rate.

[0259] 51. Spindle Stop: (Keep for future reference)

[0260] 52. Spindle Start: (Keep this for future reference)

[0261] 53. FEED STOP: (Keep this for future reference)

[0262] 54. FEED START: (This button is reserved for future use; the corresponding indicator light shows that the servo system is on.)

[0263] The process flow diagram of the CNC steel drill-cut lock production system is as follows: Figure 20 As shown, it includes the following steps:

[0264] 1. Power on the system, including turning on the main power, control system, and host PC. Wait until all panel lights stop flashing, indicating that the PLC has started. Wait for the FEED START indicator light on the panel to start flashing, indicating that the servo has established communication with the PLC. If all servos are enabled, the FEED START indicator light will become solid.

[0265] 2. Open the host computer control software, edit the program, and transfer the data to the PLC data area.

[0266] For detailed instructions, please refer to the full manual and the host computer software programming guide.

[0267] 3. Manual test drilling

[0268] Pressing the manual drilling button for each drilling unit will initiate manual drilling. Pressing the manual drilling button during rapid advance or feed will cancel the current drilling operation and initiate a rewind.

[0269] Manual drilling conditions: Manual mode, tool magazine safe, hydraulic start, servo no alarm or limit, frequency converter no alarm, all parts not interlocked, PLC has processing data, material clamping, cooling no low liquid level alarm.

[0270] 4. Automatic operation

[0271] 1) Place the workpiece to be processed on the F4 transverse feed channel or the longitudinal feed channel to meet the automatic processing conditions.

[0272] To determine if automatic processing is possible: Press the "Automatic" button on the control panel, and the "CYCLESTART" indicator light on the control panel should remain constantly lit; otherwise, check the status on the monitoring screen.

[0273] Automatic operation conditions: Automatic mode, material in F4 horizontal feed station 4 or material in the longitudinal feed feed channel, upper unit spindle is located in the processing area, hydraulic start, servo no alarm or limit, frequency converter no alarm, all parts are not interlocked, spindle is safe, no material is being pressed, tool magazine is safe, PLC has processing data, cooling system has no low liquid level alarm.

[0274] 2) Start automatic operation

[0275] Press the "CYCLE START" button on the operation panel. First, the horizontal feed is executed. After the material is fed to the vertical feed, the pushing action is executed. The side pusher holds the material in place. Then, the trolley clamp automatically adjusts its height according to the material specifications. After the adjustment and positioning are completed, the trolley approaches the workpiece at a low speed. When the workpiece enters the throat of the trolley clamp, the induction switch automatically sends a signal, the trolley stops moving forward, and the clamping action is executed. After clamping the workpiece, the side pusher is released, and the trolley clamping the workpiece begins to feed towards the main machine at a higher speed. When the workpiece passes the photoelectric photoelectric switch, it stops and then slowly retreats at a low speed until it exits the photoelectric photoelectric switch. At the moment of exiting the photoelectric photoelectric switch, the zero point of the material end is obtained, and automatic feeding begins. Processing begins.

[0276] 3) Processing completed

[0277] After the workpiece is finished, the "CYCLE START" indicator light will remain constantly lit.

[0278] 4) Process pause during processing

[0279] If the process needs to be paused for any reason during processing, simply press the "CYCLE STOP" button, and the equipment will enter a paused state, with the "CYCLE START" indicator light flashing. To resume processing, simply press the "CYCLE START" button again.

[0280] 5) Cancel the hole being drilled.

[0281] During drilling, you can cancel the hole being drilled by pressing the "Reference Side Drill / Cancel" / "Upper Unit Drill / Cancel" / "Move Side Drill / Cancel" buttons on the operation panel. You can also cancel the hole that is about to be drilled using these buttons. Operation method: After positioning, press the drill cancel button on the side you want to cancel drilling on during spindle rapid traverse or drilling. To cancel drilling in the upper unit, press the "Upper Unit Drill / Cancel" button during upper unit spindle rapid traverse or drilling.

[0282] 6) Handling interruptions during automated machining processes

[0283] During processing, various reasons may necessitate switching the equipment to manual mode. Upon switching to manual mode, the current automatic machining program is interrupted and terminated (the automatic machining program is automatically terminated whenever the system switches from automatic to manual mode). If the workpiece is not fully processed and needs to be reprocessed next time, it needs to be re-fed (see previous related operations). The required procedure is as follows: Press the "Power-Off Memory" button, then return the material, and then press "Automatic Start".

[0284] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A CNC steel drilling and cutting production method, characterized in that, Includes the following steps: Extract the process information for drilling and cutting the steel profiles from the DSTV file. The process information includes the length and quantity of the components. Automatic nesting and assembly is performed based on the length and quantity of the components and the length of the raw materials. The automatic nesting and assembly refers to combining multiple NC1 parts corresponding to DSTV files into a raw material of a specified length and generating raw material processing data. Drilling and cutting operations are performed on the steel profiles based on the raw material processing data. The automatic nesting and assembly uses an automatic component assembly algorithm, which specifically includes the following steps: The original process information is formed into an array. This array is then categorized and screened, with components of the same specifications placed into a new array, resulting in a two-dimensional array. One dimension represents the specifications, and the other represents the number of components. For each component of the same specification, nesting is performed. The algorithm is as follows: the pointer starts filtering from 0, placing component 0 into the raw materials and marking it as used. Then the pointer is incremented by 1, and component 1 is selected and placed into the raw materials. If the length still does not exceed the length of the raw materials, it is marked as used, and the pointer is incremented by 1 again. If it exceeds the length of the raw materials, the pointer is incremented by 1 again, and the process is repeated until all components have been traversed and the length still exceeds the length of the raw materials. A nesting workpiece is then completed, and a PNC file is generated for processing. The pointer is reset, and the algorithm continues to complete the second nesting workpiece, until all components are marked as used. When performing nested material combination, the determination of the first component is random. After obtaining the first component, the length of the first component and the length of the raw material are known. The remaining length that can be arranged is obtained by subtracting the length of the first component from the length of the raw material. Then, one or more components that satisfy the remaining length that can be arranged are found in the array, so that the raw material is cut according to the combination and the remaining material is minimized. Extract the process information for drilling and cutting the steel profiles from the DSTV file, specifically including: Read CNC machining files generated by the steel structure design software TEKLA; Open the CNC machining file in text format and extract key data to obtain process information; The extracted key data includes an array of outlines for cutting, hole diameter length and hole diameter coordinates for drilling, and data for drawing lines. The extraction of key data includes the following steps: Locate the outline array from the Nc1 file; the outline array includes length information, width information, and chamfer information. From the length and width information, the two rows of data before and after the data mutation are extracted and processed; based on the data of the mutation part, the parameters required for cutting are obtained; If chamfer information exists in the row data of the mutation, the rounded corners should be cut; if there is no chamfer information, there are no rounded corners, and they should be cut directly. In the data of the material tail or the material head section, if there is a sudden change in the second column of data, the two rows of data before and after the change are the critical values ​​of the contour data. The point of change has a transition with a chamfer R-angle. If there is a transition with an R-angle, the rounded corner needs to be cut. If there is no R-angle transition, it can be cut directly.

2. The CNC steel drilling and cutting production method as described in claim 1, characterized in that, The automatic nesting and dispensing assembly includes the following steps: The process information of the main profiles of the same components is placed in an array; The component lengths in the array are sequentially superimposed to obtain the total length. When the total length is greater than or equal to the length of the raw material, a set of workpieces is completed and a PNC file is generated.

3. The CNC steel drilling and cutting production method as described in claim 2, characterized in that, The length of the raw material is equal to the actual length of the raw material plus the processing allowance.

4. The CNC steel drilling and cutting production method according to any one of claims 1-3, characterized in that, It also includes generating a graphical display corresponding to the raw material processing data, the display content of which is: a rectangle corresponding to the length of the raw material, cutting lines, and the length of the components segmented from the raw material.

5. The CNC steel drilling and cutting production method according to any one of claims 1-3, characterized in that, It also includes real-time monitoring of drilling and cutting operations on steel profiles, including real-time monitoring of 3D drilling, cutting machines, and locking machines.

6. The CNC steel drilling and cutting production method as described in claim 5, characterized in that, The data from the real-time monitoring of the 3D drilling system includes: The 3D drill magazine includes 3D position parameters, laser alignment reference, web height detection reference, engraving font, support duration, tool mode, drill diameter, drill length, tip compensation, feed rate, spindle speed, chip breaking depth, spindle retraction height, chip breaking time, engraving depth, and engraving speed.

7. The CNC steel drilling and cutting production method as described in claim 6, characterized in that, Real-time monitoring data for the cutting machine includes: Maximum robot speed, maximum robot movement speed, deviation between laser detection and TCP point 3D coordinates, distance between photoelectric beam and host zero position, plasma arc initiation height, plasma cutting speed, plasma arc transition distance, and plasma kerf compensation.

8. CNC steel drilling and cutting lock production software, characterized in that, It includes a data import module, an automatic nesting and assembly module, and a raw material processing data output module. The data import module extracts the process information for drilling and cutting the steel profiles from the DSTV file. The process information includes the length and quantity of the components. The automatic nesting and assembly module automatically nests and assembles materials according to the length and quantity of the components and the length of the raw materials. The automatic nesting and assembly refers to assembling multiple NC1 parts corresponding to multiple DSTV files into a raw material of a specified length and generating raw material processing data. The raw material processing data output module outputs the raw material processing data to the industrial control computer that controls the drilling and cutting operations of the steel profile.

9. A CNC steel drill-cutting lock production system, characterized in that, This includes the CNC steel profile drilling and cutting lock production software as described in claim 8, the three-dimensional drilling system for steel profile drilling operations, and the cutting system for steel profile cutting operations. The CNC steel drilling and cutting software transmits the raw material processing data to the three-dimensional drilling system and the cutting system respectively.

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