A method for compensating for circular arc processing of a rope saw

Abstract

This invention provides a compensation method, device, equipment, and medium for wire sawing in circular arc machining, relating to the field of CNC machining technology. The method includes: creating a dynamic balance model of wire saw bending parameters using various parameters affecting the degree of wire saw bending; adjusting various parameters under reference machining conditions; automatically calculating a reference percentage using the dynamic balance model of wire saw bending parameters; testing the reference lag distance of the wire saw; and using the reference lag distance as a reference compensation value to compensate for the coordinates of the theoretical trajectory point; during machining, when parameters change and new machining conditions arise, automatically calculating the real-time percentage using the dynamic balance model of wire saw bending parameters; calculating the real-time lag distance based on the reference percentage, reference lag distance, and real-time percentage; and using the real-time lag distance as a real-time compensation value to compensate for the coordinates of the theoretical trajectory point. The advantages of this invention are: it can effectively achieve automatic compensation for circular arc machining, improving machining accuracy.

Description

Technical Field

[0001] This invention relates to the field of CNC machining technology, and in particular to a compensation method for wire sawing of circular arcs. Background Technology

[0002] A wire saw (also known as a beaded wire saw) is a tool used for cutting and demolishing materials such as mines, raw blocks, curved slabs, large stone slabs, thick concrete, irregular reinforced concrete, bridges, and roads. For example... Figure 1 As shown, the structure of the wire saw 100 is to sinter diamond particles onto beads, press multiple beads onto a steel wire rope at a certain interval, and then use a metal connector to connect the two ends of the steel wire rope together to form a ring structure. The drive device 200 is used to drive the wire saw 100 to move and achieve cutting.

[0003] A wire saw is a 2D machining tool that can cut workpieces (such as stone) into curved surfaces with a two-dimensional profile. Figure 2 As shown, guide wheels 300 are set on both sides of the processing section of the wire saw 100, and the guide wheels 300 always follow the cutting direction of the curve and press perpendicularly to the cutting direction. In other words, the pressing direction of the guide wheel 300 is consistent with the cutting direction.

[0004] Because wire saws possess a certain degree of flexibility, during actual cutting, they bend due to the reverse force from the workpiece. This causes a lag between the actual cutting point and the theoretical trajectory coordinates; the cutting line between the wire saw and the workpiece is not a straight line but an arc, and this deviation gradually increases from the sides of the workpiece towards the center. This significantly impacts the machining accuracy. Therefore, to reduce the impact of the wire saw's bending on machining accuracy, a method for automatically compensating for the arc machining of the wire saw is urgently needed. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a compensation method for the circular arc machining of wire saws, thereby solving the problem that the machining accuracy is affected by the flexible bending of existing wire saws.

[0006] In a first aspect, the present invention provides a compensation method for wire sawing of circular arcs, the method comprising the following steps:

[0007] By utilizing various parameters that affect the bending degree of the wire saw, a parametric dynamic equilibrium model for the bending of the wire saw is created.

[0008] Under reference processing conditions, adjust all parameters, and automatically calculate a reference percentage based on the reference processing conditions using the parameter dynamic balance model of wire saw bending. Under the reference processing conditions, test the reference hysteresis distance of the wire saw, use the reference hysteresis distance as a reference compensation value to compensate the coordinates of the theoretical trajectory point to obtain the reference compensation trajectory point coordinates, and control the wire saw to process according to the reference compensation trajectory point coordinates.

[0009] During the processing, when parameters change and new processing conditions are generated, the wire saw bending parameter dynamic balance model automatically calculates a real-time percentage based on the new processing conditions. It also calculates the real-time lag distance based on the reference percentage, reference lag distance, and real-time percentage. The real-time lag distance is used as the real-time compensation value to compensate the theoretical trajectory point coordinates to obtain the real-time compensated trajectory point coordinates. The wire saw is then controlled to perform processing based on the real-time compensated trajectory point coordinates.

[0010] Furthermore, the calculation of the real-time lag distance based on the reference percentage, reference lag distance, and real-time percentage specifically involves:

[0011] Assume the reference percentage is RV%, the reference lag distance is RVS, the real-time percentage is CV%, and the real-time lag distance is L;

[0012] The real-time lag distance L is calculated using the following formula (1):

[0013]

[0014] Furthermore, the specific steps of using the real-time lag distance as a real-time compensation value to compensate for the theoretical trajectory point coordinates to obtain the real-time compensated trajectory point coordinates are as follows:

[0015] The real-time compensation values ​​ΔX and ΔY of the X-axis and Y-axis of the theoretical trajectory points are calculated using the following equations (2) and (3), respectively:

[0016] △X=X+L*COS(RADIANS(A-90)) (2)

[0017] △Y=Y+L*SIN(RADIANS(A-90)) (3)

[0018] Where L represents the real-time lag distance, A represents the angle of the guide wheel in the wire saw, X represents the X-axis coordinate value of the theoretical trajectory point, and Y represents the Y-axis coordinate value of the theoretical trajectory point.

[0019] The coordinates of the compensation trajectory points in real time after compensation are calculated using the following equations (4) and (5):

[0020] X(CV)=△X+X (4)

[0021] Y(CV)=△Y+Y (5)

[0022] Where X(CV) represents the X-axis coordinate value of the real-time compensated trajectory point after compensation, and Y(CV) represents the Y-axis coordinate value of the real-time compensated trajectory point after compensation.

[0023] Furthermore, the specific steps for creating a parametric dynamic equilibrium model for wire saw bending using various parameters affecting the degree of wire saw bending are as follows:

[0024] Identify the parameters affecting the bending degree of the wire saw; represent each parameter individually using a first rectangle of the same height but different widths, and combine all the first rectangles of the parameters into a second rectangle; within each first rectangle, use a third rectangle to draw a given appropriate range of the parameter corresponding to that first rectangle, and the third rectangle spans the entire width of the first rectangle; obtain a percentage by dividing the sum of the areas of all third rectangles by the area of ​​the second rectangle, thereby creating a parametric dynamic equilibrium model of the wire saw bending.

[0025] Secondly, the present invention provides a compensation device for wire sawing of circular arcs, the device comprising a model creation module, a reference module and a real-time compensation module.

[0026] The model creation module is used to create a parametric dynamic equilibrium model of the wire saw bending by utilizing various parameters that affect the degree of wire saw bending.

[0027] The reference module is used to adjust various parameters under reference processing conditions. It automatically calculates a reference percentage based on the reference processing conditions through the dynamic balance model of the wire saw bending parameters, and tests the reference hysteresis distance of the wire saw under the reference processing conditions. The reference hysteresis distance is used as a reference compensation value to compensate the coordinates of the theoretical trajectory point to obtain the reference compensation trajectory point coordinates. The wire saw is then controlled to perform processing based on the reference compensation trajectory point coordinates.

[0028] The real-time compensation module is used to automatically calculate a real-time percentage based on the new processing conditions when parameters change during processing. This is achieved through a dynamic balance model of the wire saw bending parameters. The module also calculates the real-time lag distance based on the reference percentage, reference lag distance, and real-time percentage. The real-time lag distance is then used as the real-time compensation value to compensate the theoretical trajectory point coordinates, resulting in the real-time compensated trajectory point coordinates. Finally, the wire saw is controlled to perform processing based on the real-time compensated trajectory point coordinates.

[0029] Furthermore, the calculation of the real-time lag distance based on the reference percentage, reference lag distance, and real-time percentage specifically involves:

[0030] Assume the reference percentage is RV%, the reference lag distance is RVS, the real-time percentage is CV%, and the real-time lag distance is L;

[0031] The real-time lag distance L is calculated using the following formula (1):

[0032]

[0033] Furthermore, the specific steps of using the real-time lag distance as a real-time compensation value to compensate for the theoretical trajectory point coordinates to obtain the real-time compensated trajectory point coordinates are as follows:

[0034] The real-time compensation values ​​ΔX and ΔY of the X-axis and Y-axis of the theoretical trajectory points are calculated using the following equations (2) and (3), respectively:

[0035] △X=X+L*COS(RADIANS(A-90)) (2)

[0036] △Y=Y+L*SIN(RADIANS(A-90)) (3)

[0037] Where L represents the real-time lag distance, A represents the angle of the guide wheel in the wire saw, X represents the X-axis coordinate value of the theoretical trajectory point, and Y represents the Y-axis coordinate value of the theoretical trajectory point.

[0038] The coordinates of the compensation trajectory points in real time after compensation are calculated using the following equations (4) and (5):

[0039] X(CV)=△X+X (4)

[0040] Y(CV)=△Y+Y (5)

[0041] Where X(CV) represents the X-axis coordinate value of the real-time compensated trajectory point after compensation, and Y(CV) represents the Y-axis coordinate value of the real-time compensated trajectory point after compensation.

[0042] Furthermore, the model creation module specifically comprises:

[0043] Identify the parameters affecting the bending degree of the wire saw; represent each parameter individually using a first rectangle of the same height but different widths, and combine all the first rectangles of the parameters into a second rectangle; within each first rectangle, use a third rectangle to draw a given appropriate range of the parameter corresponding to that first rectangle, and the third rectangle spans the entire width of the first rectangle; obtain a percentage by dividing the sum of the areas of all third rectangles by the area of ​​the second rectangle, thereby creating a parametric dynamic equilibrium model of the wire saw bending.

[0044] Thirdly, the present invention provides an electronic device including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the program to implement the method described in the first aspect.

[0045] Fourthly, the present invention provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the method described in the first aspect.

[0046] One or more technical solutions provided in the embodiments of the present invention have at least the following technical effects or advantages:

[0047] 1. By creating a parametric dynamic balance model for wire saw bending, and testing the reference hysteresis distance of the wire saw under reference processing conditions, and calculating the reference percentage using the parametric dynamic balance model for wire saw bending, when parameters change and new processing conditions arise, the parametric dynamic balance model for wire saw bending can automatically output the real-time percentage. Based on the reference percentage, reference hysteresis distance, and real-time percentage, the real-time hysteresis distance is pre-calculated and used as a real-time compensation value to compensate for the theoretical trajectory point coordinates. Thus, the actual processing code is the pre-compensated processing code, which can effectively achieve automatic compensation for arc processing, thereby reducing the impact of the wire saw's flexible bending on processing accuracy and improving processing precision.

[0048] 2. By comprehensively analyzing and considering various parameters affecting the bending degree of the wire saw, and using these parameters to create a dynamic equilibrium model for wire saw bending, the original dynamic equilibrium state is broken when any parameter changes within a given appropriate range. At this time, the dynamic equilibrium model for wire saw bending automatically calculates and outputs a new percentage based on the sum of the areas of all third rectangles and the area of ​​the second rectangle, thus generating a new dynamic equilibrium state. Therefore, the technical solution of this invention breaks free from the constraints of traditional methods of changing the workpiece trajectory. Since changing the workpiece trajectory can only be achieved under a certain equilibrium condition, and under this condition, regardless of which parameter is changed, machining accuracy errors will still occur under the influence of other parameters. However, this invention takes into account all parameters affecting the bending degree of the wire saw, and can truly achieve dynamic equilibrium, which helps to improve machining accuracy.

[0049] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of the present invention more apparent and understandable, specific embodiments of the present invention are described below. Attached Figure Description

[0050] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0051] Figure 1 This is a schematic diagram of the overall structure of a wire saw when equipped with a drive unit;

[0052] Figure 2 A schematic diagram showing the structure of a wire saw with guide wheels on both sides of the processing section;

[0053] Figure 3 This is a flowchart illustrating the execution of a compensation method for wire sawing in a circular arc machining process according to Embodiment 1 of the present invention.

[0054] Figure 4 This is a schematic diagram of the bow shape of the wire saw in this invention when the feed speed is relatively small;

[0055] Figure 5 This is a schematic diagram of the bow shape of the wire saw when the feed speed is relatively high in this invention;

[0056] Figure 6 This is a schematic diagram showing the appropriate range of various parameters under reference processing conditions according to the present invention;

[0057] Figure 7 This is a schematic diagram illustrating the appropriate range of various parameters given by the present invention when new processing conditions are generated due to parameter changes;

[0058] Figure 8 This is one of the state diagrams for the machining of the cylinder in this invention;

[0059] Figure 9 This is the second state diagram of the cylindrical machining process of the present invention;

[0060] Figure 10 This is the third state diagram of the cylindrical machining process of the present invention;

[0061] Figure 11 This is a schematic diagram of the structure of a compensation device for wire sawing in the second embodiment of the present invention;

[0062] Figure 12 This is a schematic diagram of the electronic device in Embodiment 3 of the present invention;

[0063] Figure 13 This is a schematic diagram of the structure of the medium in Embodiment 4 of the present invention.

[0064] Explanation of reference numerals in the attached figures:

[0065] Wire saw 100;

[0066] Drive unit 200;

[0067] Guide wheel 300. Detailed Implementation

[0068] To better understand the technical solution of the present invention, the technical solution of the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0069] Example 1

[0070] This embodiment provides a compensation method for wire sawing of circular arcs, such as... Figure 3 As shown, the method includes the following steps:

[0071] Step S1: Using the various parameters that affect the bending degree of the wire saw, create a parameter dynamic balance model of the wire saw bending, so as to realize the automatic adjustment of the percentage using the parameter dynamic balance model of the wire saw bending, thereby facilitating the real-time calculation of the lag distance for compensation.

[0072] Step S2: Adjust all parameters under reference processing conditions. Calculate a reference percentage using the wire saw bending parameter dynamic balance model based on the reference processing conditions. Test the reference hysteresis distance of the wire saw under the reference processing conditions. Use the reference hysteresis distance as a reference compensation value to compensate the theoretical trajectory point coordinates to obtain the reference compensation trajectory point coordinates. Control the wire saw to process according to the reference compensation trajectory point coordinates. The reference percentage and reference hysteresis distance are used as reference values ​​for compensation calculation. In practice, after adjusting the reference processing conditions, the reference percentage needs to be automatically generated using the wire saw bending parameter dynamic balance model based on the reference processing conditions. The reference hysteresis distance of the wire saw needs to be manually tested under the reference processing conditions and then entered into the system to facilitate the subsequent calculation of the real-time hysteresis distance.

[0073] Step S3: During the processing, when the parameters change and new processing conditions are generated, the wire saw bending parameter dynamic balance model automatically calculates a real-time percentage based on the new processing conditions. The real-time lag distance is calculated based on the reference percentage, reference lag distance, and real-time percentage. The real-time lag distance is used as the real-time compensation value to compensate the theoretical trajectory point coordinates to obtain the real-time compensated trajectory point coordinates. The wire saw is controlled to perform processing based on the real-time compensated trajectory point coordinates.

[0074] The principle of the compensation method of this invention is as follows: Due to the flexibility of the wire saw, it always exhibits lag along the tangent direction of the processed arc during actual processing. Therefore, this invention creates a dynamic balance model of wire saw bending parameters, tests the reference lag distance of the wire saw under reference processing conditions, and calculates a reference percentage using the dynamic balance model. This allows the model to automatically output a real-time percentage when parameters change and new processing conditions arise. Furthermore, it pre-calculates the real-time lag distance based on the reference percentage, reference lag distance, and real-time percentage, and uses this real-time lag distance as a real-time compensation value to compensate for the theoretical trajectory point coordinates. Thus, the actual processing code is the pre-compensated processing code, effectively achieving automatic compensation for arc processing, thereby reducing the impact of the wire saw's flexible bending on processing accuracy and improving overall processing precision.

[0075] In some embodiments of the present invention, the step of creating a parametric dynamic equilibrium model for the bending of the wire saw using various parameters that affect the degree of bending specifically involves:

[0076] The parameters affecting the bending degree of the wire saw are identified. Each parameter is represented by a first rectangle of the same height but different widths. All the first rectangles are then joined together to form a second rectangle, specifically by joining the first rectangles together along their width. Within each first rectangle, a third rectangle is used to draw a suitable range for the parameter corresponding to that first rectangle. This suitable range is a pre-defined, appropriately sized range, and the third rectangle spans the entire width of the first rectangle. The sum of the areas of all the third rectangles is divided by the area of ​​the second rectangle to obtain a percentage, thus creating a dynamic equilibrium model of the wire saw bending parameters. The width of the first rectangle represents the magnitude of the influence of the parameter corresponding to that rectangle on the wire saw bending; the greater the influence of the parameter on the wire saw bending, the larger the width of the first rectangle. It should be noted that if two parameters have the same degree of influence on the wire saw bending, the widths of the first rectangles corresponding to the two parameters are the same.

[0077] Since the bending degree of a wire saw during actual processing is affected by various parameters, this invention comprehensively analyzes and considers all parameters affecting the bending degree of the wire saw, and uses these parameters to create a dynamic equilibrium model for wire saw bending. This ensures that when any parameter changes within a given appropriate range, the original dynamic equilibrium state is broken. At this point, the dynamic equilibrium model automatically calculates and outputs a new percentage based on the sum of the areas of all third rectangles and the area of ​​the second rectangle, thus generating a new dynamic equilibrium state. Therefore, the technical solution of this invention breaks free from the constraints of traditional methods that change the workpiece trajectory. Changing the workpiece trajectory can only be achieved under a single equilibrium condition, and under this condition, regardless of which parameter is changed, processing accuracy errors will still occur due to the influence of other parameters. This invention, however, considers all parameters affecting the bending degree of the wire saw, achieving true dynamic equilibrium and contributing to improved processing accuracy.

[0078] More specifically, the parameters affecting the bending degree of the wire saw include at least the feed rate, processing span, wire saw tension, wire saw linear speed, diamond hardness, and material hardness, and each parameter includes both maximum and minimum values. It should be noted that these six parameters—feed rate, processing span, wire saw tension, wire saw linear speed, diamond hardness, and material hardness—are all important factors that have been identified through actual analysis and screening and that substantially affect the bending degree of the saw.

[0079] The following details the significance of each parameter in the parametric dynamic equilibrium model of wire saw bending:

[0080] Feed rate: Feed rate is the most influential parameter during machining. A slower feed rate results in higher machining accuracy but lower efficiency. This is mainly due to the grinding ability of the diamond on the wire saw on the workpiece (such as stone). The cutting amount of the wire saw per unit time is not infinite. When the cutting amount exceeds the feed rate, it increases the reaction force and causes the wire saw to become taut. If the feed rate continues to increase, it will eventually reach an equilibrium state. The difference is that the cutting lag distance is relatively greater than the lag distance before acceleration. Therefore, adjusting the feed rate, within its limit range, will affect the lag error between the wire saw cutting position and the actual machining point. Figure 4 The feed rate shown is relative to Figure 5 The feed speed is relatively small, and the bow height of the wire saw 100 between the two guide wheels 300 is also relatively small; therefore, the larger the feed speed, the greater the hysteresis compensation.

[0081] Processing span: such as Figure 4As shown, the distance between the two guide wheels 300 is the processing span. The larger the processing length of the workpiece within the processing range of the wire saw, the larger the span. At the same feed speed, the force on the wire saw is the same. At this time, the larger the processing span, the greater the deformation and stretching of the wire saw, the greater the bow height, and the greater the hysteresis. In summary, the larger the processing span, the greater the hysteresis compensation.

[0082] Wire saw tension: During wire saw cutting, a certain tension must be maintained to ensure that the flexible wire saw has a certain degree of rigidity. The greater the tension, the smaller the deformation and hysteresis of the wire saw after being stretched. However, the tension of the wire saw is limited by the mechanical structure and cannot be infinitely large. Exceeding the limit will lead to wire saw breakage or mechanical deformation. At the same time, it cannot be too small. If it is below the limit value, the diamond cannot apply pressure to the workpiece properly, and the cutting requirements cannot be met. Usually, the system adjusts the pressure within the range of 60-70 kg / cm2, which hardly changes during processing and is only a reference variable. However, the system can monitor the pressure changes and maintain a fixed output pressure through a dynamic pressure compensation system. Therefore, the pressure parameter is only a constant value in this compensation system, and any changes will be used as a reference for dynamic adjustment within the system.

[0083] Wire saw linear speed: The linear speed of the wire saw is a constant value during processing. Different linear speeds are matched according to different workpieces. During the debugging process, the linear speed can be adjusted to the optimal value. The change in linear speed will affect the amount of diamond cutting per unit time. The optimal linear speed can be adjusted based on the current of the drive motor and the degree of bending of the wire saw. In the dynamic adjustment system, the speed of the wire saw cannot be used as a condition. The closer the actual linear speed is to the reference value, the better the effect. The linear speed is too fast or too slow, which will lead to a large cutting lag. Therefore, the adjustment of the linear speed is also very important in the automatic compensation system.

[0084] Diamond hardness and material hardness: The diamond hardness of a wire saw and the hardness of the material (i.e., the material of the workpiece being processed) are actually a pair. Each type of material requires an optimal diamond formula to match it, and each finished diamond wire saw has an optimal material to process. These two parameters are constants in the system, which are coefficients. The size of the coefficient will affect the final percentage.

[0085] In one specific embodiment of the present invention, the maximum feed rate is 50 mm / min, and the minimum feed rate is 0 mm / min; the maximum machining span is 3.5 m, and the minimum machining span is 1 m; the maximum wire saw tension is 18000 N, and the minimum wire saw tension is 12000 N; the maximum wire saw linear speed is 50 m / s, and the minimum wire saw linear speed is 5 m / s; the maximum diamond hardness is 10, and the minimum diamond hardness is 1; the maximum material hardness is 10, and the minimum material hardness is 1. Of course, the present invention is not limited to this; in specific implementations, the maximum and minimum values ​​of the feed rate, machining span, wire saw tension, wire saw linear speed, diamond hardness, and material hardness can be adjusted according to actual needs.

[0086] The following specific examples will further illustrate the dynamic equilibrium model of wire saw bending parameters in this invention:

[0087] like Figure 6 As shown, assuming that Figure 6 The diagram shows the appropriate range of parameters under reference processing conditions (the shaded area in the diagram represents the appropriate range of parameters). Under these reference processing conditions, the percentage output by the dynamic equilibrium model of wire saw bending parameters is 34%. During processing, when parameters change and new processing conditions arise (such as...), Figure 7 As shown, both the feed rate and the wire saw speed have changed. At this point, the dynamic balance model of the wire saw bending parameters will automatically output a new percentage based on the new processing conditions, such as... Figure 7 The changed output percentage is 36%. This demonstrates that by employing the dynamic equilibrium model for wire saw bending created using this invention, it can be ensured that regardless of how the parameters are adjusted, the dynamic equilibrium model can adaptively output a new percentage based on the adjusted parameter state, thus facilitating real-time calculation of the lag distance for compensation based on the output percentage.

[0088] In some embodiments of the present invention, in step S3, calculating the real-time lag distance based on the reference percentage, the reference lag distance, and the real-time percentage specifically involves:

[0089] Assume the reference percentage is RV%, the reference lag distance is RVS, the real-time percentage is CV%, and the real-time lag distance is L;

[0090] The real-time lag distance L is calculated using the following formula (1):

[0091]

[0092] Since both the reference percentage and the reference lag distance are known, the real-time percentage can be automatically output through the dynamic equilibrium model of the wire saw bending parameters. Therefore, it is possible to achieve real-time calculation of the real-time lag distance.

[0093] It should be noted that, in specific implementation of step S3 of the present invention, when the parameters change for the first time based on the reference processing conditions, the real-time lag distance can be calculated using the reference percentage output under the reference processing conditions, the tested reference lag distance, and the real-time percentage; and when the parameters change again, the previous processing conditions can be used as the reference processing conditions, the previous output real-time percentage can be used as the reference percentage, the previous calculated real-time lag distance can be used as the reference lag distance, and the current real-time lag distance can be calculated using the reference percentage, the reference lag distance, and the latest output real-time percentage.

[0094] In some embodiments of the present invention, in step S3, the step of using the real-time lag distance as a real-time compensation value to compensate the theoretical trajectory point coordinates to obtain the real-time compensated trajectory point coordinates specifically involves:

[0095] The real-time compensation values ​​ΔX and ΔY of the X-axis and Y-axis of the theoretical trajectory points are calculated using the following equations (2) and (3), respectively:

[0096] △X=X+L*COS(RADIANS(A-90)) (2)

[0097] △Y=Y+L*SIN(RADIANS(A-90)) (3)

[0098] Where L represents the real-time lag distance, A represents the angle of the guide wheel in the wire saw, X represents the X-axis coordinate value of the theoretical trajectory point, and Y represents the Y-axis coordinate value of the theoretical trajectory point.

[0099] The coordinates of the compensation trajectory points in real time after compensation are calculated using the following equations (4) and (5):

[0100] X(CV)=△X+X (4)

[0101] Y(CV)=△Y+Y (5)

[0102] Where X(CV) represents the X-axis coordinate value of the real-time compensated trajectory point after compensation, and Y(CV) represents the Y-axis coordinate value of the real-time compensated trajectory point after compensation.

[0103] Similarly, in step S2, "using the reference lag distance as the reference compensation value to compensate the coordinates of the theoretical trajectory point to obtain the reference compensation trajectory point coordinates" is also compensated through the above formulas (2)-(5), which will not be elaborated here.

[0104] The technical solution of the present invention will be further explained below using the machining of a cylinder as an example:

[0105] like Figure 8 As shown, when machining a cylinder with an arc, when the theoretical coordinates reach the starting point of the arc machining, there is a lag distance Δs between the actual position of the wire saw and the theoretical coordinates; for example... Figure 9 As shown, when the theoretical coordinates are compensated using the technical solution of this invention (i.e., the lag distance Δs is compensated into the theoretical coordinates), the wire saw can accurately enter the actual starting point of the circular arc processing; for example... Figure 10 As shown, by calculating the hysteresis distance Δs in real time and compensating the theoretical coordinates with the calculated hysteresis distance Δs in real time, it is possible to ensure that the actual processing trajectory of the wire saw is closer to the cylinder, thereby improving the processing accuracy.

[0106] Based on the same inventive concept, this application also provides an apparatus corresponding to the method in Embodiment 1, as detailed in Embodiment 2.

[0107] Example 2

[0108] This embodiment provides a compensation device for wire sawing of circular arcs, such as... Figure 11 As shown, the device includes a model creation module, a reference module, and a real-time compensation module;

[0109] The model creation module is used to create a parametric dynamic balance model of wire saw bending by using various parameters that affect the degree of wire saw bending. The parametric dynamic balance model of wire saw bending is used to realize automatic adjustment of percentage, thereby facilitating real-time calculation of lag distance for compensation.

[0110] The reference module is used to adjust various parameters under reference processing conditions. It automatically calculates a reference percentage based on the reference processing conditions using a dynamic balance model of wire saw bending parameters, and tests the reference lag distance of the wire saw under these conditions. The reference lag distance is then used as a reference compensation value to compensate the theoretical trajectory point coordinates, resulting in reference compensated trajectory point coordinates. The wire saw is then controlled to perform processing based on these reference compensated trajectory point coordinates. Specifically, the reference percentage and reference lag distance are used as reference values ​​for compensation calculation. In practice, after adjusting the reference processing conditions, the reference percentage needs to be automatically generated using the dynamic balance model of wire saw bending parameters, and the reference lag distance of the wire saw needs to be manually tested under these conditions. This reference lag distance is then entered into the system to facilitate subsequent calculation of the real-time lag distance.

[0111] The real-time compensation module is used to automatically calculate a real-time percentage based on the new processing conditions when parameters change during processing. This is achieved through a dynamic balance model of the wire saw bending parameters. The module also calculates the real-time lag distance based on the reference percentage, reference lag distance, and real-time percentage. The real-time lag distance is then used as the real-time compensation value to compensate the theoretical trajectory point coordinates, resulting in the real-time compensated trajectory point coordinates. Finally, the wire saw is controlled to perform processing based on the real-time compensated trajectory point coordinates.

[0112] The principle of the compensation method of this invention is as follows: Due to the flexibility of the wire saw, it always exhibits lag along the tangent direction of the processed arc during actual processing. Therefore, this invention creates a dynamic balance model of wire saw bending parameters, tests the reference lag distance of the wire saw under reference processing conditions, and calculates a reference percentage using the dynamic balance model. This allows the model to automatically output a real-time percentage when parameters change and new processing conditions arise. Furthermore, it pre-calculates the real-time lag distance based on the reference percentage, reference lag distance, and real-time percentage, and uses this real-time lag distance as a real-time compensation value to compensate for the theoretical trajectory point coordinates. Thus, the actual processing code is the pre-compensated processing code, effectively achieving automatic compensation for arc processing, thereby reducing the impact of the wire saw's flexible bending on processing accuracy and improving overall processing precision.

[0113] In some embodiments of the present invention, the step of creating a parametric dynamic equilibrium model for the bending of the wire saw using various parameters that affect the degree of bending specifically involves:

[0114] The parameters affecting the bending degree of the wire saw are identified. Each parameter is represented by a first rectangle of the same height but different widths. All the first rectangles are then joined together to form a second rectangle, specifically by joining the first rectangles together along their width. Within each first rectangle, a third rectangle is used to draw a suitable range for the parameter corresponding to that first rectangle. This suitable range is a pre-defined, appropriately sized range, and the third rectangle spans the entire width of the first rectangle. The sum of the areas of all the third rectangles is divided by the area of ​​the second rectangle to obtain a percentage, thus creating a dynamic equilibrium model of the wire saw bending parameters. The width of the first rectangle represents the magnitude of the influence of the parameter corresponding to that rectangle on the wire saw bending; the greater the influence of the parameter on the wire saw bending, the larger the width of the first rectangle. It should be noted that if two parameters have the same degree of influence on the wire saw bending, the widths of the first rectangles corresponding to the two parameters are the same.

[0115] Since the bending degree of a wire saw during actual processing is affected by various parameters, this invention comprehensively analyzes and considers all parameters affecting the bending degree of the wire saw, and uses these parameters to create a dynamic equilibrium model for wire saw bending. This ensures that when any parameter changes within a given appropriate range, the original dynamic equilibrium state is broken. At this point, the dynamic equilibrium model automatically calculates and outputs a new percentage based on the sum of the areas of all third rectangles and the area of ​​the second rectangle, thus generating a new dynamic equilibrium state. Therefore, the technical solution of this invention breaks free from the constraints of traditional methods that change the workpiece trajectory. Changing the workpiece trajectory can only be achieved under a single equilibrium condition, and under this condition, regardless of which parameter is changed, processing accuracy errors will still occur due to the influence of other parameters. This invention, however, considers all parameters affecting the bending degree of the wire saw, achieving true dynamic equilibrium and contributing to improved processing accuracy.

[0116] More specifically, the parameters affecting the bending degree of the wire saw include at least the feed rate, processing span, wire saw tension, wire saw linear speed, diamond hardness, and material hardness, and each parameter includes both maximum and minimum values. It should be noted that these six parameters—feed rate, processing span, wire saw tension, wire saw linear speed, diamond hardness, and material hardness—are all important factors that have been identified through actual analysis and screening and that substantially affect the bending degree of the saw.

[0117] The following details the significance of each parameter in the parametric dynamic equilibrium model of wire saw bending:

[0118] Feed rate: Feed rate is the most influential parameter during machining. A slower feed rate results in higher machining accuracy but lower efficiency. This is mainly due to the grinding ability of the diamond on the wire saw on the workpiece (such as stone). The cutting amount of the wire saw per unit time is not infinite. When the cutting amount exceeds the feed rate, it increases the reaction force and causes the wire saw to become taut. If the feed rate continues to increase, it will eventually reach an equilibrium state. The difference is that the cutting lag distance is relatively greater than the lag distance before acceleration. Therefore, adjusting the feed rate, within its limit range, will affect the lag error between the wire saw cutting position and the actual machining point. Figure 4 The feed rate shown is relative to Figure 5 The feed speed is relatively small, and the bow height of the wire saw 100 between the two guide wheels 300 is also relatively small; therefore, the larger the feed speed, the greater the hysteresis compensation.

[0119] Processing span: such as Figure 4As shown, the distance between the two guide wheels 300 is the processing span. The larger the processing length of the workpiece within the processing range of the wire saw, the larger the span. At the same feed speed, the force on the wire saw is the same. At this time, the larger the processing span, the greater the deformation and stretching of the wire saw, the greater the bow height, and the greater the hysteresis. In summary, the larger the processing span, the greater the hysteresis compensation.

[0120] Wire saw tension: During wire saw cutting, a certain tension must be maintained to ensure that the flexible wire saw has a certain degree of rigidity. The greater the tension, the smaller the deformation and hysteresis of the wire saw after being stretched. However, the tension of the wire saw is limited by the mechanical structure and cannot be infinitely large. Exceeding the limit will lead to wire saw breakage or mechanical deformation. At the same time, it cannot be too small. If it is below the limit value, the diamond cannot apply pressure to the workpiece properly, and the cutting requirements cannot be met. Usually, the system adjusts the pressure within the range of 60-70 kg / cm2, which hardly changes during processing and is only a reference variable. However, the system can monitor the pressure changes and maintain a fixed output pressure through a dynamic pressure compensation system. Therefore, the pressure parameter is only a constant value in this compensation system, and any changes will be used as a reference for dynamic adjustment within the system.

[0121] Wire saw linear speed: The linear speed of the wire saw is a constant value during processing. Different linear speeds are matched according to different workpieces. During the debugging process, the linear speed can be adjusted to the optimal value. The change in linear speed will affect the amount of diamond cutting per unit time. The optimal linear speed can be adjusted based on the current of the drive motor and the degree of bending of the wire saw. In the dynamic adjustment system, the speed of the wire saw cannot be used as a condition. The closer the actual linear speed is to the reference value, the better the effect. The linear speed is too fast or too slow, which will lead to a large cutting lag. Therefore, the adjustment of the linear speed is also very important in the automatic compensation system.

[0122] Diamond hardness and material hardness: The diamond hardness of a wire saw and the hardness of the material (i.e., the material of the workpiece being processed) are actually a pair. Each type of material requires an optimal diamond formula to match it, and each finished diamond wire saw has an optimal material to process. These two parameters are constants in the system, which are coefficients. The size of the coefficient will affect the final percentage.

[0123] In one specific embodiment of the present invention, the maximum feed rate is 50 mm / min, and the minimum feed rate is 0 mm / min; the maximum machining span is 3.5 m, and the minimum machining span is 1 m; the maximum wire saw tension is 18000 N, and the minimum wire saw tension is 12000 N; the maximum wire saw linear speed is 50 m / s, and the minimum wire saw linear speed is 5 m / s; the maximum diamond hardness is 10, and the minimum diamond hardness is 1; the maximum material hardness is 10, and the minimum material hardness is 1. Of course, the present invention is not limited to this; in specific implementations, the maximum and minimum values ​​of the feed rate, machining span, wire saw tension, wire saw linear speed, diamond hardness, and material hardness can be adjusted according to actual needs.

[0124] The following specific examples will further illustrate the dynamic equilibrium model of wire saw bending parameters in this invention:

[0125] like Figure 6 As shown, assuming that Figure 6 The diagram shows the appropriate range of parameters under reference processing conditions (the shaded area in the diagram represents the appropriate range of parameters). Under these reference processing conditions, the percentage output by the dynamic equilibrium model of wire saw bending parameters is 34%. During processing, when parameters change and new processing conditions arise (such as...), Figure 7 As shown, both the feed rate and the wire saw speed have changed. At this point, the dynamic balance model of the wire saw bending parameters will automatically output a new percentage based on the new processing conditions, such as... Figure 7 The changed output percentage is 36%. This demonstrates that by employing the dynamic equilibrium model for wire saw bending created using this invention, it can be ensured that regardless of how the parameters are adjusted, the dynamic equilibrium model can adaptively output a new percentage based on the adjusted parameter state, thus facilitating real-time calculation of the lag distance for compensation based on the output percentage.

[0126] In some embodiments of the present invention, in the real-time compensation module, the calculation of the real-time lag distance based on the reference percentage, the reference lag distance, and the real-time percentage specifically involves:

[0127] Assume the reference percentage is RV%, the reference lag distance is RVS, the real-time percentage is CV%, and the real-time lag distance is L;

[0128] The real-time lag distance L is calculated using the following formula (1):

[0129]

[0130] Since both the reference percentage and the reference lag distance are known, the real-time percentage can be automatically output through the dynamic equilibrium model of the wire saw bending parameters. Therefore, it is possible to achieve real-time calculation of the real-time lag distance.

[0131] It should be noted that, in specific implementation, when the parameters change for the first time based on the reference processing conditions, the real-time lag distance can be calculated using the reference percentage output under the reference processing conditions, the tested reference lag distance, and the real-time percentage. When the parameters change again, the previous processing conditions can be used as the reference processing conditions, the previous output real-time percentage can be used as the reference percentage, the previous calculated real-time lag distance can be used as the reference lag distance, and the current real-time lag distance can be calculated using the reference percentage, the reference lag distance, and the latest output real-time percentage.

[0132] In some embodiments of the present invention, in the real-time compensation module, the step of using the real-time lag distance as a real-time compensation value to compensate the theoretical trajectory point coordinates to obtain the real-time compensated trajectory point coordinates specifically involves:

[0133] The real-time compensation values ​​ΔX and ΔY of the X-axis and Y-axis of the theoretical trajectory points are calculated using the following equations (2) and (3), respectively:

[0134] △X=X+L*COS(RADIANS(A-90)) (2)

[0135] △Y=Y+L*SIN(RADIANS(A-90)) (3)

[0136] Where L represents the real-time lag distance, A represents the angle of the guide wheel in the wire saw, X represents the X-axis coordinate value of the theoretical trajectory point, and Y represents the Y-axis coordinate value of the theoretical trajectory point.

[0137] The coordinates of the compensation trajectory points in real time after compensation are calculated using the following equations (4) and (5):

[0138] X(CV)=△X+X (4)

[0139] Y(CV)=△Y+Y (5)

[0140] Where X(CV) represents the X-axis coordinate value of the real-time compensated trajectory point after compensation, and Y(CV) represents the Y-axis coordinate value of the real-time compensated trajectory point after compensation.

[0141] Similarly, the "using the reference lag distance as a reference compensation value to compensate the coordinates of the theoretical trajectory point to obtain the reference compensation trajectory point coordinates" in the reference module is also specifically achieved through the above formulas (2)-(5), which will not be elaborated here.

[0142] The technical solution of the present invention will be further explained below using the machining of a cylinder as an example:

[0143] like Figure 8 As shown, when machining a cylinder with an arc, when the theoretical coordinates reach the starting point of the arc machining, there is a lag distance Δs between the actual position of the wire saw and the theoretical coordinates; for example... Figure 9 As shown, when the theoretical coordinates are compensated using the technical solution of this invention (i.e., the lag distance Δs is compensated into the theoretical coordinates), the wire saw can accurately enter the actual starting point of the circular arc processing; for example... Figure 10 As shown, by calculating the hysteresis distance Δs in real time and compensating the theoretical coordinates with the calculated hysteresis distance Δs in real time, it is possible to ensure that the actual processing trajectory of the wire saw is closer to the cylinder, thereby improving the processing accuracy.

[0144] Based on the same inventive concept, this application provides an electronic device embodiment corresponding to Embodiment 1, as detailed in Embodiment 3.

[0145] Example 3

[0146] This embodiment provides an electronic device, such as... Figure 12 As shown, it includes a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it can implement any of the embodiments in Example 1.

[0147] Since the electronic device described in this embodiment is the device used to implement the method in Embodiment 1 of this application, those skilled in the art can understand the specific implementation method and various variations of the electronic device in this embodiment based on the method described in Embodiment 1 of this application. Therefore, how the electronic device implements the method in the embodiment of this application will not be described in detail here. Any device used by those skilled in the art to implement the method in the embodiment of this application falls within the scope of protection of this application.

[0148] Based on the same inventive concept, this application provides a storage medium corresponding to Embodiment 1, as detailed in Embodiment 4.

[0149] Example 4

[0150] This embodiment provides a computer-readable storage medium, such as... Figure 13 As shown, a computer program is stored thereon, which, when executed by a processor, can implement any of the embodiments in Example 1.

[0151] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, apparatus, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0152] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus, and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0153] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0154] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0155] While specific embodiments of the present invention have been described above, those skilled in the art should understand that the specific embodiments described are merely illustrative and not intended to limit the scope of the present invention. Equivalent modifications and variations made by those skilled in the art in accordance with the spirit of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. A method for compensating for circular arc processing of a wire saw, characterized by: The method includes the following steps: A parametric dynamic equilibrium model for wire saw bending is created using various parameters affecting the degree of wire saw bending. Specifically, this includes: identifying the parameters influencing the degree of wire saw bending, including at least feed rate, processing span, wire saw tension, wire saw linear speed, diamond hardness, and material hardness, with each parameter having both a maximum and minimum value; representing each parameter individually using a first rectangle of the same height but different widths, and merging all the first rectangles into a second rectangle; within each first rectangle, using a third rectangle to draw a given appropriate range for the parameter corresponding to that first rectangle, with the third rectangle spanning the entire width of the first rectangle; and obtaining a percentage by dividing the sum of the areas of all third rectangles by the area of ​​the second rectangle, thereby creating the parametric dynamic equilibrium model for wire saw bending. Under reference processing conditions, adjust all parameters, and automatically calculate a reference percentage based on the reference processing conditions using the parameter dynamic balance model of wire saw bending. Under the reference processing conditions, test the reference hysteresis distance of the wire saw, use the reference hysteresis distance as a reference compensation value to compensate the coordinates of the theoretical trajectory point to obtain the reference compensation trajectory point coordinates, and control the wire saw to process according to the reference compensation trajectory point coordinates. During the processing, when parameters change and new processing conditions are generated, the wire saw bending parameter dynamic balance model automatically calculates a real-time percentage based on the new processing conditions. It also calculates the real-time lag distance based on the reference percentage, reference lag distance, and real-time percentage. The real-time lag distance is used as the real-time compensation value to compensate the theoretical trajectory point coordinates to obtain the real-time compensated trajectory point coordinates. The wire saw is then controlled to perform processing based on the real-time compensated trajectory point coordinates.

2. The method of claim 1, wherein: The calculation of the real-time lag distance based on the reference percentage, reference lag distance, and real-time percentage is specifically as follows: Assume the reference percentage is RV%, the reference lag distance is RVS, the real-time percentage is CV%, and the real-time lag distance is L; The real-time lag distance L is calculated using the following formula (1): （1）。 3. The method of claim 1, wherein: The specific steps for compensating the theoretical trajectory point coordinates using the real-time lag distance as a real-time compensation value to obtain the real-time compensated trajectory point coordinates are as follows: The real-time compensation values ​​ΔX and ΔY of the X-axis and Y-axis of the theoretical trajectory points are calculated using the following equations (2) and (3), respectively: △X=X+L*COS(RADIANS(A-90)) (2) △Y=Y+L*SIN(RADIANS(A-90)) (3) Where L represents the real-time lag distance, A represents the angle of the guide wheel in the wire saw, X represents the X-axis coordinate value of the theoretical trajectory point, and Y represents the Y-axis coordinate value of the theoretical trajectory point. The coordinates of the real-time compensation trajectory points after compensation are calculated using the following equations (4) and (5): X(CV) = △X + X (4) Y(CV) = △Y + Y (5) Where X(CV) represents the X-axis coordinate value of the real-time compensated trajectory point after compensation, and Y(CV) represents the Y-axis coordinate value of the real-time compensated trajectory point after compensation.

4. A compensation device for circular arc processing of a wire saw, characterized in that: The device includes a model creation module, a reference module, and a real-time compensation module; The model creation module is used to create a parametric dynamic equilibrium model of wire saw bending using various parameters that affect the degree of wire saw bending. Specifically, this includes: determining the various parameters affecting the degree of wire saw bending, including at least feed rate, processing span, wire saw tension, wire saw linear speed, diamond hardness, and material hardness, with each parameter having a maximum and minimum value; representing each parameter individually using a first rectangle of the same height but different widths, and merging all the first rectangles of all parameters into a second rectangle; within each first rectangle, using a third rectangle to draw a given appropriate range for the parameter corresponding to that first rectangle, with the third rectangle spanning the entire width of the first rectangle; and obtaining a percentage by dividing the sum of the areas of all third rectangles by the area of ​​the second rectangle, thereby creating the parametric dynamic equilibrium model of wire saw bending. The reference module is used to adjust various parameters under reference processing conditions. It automatically calculates a reference percentage based on the reference processing conditions through the dynamic balance model of the wire saw bending parameters, and tests the reference hysteresis distance of the wire saw under the reference processing conditions. The reference hysteresis distance is used as a reference compensation value to compensate the coordinates of the theoretical trajectory point to obtain the reference compensation trajectory point coordinates. The wire saw is then controlled to perform processing based on the reference compensation trajectory point coordinates. The real-time compensation module is used to automatically calculate a real-time percentage based on the new processing conditions when parameters change during processing. This is achieved through a dynamic balance model of the wire saw bending parameters. The module also calculates the real-time lag distance based on the reference percentage, reference lag distance, and real-time percentage. The real-time lag distance is then used as the real-time compensation value to compensate the theoretical trajectory point coordinates, resulting in the real-time compensated trajectory point coordinates. Finally, the wire saw is controlled to perform processing based on the real-time compensated trajectory point coordinates.

5. The compensation device for circular arc processing of a wire saw according to claim 4, characterized in that: The calculation of the real-time lag distance based on the reference percentage, reference lag distance, and real-time percentage is specifically as follows: Assume the reference percentage is RV%, the reference lag distance is RVS, the real-time percentage is CV%, and the real-time lag distance is L; The real-time lag distance L is calculated using the following formula (1): （1）。 6. The compensation device for wire sawing circular arc machining according to claim 4, characterized in that: The specific steps for compensating the theoretical trajectory point coordinates using the real-time lag distance as a real-time compensation value to obtain the real-time compensated trajectory point coordinates are as follows: The real-time compensation values ​​ΔX and ΔY of the X-axis and Y-axis of the theoretical trajectory points are calculated using the following equations (2) and (3), respectively: △X=X+L*COS(RADIANS(A-90)) (2) △Y=Y+L*SIN(RADIANS(A-90)) (3) Where L represents the real-time lag distance, A represents the angle of the guide wheel in the wire saw, X represents the X-axis coordinate value of the theoretical trajectory point, and Y represents the Y-axis coordinate value of the theoretical trajectory point. The coordinates of the compensation trajectory points in real time after compensation are calculated using the following equations (4) and (5): X(CV) = △X + X (4) Y(CV)=△Y+Y (5) Where X(CV) represents the X-axis coordinate value of the real-time compensated trajectory point after compensation, and Y(CV) represents the Y-axis coordinate value of the real-time compensated trajectory point after compensation.

7. An electronic device comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the program, it implements the method as described in any one of claims 1 to 3.

8. A computer-readable storage medium having stored thereon a computer program, characterized in that, When the program is executed by the processor, it implements the method as described in any one of claims 1 to 3.

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