An eight-station control system and control method for milling cutter grinding

Abstract

The present invention relates to an eight-station control system and method for milling cutter grinding. By controlling the rotation angle of a turntable and the motion parameters of the grinding wheel motion axis of each station, the grinding of the end edge, peripheral edge, slot and other parts of the milling cutter is realized. The system includes a touch screen, a servo device, a detection device and a controller. The touch screen is used to display and input the processing requirements and grinding parameters of the milling cutter and send control instructions. The detection device performs image measurement and analysis on the milling cutter after processing and compares it with the target size. The controller includes a programming machine, a PLC and a data module. The programming machine generates a Chinese programming script. The PLC is used to control the operation and synchronization of each channel and realize the dynamic configuration of the channel axis. The data module is used to store and calculate the processing model, grinding parameters and error compensation data of the milling cutter. The present invention improves the efficiency, accuracy and reliability of milling cutter grinding; simplifies the system control logic and programming difficulty; and realizes the dynamic configuration and error compensation functions of the channel axis.

Description

Technical Field

[0001] The invention belongs to the technical field of electromechanical control systems, and in particular relates to an eight-station control system and a control method for milling cutter grinding. Background Art

[0002] Milling cutter is a commonly used cutting tool used to process parts of various shapes on machine tools. The geometric shape and size of the milling cutter directly affect its cutting performance and service life, so the milling cutter needs to be accurately ground. At present, milling cutter grinding mainly uses CNC grinders or special grinders to control the relative movement between the grinding wheel and the milling cutter to achieve the grinding of the end edge, peripheral edge, slot and other parts of the milling cutter.

[0003] However, the existing milling cutter grinding technology has the following shortcomings:

[0004] Low grinding efficiency. Due to the complex shape of the milling cutter, it is necessary to change the clamp, shaft, and cutter many times, resulting in long processing time and low efficiency;

[0005] Poor grinding accuracy. Since the geometric parameters of the milling cutter are difficult to measure and control, as well as the wear and deformation of the grinding wheel, there is a large error between the milling cutter and the target size after processing;

[0006] Grinding parameters are difficult to determine. Due to the different materials, shapes, and sizes of milling cutters, it is necessary to determine appropriate grinding parameters such as speed, position, acceleration, etc. based on experience or experiments, which is both time-consuming and resource-consuming;

[0007] The system control is complex. Since it is necessary to control multiple motion axes and actuators such as cylinders, as well as to achieve coordination and synchronization between various workstations, the system control logic is complex and programming is difficult.

[0008] Therefore, how to improve the efficiency, accuracy and reliability of milling cutter grinding is a technical problem that needs to be solved urgently. Summary of the invention

[0009] 1. The present invention relates to an eight-station control system for milling cutter grinding, which solves the technical problems of low efficiency, poor precision and complex operation of milling cutter grinding in the prior art.

[0010] The technical solution of the present invention includes:

[0011] An eight-station control system for milling cutter grinding, comprising:

[0012] The eight stations include seven processing stations and one auxiliary station. The seven processing stations are loading and unloading stations, step difference stations, end edge grinding stations, slotting stations, fine slotting stations and peripheral edge opening stations. Each processing station is equipped with a chuck for clamping the milling cutter to be processed.

[0013] Touch screen, used to display and input milling cutter processing requirements and grinding parameters, and send control instructions;

[0014] Servo equipment, including servo drive, inverter, motor and IO module, wherein the inverter communicates with the touch screen based on the modbusRTU protocol, and the drive and IO module are connected based on the EtherCAT bus protocol and controlled by the program in the controller;

[0015] The detection device is installed on the loading and unloading station and connected to the controller to measure and analyze the image of the milling cutter after processing and compare it with the target size;

[0016] The controller communicates with the touch screen based on the modbusTcp / IP protocol and is used to control the rotation angle of the turntable and the motion parameters of the grinding wheel motion axis of each processing station, wherein the controller includes:

[0017] The programming machine is used to generate Chinese programming scripts according to the processing requirements of the milling cutter and load the scripts into the channels corresponding to each processing station;

[0018] PLC, used to control the operation and synchronization of each channel according to the script, and realize the dynamic configuration of the channel axis according to the rotation angle of the turntable;

[0019] The data module is used to store and calculate the milling cutter processing model, grinding parameters, and error compensation data.

[0020] The beneficial effects of the present invention are: improving the efficiency and precision of milling cutter grinding, simplifying the operation process, and enhancing the flexibility and intelligence of the system.

[0021] The working principle of the present invention is: input the processing requirements of the milling cutter through the touch screen, and calculate the estimated value of the grinding parameters according to the processing model in the data module; generate a Chinese programming script through a programming machine, and load the script into each channel; control the operation and synchronization of each channel through a PLC, and realize the dynamic configuration of the channel axis according to the rotation angle of the turntable; control the movement of the grinding wheel motion axis and the cylinder through a servo device; perform image measurement and analysis on the processed milling cutter through a detection device, and adjust the grinding parameters according to the error between the measurement result and the target size.

[0022] 2. Under the best implementation conditions, the present invention solves the technical problems in the prior art of inaccurate, unstable and non-automatic milling cutter image measurement.

[0023] In a preferred embodiment, the present invention adopts the following technical solution: the detection device includes a high-power electron microscope and an image processing module, wherein the high-power electron microscope is used to magnify and photograph the processed milling cutter and transmit the image to the image processing module; the image processing module is used to process the image, extract the key geometric dimensions of the milling cutter, and compare the measurement results with the target dimensions.

[0024] Under a preferred implementation, the beneficial effects of the present invention are: improving the accuracy, stability and automation of milling cutter image measurement, and providing a basis for adjusting grinding parameters.

[0025] The working principle of the present invention is: the processed milling cutter is magnified and photographed through a high-power electron microscope, and the image is transmitted to an image processing module; the image is binarized, filtered, edge extracted, straight line fitted and other operations are performed on the image through the image processing module, so as to obtain the helix angle, front angle, back angle, core thickness, radius and other parameters of the milling cutter; by comparing the measurement result with the target size, the error value is calculated, and the error value is transmitted to a controller.

[0026] 3. Under the best implementation conditions, the present invention solves the technical problems in the prior art of the milling cutter image processing algorithm being complex, time-consuming, and unstable.

[0027] In a preferred embodiment, the present invention adopts the following technical solution: the image processing module adopts an algorithm based on edge detection and Hough transform to perform binarization, filtering, edge extraction, and straight line fitting operations on the milling cutter image, thereby obtaining the milling cutter's helix angle α, front angle β, back angle γ, core thickness h, and radius r parameters.

[0028] Under a preferred implementation, the beneficial effects of the present invention are: simplifying the milling cutter image processing algorithm, improving the speed and stability of the algorithm, and improving the extraction accuracy of the milling cutter parameters.

[0029] The working principle of the present invention is: Gaussian filtering, gradient calculation, non-maximum suppression and double threshold detection are performed on the image through an edge detection algorithm to obtain an edge image; each pixel point in the edge image is voted through a Hough transform algorithm to obtain an accumulator matrix in a polar coordinate space, and the local maximum value in the matrix is ​​found through threshold and peak detection, corresponding to a straight line in the image space; the straight line parameters obtained by the Hough transform are solved by the least square method through a straight line fitting algorithm to obtain the equation of the fitting line; according to the equation of the fitting line and the geometric relationship, the helix angle, front angle, back angle, core thickness, radius and other parameters of the milling cutter are calculated.

[0030] 4. Under the best implementation conditions, the present invention solves the technical problems in the prior art that the grinding parameter design and debugging process is complicated, time-consuming, and inaccurate.

[0031] In a preferred embodiment, the present invention adopts the following technical solution: the data module establishes a processing model according to the key geometric parameters of the milling cutter, and calculates the estimated values ​​of the grinding parameters according to the processing model; the data module also uses the dichotomy method to adjust the grinding parameters according to the difference between the measurement results returned by the detection device and the estimated values, and transmits the adjusted grinding parameters to the PLC.

[0032] Under the preferred implementation conditions, the beneficial effects of the present invention are: simplifying the design and debugging process of grinding parameters, improving the design efficiency and accuracy of grinding parameters, and improving the quality of milling cutter grinding.

[0033] The working principle of the present invention is: a processing model is established according to the key geometric parameters of the milling cutter through a data module, an estimated value of the grinding parameter is calculated according to the processing model, and the estimated value is displayed on the touch screen, so that the user can adjust the grinding parameter according to his own experience or needs; the image of the milling cutter after processing is measured and analyzed by a detection device, and the measurement result is compared with the target size, the error value is calculated, and the error value is transmitted to the controller; the grinding parameter is adjusted by binary method according to the error value by the controller, that is, the grinding parameter is increased or decreased according to the positive or negative value of the error, and the current step length is recorded and halved until the error is within the accuracy range or the minimum step length is reached; the adjusted grinding parameter is transmitted to the PLC through the controller, and the speed, position and acceleration parameters of the grinding wheel motion axis of each channel are controlled.

[0034] 5. Under the best implementation conditions, the present invention solves the technical problems in the prior art such as the fixed and inflexible channel axis configuration and the inability to adapt to various knife types.

[0035] In a preferred embodiment, the present invention adopts the following technical scheme: the PLC selects the corresponding channel axis dynamic configuration scheme according to the rotation angle of the turntable, and rewrites the physical axis number of the rotating axis according to the chuck corresponding to each channel in the scheme; wherein the channel axis dynamic configuration scheme refers to determining the correspondence between the chuck corresponding to each channel and the physical axis number j of the rotating axis according to the turntable rotation angle θ and the chuck number i, that is, j=f(θ,i); the physical axis number of the rotating axis refers to the number used to identify the storage position and operating status of the rotating axis in the PLC; the error compensation value refers to the calculation of the increment or decrement ò required to adjust the grinding parameters according to the error δ between the measurement result returned by the detection device and the target size, that is, ò=g(δ);

[0036] The PLC also controls the speed v, position x, and acceleration a parameters of the grinding wheel motion axis of each channel according to the grinding parameters and the error compensation value.

[0037] Under the preferred implementation conditions, the beneficial effects of the present invention are: improving the flexibility and adaptability of the channel axis configuration, being able to perform dynamic adjustments according to different tool types and processing requirements, and improving the intelligence level of the system.

[0038] The working principle of the present invention is: the reconfiguration register status is scanned by PLC, and after receiving the reconfiguration command, the corresponding configuration scheme is selected according to the current turntable angle, the physical axis number of the rotating axis is rewritten according to the chuck corresponding to each channel in the scheme, and the axis coordinates are recalculated; the error compensation value in the data module is called according to the milling cutter parameters in the current chuck by PLC, and the grinding parameters are corrected according to the error compensation value; the speed, position and acceleration parameters of the grinding wheel motion axis of each channel are controlled by PLC.

[0039] 6. The present invention relates to an eight-station control method for milling cutter grinding, which solves the technical problems of low milling cutter grinding efficiency, poor precision, and complex operation in the prior art.

[0040] The technical solution of the present invention comprises the following steps:

[0041] S1. Input the processing requirements of the milling cutter on the touch screen, including the number of blades n, helix angle α, rake angle β, back angle γ, core thickness h, and radius r parameters;

[0042] S2, the controller calls the processing model in the data module according to the processing requirements of the milling cutter, calculates the estimated value of the grinding parameters, and displays the estimated value on the touch screen;

[0043] S3. Select the processing chuck on the touch screen and click the processing button. The controller starts the channel operation function. Each channel controls the movement of the grinding wheel motion axis and the cylinder according to the loaded script.

[0044] S4, the current processing station action is completed, after switching the processing station, the IO port operation designed in the script is executed to change the reconfiguration register state;

[0045] S5. The controller scans and finds that the register state has changed, that is, it receives a reconfiguration command, selects the corresponding configuration scheme according to the current turntable angle, rewrites the physical axis number of the rotating axis according to the chuck corresponding to each channel in the scheme, and recalculates the axis coordinates;

[0046] S6. After completing the dynamic configuration of the channel axis, restore the reconfiguration register state and start executing the processing action;

[0047] S7. When a chuck completes the processing of six stations in sequence starting from the loading and unloading and step difference stations, it means that the processing of a milling cutter is completed. The detection device performs image measurement and analysis on the processed milling cutter and compares the measurement result with the target size.

[0048] S8. If there is an error beyond the accuracy range between the measurement result and the target size, the error value is recorded, and the grinding parameters of the corresponding size are found according to the processing model in the data module, and the grinding parameters are modified according to the preset step length, and step S7 is repeated; the number of repetitions does not exceed 3 times, and if it exceeds 3 times, it will be treated as a defective product;

[0049] S9. If the measurement result and the target size are within the accuracy range, the processing is completed.

[0050] The beneficial effects of the present invention are: improving the efficiency and precision of milling cutter grinding, simplifying the operation process, and enhancing the flexibility and intelligence of the system.

[0051] The working principle of the present invention is: input the processing requirements of the milling cutter through the touch screen, and calculate the estimated value of the grinding parameters according to the processing model in the data module; generate a Chinese programming script through a programming machine, and load the script into each channel; control the operation and synchronization of each channel through a PLC, and realize the dynamic configuration of the channel axis according to the rotation angle of the turntable; control the movement of the grinding wheel motion axis and the cylinder through a servo device; perform image measurement and analysis on the processed milling cutter through a detection device, and adjust the grinding parameters according to the error between the measurement result and the target size.

[0052] 7. Under the best implementation conditions, the present invention solves the technical problems in the prior art that the design and debugging process of grinding parameters is complicated, time-consuming, and inaccurate.

[0053] In a preferred embodiment, the present invention adopts the following technical solution: after calculating the estimated value of the grinding parameters, the following sub-steps are also included:

[0054] Display the estimated grinding parameters on the touch screen and provide modification options so that users can adjust the grinding parameters according to their own experience or needs;

[0055] After the user confirms the grinding parameters, the grinding parameters are transmitted to the PLC, and the processing progress and status are displayed on the touch screen.

[0056] Under preferred implementation conditions, the beneficial effects of the present invention are: improving the design efficiency and accuracy of grinding parameters, and improving the operational convenience and satisfaction of users.

[0057] The working principle of the present invention is: the processing requirements of the milling cutter are input through the touch screen, and the estimated values ​​of the grinding parameters are calculated according to the processing model in the data module, and the estimated values ​​are displayed on the touch screen, so that the user can adjust the grinding parameters according to his own experience or needs; control instructions are sent through the touch screen, the grinding parameters are transmitted to the PLC, and the processing progress and status are displayed on the touch screen.

[0058] 8. Under the best implementation conditions, the present invention solves the technical problems in the prior art such as the inaccurate, unstable and non-automatic adjustment process of the grinding parameters.

[0059] In a preferred implementation, the present invention adopts the following technical solution: when modifying the grinding parameters, the step length is adjusted by using the dichotomy method, specifically:

[0060] If the error between the measurement result and the target size is a positive value, it means that the grinding is too deep and the grinding parameters need to be reduced; if the error between the measurement result and the target size is a negative value, it means that the grinding is not deep enough and the grinding parameters need to be increased;

[0061] After each modification of the grinding parameters, the current step length Δ is recorded and the step length is halved, that is, Δ 修改 =Δ / 2;

[0062] If the error between the measured result and the target size is within the accuracy range, stop modifying the grinding parameters; if the error between the measured result and the target size is still beyond the accuracy range, continue to modify the grinding parameters until the accuracy requirement is met or the minimum step length is reached.

[0063] Under a preferred implementation, the beneficial effects of the present invention are: improving the adjustment accuracy and stability of grinding parameters, and improving the quality and efficiency of milling cutter grinding.

[0064] The working principle of the present invention is: the image measurement and analysis of the processed milling cutter is performed through the detection device, and the measurement result is compared with the target size, the error value is calculated, and the error value is transmitted to the controller; the grinding parameter is adjusted by binary method according to the error value through the controller, that is, the grinding parameter is increased or decreased according to the positive and negative values ​​of the error, and the current step length is recorded, and the step length is halved until the error is within the accuracy range or the minimum step length is reached; the adjusted grinding parameters are transmitted to the PLC through the controller, and the speed, position, and acceleration parameters of the grinding wheel motion axis of each channel are controlled.

[0065] 9. Under the best implementation conditions, the present invention solves the technical problems in the prior art of inaccurate, unstable and non-automatic dynamic configuration process of the channel axis.

[0066] In a preferred implementation, the present invention adopts the following technical solution: after completing the dynamic configuration of the channel axis, the following sub-steps are also included:

[0067] The controller calculates the number of blades n, helix angle α, rake angle β, back angle γ, core thickness h, radius r and other parameters of the milling cutter in the current chuck according to the turntable rotation angle θ and the chuck number i, and displays these parameters on the touch screen;

[0068] The controller calls the error compensation value ò in the data module according to the parameters of the milling cutter in the current chuck, and corrects the grinding parameters according to the error compensation value.

[0069] In a preferred implementation, the beneficial effects of the present invention are: improving the accuracy and stability of the dynamic configuration of the channel axis, and improving the efficiency and accuracy of the display and correction of the milling cutter parameters.

[0070] The working principle of the present invention is: the controller scans the reconfiguration register status, and after receiving the reconfiguration command, the corresponding configuration scheme is selected according to the current turntable angle, the physical axis number of the rotating axis is rewritten according to the chuck corresponding to each channel in the scheme, and the axis coordinates are recalculated; the controller calculates the number of blades, helix angle, front angle, back angle, core thickness, radius and other parameters of the milling cutter in the current chuck according to the turntable rotation angle and the chuck number, and displays these parameters on the touch screen; the controller calls the error compensation value in the data module according to the milling cutter parameters in the current chuck, and corrects the grinding parameters according to the error compensation value. BRIEF DESCRIPTION OF THE DRAWINGS

[0071] Figure 1 It is a system diagram of the present invention.

[0072] Figure 2 A method diagram of the present invention. DETAILED DESCRIPTION

[0073] In order to enable those skilled in the art to better understand the technical solution, the technical solution is described in detail below in conjunction with the embodiments. The description in this section is only exemplary and explanatory and should not have any limiting effect on the scope of protection of this patent.

[0074] Embodiment 1:

[0075] like Figure 1 As shown, the technical solution of the present invention includes:

[0076] An eight-station control system for milling cutter grinding, comprising:

[0077] The eight stations include seven processing stations and one auxiliary station. The seven processing stations are loading and unloading stations, step difference stations, end edge grinding stations, slotting stations, fine slotting stations and peripheral edge opening stations. Each processing station is equipped with a chuck for clamping the milling cutter to be processed.

[0078] Touch screen, used to display and input milling cutter processing requirements and grinding parameters, and send control instructions;

[0079] Servo equipment, including servo drive, inverter, motor and IO module, wherein the inverter communicates with the touch screen based on the modbusRTU protocol, and the drive and IO module are connected based on the EtherCAT bus protocol and controlled by the program in the controller;

[0080] The detection device is installed on the loading and unloading station and connected to the controller to measure and analyze the image of the milling cutter after processing and compare it with the target size;

[0081] The controller communicates with the touch screen based on the modbusTcp / IP protocol and is used to control the rotation angle of the turntable and the motion parameters of the grinding wheel motion axis of each processing station, wherein the controller includes:

[0082] The programming machine is used to generate Chinese programming scripts according to the processing requirements of the milling cutter and load the scripts into the channels corresponding to each processing station;

[0083] PLC, used to control the operation and synchronization of each channel according to the script, and realize the dynamic configuration of the channel axis according to the rotation angle of the turntable;

[0084] The data module is used to store and calculate the milling cutter processing model, grinding parameters, and error compensation data.

[0085] The working principle of the above technology is: input the processing requirements of the milling cutter through the touch screen, and calculate the estimated value of the grinding parameters according to the processing model in the data module; generate Chinese programming scripts through the programming machine, and load the scripts into each channel; control the operation and synchronization of each channel through PLC, and realize the dynamic configuration of the channel axis according to the rotation angle of the turntable; control the movement of the grinding wheel motion axis and the cylinder through the servo device; perform image measurement and analysis of the processed milling cutter through the detection device, and adjust the grinding parameters according to the error between the measurement result and the target size.

[0086] In a preferred embodiment, the present invention adopts the following technical solution: the detection device includes a high-power electron microscope and an image processing module, wherein the high-power electron microscope is used to magnify and photograph the processed milling cutter and transmit the image to the image processing module; the image processing module is used to process the image, extract the key geometric dimensions of the milling cutter, and compare the measurement results with the target dimensions.

[0087] The working principle of the above technology is: the processed milling cutter is magnified and photographed through a high-power electron microscope, and the image is transmitted to the image processing module; the image is binarized, filtered, edge extracted, straight line fitted and other operations are performed on the image through the image processing module to obtain the milling cutter's helix angle, front angle, back angle, core thickness, radius and other parameters; by comparing the measurement result with the target size, the error value is calculated and transmitted to the controller.

[0088] In a preferred embodiment, the present invention adopts the following technical solution: the image processing module adopts an algorithm based on edge detection and Hough transform to perform binarization, filtering, edge extraction, and straight line fitting operations on the milling cutter image, thereby obtaining the milling cutter's helix angle α, front angle β, back angle γ, core thickness h, and radius r parameters.

[0089] The helix angle α, the front angle β, the back angle γ, the core thickness h, and the radius r of the milling cutter are obtained by computing with an image processing module, and the method comprises the following steps:

[0090] The edge detection adopts the Canny algorithm, that is, firstly, the image is subjected to Gaussian filtering, then the gradient amplitude and direction of the image are calculated, then the gradient amplitude is subjected to non-maximum suppression, and finally the edge image is obtained through double threshold detection and edge connection;

[0091] The Hough transform adopts the standard Hough transform, that is, the straight line equation y=ax+b in the image space is converted into the parametric equation ρ=xcosθ+ysinθ in the polar coordinate space, and then each pixel point in the edge image is voted to obtain the accumulator matrix in the polar coordinate space, and finally the local maximum value in the matrix is ​​found through threshold and peak detection, which corresponds to the straight line in the image space;

[0092] The linear fitting adopts the least square method, that is, the linear equations are solved according to the linear parameters ρ and θ obtained by Hough transformation. Where (x i ,y i ) is the i-th point on the line, a, b, c are the coefficients of the line equation ax+by+c=0, and then minimize the sum of squared errors Get the optimal solution Thus, the equation of the fitted straight line is obtained;

[0093] According to the equation of the fitting line and the geometric relationship, the parameters of the end mill such as the helix angle α, rake angle β, back angle r, core thickness h, radius r, etc. can be calculated. The specific formula is as follows:

[0094] where a 1 ,a 2 is the slope of the fitting straight line of two adjacent blade surfaces;

[0095] Where a and b are the slopes of the blade surface fitting line and the feed direction line;

[0096] Where a and b are the slopes of the back fitting line and the feed direction line;

[0097] Among them, a, b, and c are the coefficients of the blade surface fitting straight line;

[0098] Where x and y are the coordinates of the intersection of the blade surface fitting line and the axis.

[0099] The working principle of the above technology is: the Canny algorithm is used for edge detection, that is, the image is first Gaussian filtered, and then the gradient amplitude and direction of the image are calculated, and then the gradient amplitude is non-maximum suppressed, and finally the edge image is obtained through double threshold detection and edge connection; each pixel point in the edge image is voted for by the Hough transform algorithm to obtain the accumulator matrix in the polar coordinate space, and the local maximum value in the matrix is ​​found through threshold and peak detection, which corresponds to the straight line in the image space; the straight line parameters obtained by the Hough transform are solved by the least squares method through the straight line fitting algorithm to obtain the equation of the fitted line; according to the equation of the fitted line and the geometric relationship, the helix angle, front angle, back angle, core thickness, radius and other parameters of the milling cutter are calculated.

[0100] In a preferred embodiment, the present invention adopts the following technical solution: the data module establishes a processing model according to the key geometric parameters of the milling cutter, and calculates the estimated values ​​of the grinding parameters according to the processing model; the data module also uses the dichotomy method to adjust the grinding parameters according to the difference between the measurement results returned by the detection device and the estimated values, and transmits the adjusted grinding parameters to the PLC.

[0101] The working principle of the above technology is: a processing model is established according to the key geometric parameters of the milling cutter through the data module, the estimated value of the grinding parameters is calculated according to the processing model, and the estimated value is displayed on the touch screen, so that the user can adjust the grinding parameters according to his own experience or needs; the image of the processed milling cutter is measured and analyzed by the detection device, and the measurement result is compared with the target size, the error value is calculated, and the error value is transmitted to the controller; the grinding parameters are adjusted by binary method according to the error value through the controller, that is, the grinding parameters are increased or decreased according to the positive or negative value of the error, and the current step length is recorded and halved until the error is within the accuracy range or the minimum step length is reached; the adjusted grinding parameters are transmitted to the PLC through the controller, and the speed, position, and acceleration parameters of the grinding wheel motion axis of each channel are controlled.

[0102] In a preferred embodiment, the present invention adopts the following technical scheme: the PLC selects the corresponding channel axis dynamic configuration scheme according to the rotation angle of the turntable, and rewrites the physical axis number of the rotating axis according to the chuck corresponding to each channel in the scheme; wherein the channel axis dynamic configuration scheme refers to determining the correspondence between the chuck corresponding to each channel and the physical axis number j of the rotating axis according to the turntable rotation angle θ and the chuck number i, that is, j=f(θ,i); the physical axis number of the rotating axis refers to the number used to identify the storage position and operating status of the rotating axis in the PLC; the error compensation value refers to the calculation of the increment or decrement ò required to adjust the grinding parameters according to the error δ between the measurement result returned by the detection device and the target size, that is, ò=g(δ);

[0103] The PLC also controls the speed v, position x, and acceleration a parameters of the grinding wheel motion axis of each channel according to the grinding parameters and the error compensation value.

[0104] The working principle of the above technology is: scan the reconfiguration register status through PLC, and after receiving the reconfiguration command, select the corresponding configuration scheme according to the current turntable angle, rewrite the physical axis number of the rotating axis according to the chuck corresponding to each channel in the scheme, and recalculate the axis coordinates; call the error compensation value in the data module according to the milling cutter parameters in the current chuck through PLC, and correct the grinding parameters according to the error compensation value; control the speed, position, and acceleration parameters of the grinding wheel motion axis of each channel through PLC.

[0105] like Figure 2 As shown, the present invention relates to an eight-station control method for milling cutter grinding, comprising the following steps:

[0106] S1. Input the processing requirements of the milling cutter on the touch screen, including the number of blades n, helix angle α, rake angle β, back angle γ, core thickness h, and radius r parameters;

[0107] S2, the controller calls the processing model in the data module according to the processing requirements of the milling cutter, calculates the estimated value of the grinding parameters, and displays the estimated value on the touch screen;

[0108] S3. Select the processing chuck on the touch screen and click the processing button. The controller starts the channel operation function. Each channel controls the movement of the grinding wheel motion axis and the cylinder according to the loaded script.

[0109] S4, the current processing station action is completed, after switching the processing station, the IO port operation designed in the script is executed to change the reconfiguration register state;

[0110] S5. The controller scans and finds that the register state has changed, that is, it receives a reconfiguration command, selects the corresponding configuration scheme according to the current turntable angle, rewrites the physical axis number of the rotating axis according to the chuck corresponding to each channel in the scheme, and recalculates the axis coordinates;

[0111] S6. After completing the dynamic configuration of the channel axis, restore the reconfiguration register state and start executing the processing action;

[0112] S7. When a chuck completes the processing of six stations in sequence starting from the loading and unloading and step difference stations, it means that the processing of a milling cutter is completed. The detection device performs image measurement and analysis on the processed milling cutter and compares the measurement result with the target size.

[0113] S8. If there is an error beyond the accuracy range between the measurement result and the target size, the error value is recorded, and the grinding parameters of the corresponding size are found according to the processing model in the data module, and the grinding parameters are modified according to the preset step length, and step S7 is repeated; the number of repetitions does not exceed 3 times, and if it exceeds 3 times, it will be treated as a defective product;

[0114] S9. If the measurement result and the target size are within the accuracy range, the processing is completed.

[0115] The working principle of the above technology is: input the processing requirements of the milling cutter through the touch screen, and calculate the estimated value of the grinding parameters according to the processing model in the data module; generate Chinese programming scripts through the programming machine, and load the scripts into each channel; control the operation and synchronization of each channel through PLC, and realize the dynamic configuration of the channel axis according to the rotation angle of the turntable; control the movement of the grinding wheel motion axis and the cylinder through the servo device; perform image measurement and analysis of the processed milling cutter through the detection device, and adjust the grinding parameters according to the error between the measurement result and the target size.

[0116] In a preferred embodiment, the present invention adopts the following technical solution: after calculating the estimated value of the grinding parameters, the following sub-steps are also included:

[0117] Display the estimated grinding parameters on the touch screen and provide modification options so that users can adjust the grinding parameters according to their own experience or needs;

[0118] After the user confirms the grinding parameters, the grinding parameters are transmitted to the PLC, and the processing progress and status are displayed on the touch screen.

[0119] The working principle of the above technology is: input the processing requirements of the milling cutter through the touch screen, calculate the estimated grinding parameters based on the processing model in the data module, and display the estimated values ​​on the touch screen, so that users can adjust the grinding parameters according to their own experience or needs; send control instructions through the touch screen, transmit the grinding parameters to the PLC, and display the processing progress and status on the touch screen.

[0120] In a preferred implementation, the present invention adopts the following technical solution: when modifying the grinding parameters, the step length is adjusted by using the dichotomy method, specifically:

[0121] If the error between the measurement result and the target size is a positive value, it means that the grinding is too deep and the grinding parameters need to be reduced; if the error between the measurement result and the target size is a negative value, it means that the grinding is not deep enough and the grinding parameters need to be increased;

[0122] After each modification of the grinding parameters, the current step length Δ is recorded and the step length is halved, that is, Δ 修改 =Δ / 2;

[0123] If the error between the measured result and the target size is within the accuracy range, stop modifying the grinding parameters; if the error between the measured result and the target size is still beyond the accuracy range, continue to modify the grinding parameters until the accuracy requirement is met or the minimum step length is reached.

[0124] The working principle of the above technology is: the image of the processed milling cutter is measured and analyzed through the detection device, and the measurement result is compared with the target size, the error value is calculated, and the error value is transmitted to the controller; the grinding parameters are adjusted by binary method according to the error value through the controller, that is, the grinding parameters are increased or decreased according to the positive and negative values ​​of the error, and the current step length is recorded and halved until the error is within the accuracy range or the minimum step length is reached; the adjusted grinding parameters are transmitted to the PLC through the controller, and the speed, position, and acceleration parameters of the grinding wheel motion axis of each channel are controlled.

[0125] In a preferred implementation, the present invention adopts the following technical solution: after completing the dynamic configuration of the channel axis, the following sub-steps are also included:

[0126] The controller calculates the number of blades n, helix angle α, rake angle β, back angle γ, core thickness h, radius r and other parameters of the milling cutter in the current chuck according to the turntable rotation angle θ and the chuck number i, and displays these parameters on the touch screen;

[0127] The controller calls the error compensation value ò in the data module according to the parameters of the milling cutter in the current chuck, and corrects the grinding parameters according to the error compensation value.

[0128] The working principle of the above technology is: the controller scans the reconfiguration register status, and after receiving the reconfiguration command, the corresponding configuration scheme is selected according to the current turntable angle, and the physical axis number of the rotating axis is rewritten according to the chuck corresponding to each channel in the scheme, and the axis coordinates are recalculated; the controller calculates the number of blades, helix angle, front angle, back angle, core thickness, radius and other parameters of the milling cutter in the current chuck according to the turntable rotation angle and the chuck number, and displays these parameters on the touch screen; the controller calls the error compensation value in the data module according to the milling cutter parameters in the current chuck, and corrects the grinding parameters according to the error compensation value.

[0129] Embodiment 2:

[0130] This embodiment is used to grind a four-edge milling cutter. The specific steps are as follows:

[0131] Input the milling cutter processing requirements on the touch screen, including the number of blades n = 4, helix angle α = 30°, rake angle β = 10°, back angle γ = 5°, core thickness h = 2 mm, radius r = 5 mm parameters;

[0132] According to the processing requirements of the milling cutter, the controller calls the processing model in the data module, calculates the estimated value of the grinding parameters, and displays the estimated value on the touch screen; wherein the grinding parameters include the speed v, position x, acceleration a and other parameters of each axis, as shown in Table 1;

[0133] Select the processing chuck on the touch screen and click the processing button, the controller starts the channel operation function, and each channel controls the movement of the grinding wheel motion axis and the cylinder according to the loaded script; the script is a Chinese programming script generated according to the processing requirements of the milling cutter, as shown in Table 2;

[0134] After the current processing station action is completed and the processing station is switched, the IO port operation designed in the script is executed to change the reconfiguration register state;

[0135] The controller scans the register state change, that is, receives the reconfiguration command, selects the corresponding configuration scheme according to the current turntable angle, rewrites the physical axis number of the rotating axis according to the chuck corresponding to each channel in the scheme, and recalculates the axis coordinates; wherein, the channel axis dynamic configuration scheme is to determine the corresponding relationship between the chuck corresponding to each channel and the physical axis number j of the rotating axis according to the turntable rotation angle θ and the chuck number i, that is, j=f(θ,i); the physical axis number of the rotating axis refers to the number used to identify the storage position and operating status of the rotating axis in the PLC; as shown in Table 3;

[0136] After completing the dynamic configuration of the channel axis, restore the reconfiguration register state and start executing the processing action;

[0137] When a chuck completes the processing of six stations in sequence starting from the loading and unloading and step difference stations, it means that the processing of a milling cutter is completed. The detection device performs image measurement and analysis on the processed milling cutter and compares the measurement result with the target size. The detection device includes a high-power electron microscope and an image processing module. The image processing module uses an algorithm based on edge detection and Hough transform to perform binarization, filtering, edge extraction, and straight line fitting operations on the milling cutter image, thereby obtaining the helix angle α, front angle β, back angle γ, core thickness h, and radius r parameters of the milling cutter; the details are shown in Table 4.

[0138] If there is an error between the measurement result and the target size that exceeds the accuracy range, the error value is recorded, and the grinding parameters of the corresponding size are found according to the processing model in the data module, and the grinding parameters are modified according to the preset step length; the preset step length is 0.01 mm; as shown in Table 5;

[0139] Repeat the above steps until all error values ​​are within the accuracy range.

[0140] Table 1 Grinding parameter estimation

[0141] Workstation aisle axis Speed Position x Acceleration Loading and unloading 1 X1 100mm / s 0mm <![CDATA[10mm / s 2 ]]> step difference 2 X2 100mm / s 0mm <![CDATA[10mm / s 2 ]]> Grinding edge 3 X3 100mm / s 0mm <![CDATA[10mm / s 2 ]]> Slotting 4 X4 100mm / s 0mm <![CDATA[10mm / s 2 ]]> Fine slotting 5 X5 100mm / s 0mm <![CDATA[10mm / s 2 ]]> Opening the blade 6 X6 100mm / s 0mm <![CDATA[10mm / s 2 ]]>

[0142] Table 2 Chinese programming scripts

[0143]

[0144]

[0145] Table 3 Channel axis dynamic configuration scheme

[0146] Turntable angle θ (degrees) Chuck No. i (pcs) Physical axis number j(number) 0 1 X1 2 X2 3 X3 4 X4 5 X5 6 X6 60 2 X1 3 X2 4 X3 5 X4 6 X5 1 X6 ………… …………

[0147] Table 4 Milling cutter image measurement results

[0148]

[0149] Table 5 Grinding parameter adjustment results

[0150] The data in the table is calculated based on the processing model and error compensation value in the data module, not simply compensated by axis movement. The specific calculation process is as follows:

[0151] First, according to the helix angle α and rake angle β of the milling cutter, the cutting angle φ of the milling cutter can be calculated, that is, φ = α + β;

[0152] Secondly, according to the core thickness h and radius r of the milling cutter, the blade width m of the milling cutter can be calculated, that is,

[0153] Then, according to the blade width m and cutting angle φ of the milling cutter, the cutting depth d of the milling cutter can be calculated, that is, d = msinφ;

[0154] Finally, according to the cutting depth d of the milling cutter and the error value δ, the adjustment value ò of the grinding parameter can be calculated, that is, ò = δ / d;

[0155] Taking the step-difference station as an example, assuming that the error between the measurement result and the target size is 0.05mm, that is, the grinding is not deep enough, and the grinding parameters need to be increased. According to the above formula, we can get:

[0156] φ=30°+10°=40°

[0157]

[0158] d=5.66sin40°=3.63mm

[0159] ò=-0.05 / 3.63=-0.014

[0160] Therefore, the position x of the X2 axis of the step-difference station needs to be increased by 0.014mm, that is, from 10mm to 9.986mm. Similarly, the grinding parameters of other stations can also be adjusted according to the corresponding error values.

[0161] Parameter name Original value(mm) Adjusted value (mm) Step difference station X2 axis position x 10 9.998 Grinding end cutting station X3 axis position x 20 20.003 Slotting station X4 axis position x 30 29.996 Fine slotting station X5 axis position x 40 39.999 Opening cutting position X6 axis position x 50 50.001

[0162] This embodiment adopts the eight-station control system and method of the present invention to grind a four-edge milling cutter, achieving efficient, accurate and intelligent milling cutter grinding. This embodiment is only to illustrate a possible implementation of the present invention and does not limit the scope of protection of the present invention. Without departing from the spirit and essence of the present invention, technicians in this field can make various changes and modifications to the present invention, and these changes and modifications belong to the scope of protection of the present invention.

[0163] It should be noted that, in this article, the terms "include", "comprises" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. This article uses specific examples to illustrate the principles and implementation methods of the technical solution of this patent. The above examples are only used to help understand the method of this patent and its core ideas. The above is only a preferred implementation method of this patent. It should be pointed out that due to the limitations of textual expression and the objective existence of infinite specific structures, ordinary technicians in this technical field can make several improvements, modifications or changes without departing from the principles of this patent, and can also combine the above technical features in an appropriate manner; these improvements, modifications, changes or combinations, or the direct application of the patent's concept and technical solution to other occasions without improvement, should be regarded as the scope of protection of this patent.

Claims

1. An eight-station control system for milling cutter grinding, characterized in that: include: The eight stations include seven processing stations and one auxiliary station. The seven processing stations are loading and unloading stations, step difference stations, end edge grinding stations, slotting stations, fine slotting stations and peripheral edge opening stations. Each processing station is equipped with a chuck for clamping the milling cutter to be processed. Touch screen, used to display and input milling cutter processing requirements and grinding parameters, and send control instructions; Servo equipment, including servo drive, inverter, motor and IO module, wherein the inverter communicates with the touch screen based on the modbusRTU protocol, and the drive and IO module are connected based on the EtherCAT bus protocol and controlled by the program in the controller; The detection device is installed on the loading and unloading station and connected to the controller to measure and analyze the image of the milling cutter after processing and compare it with the target size; The controller communicates with the touch screen based on the modbusTcp / IP protocol and is used to control the rotation angle of the turntable and the motion parameters of the grinding wheel motion axis of each processing station, wherein the controller includes: The programming machine is used to generate Chinese programming scripts according to the processing requirements of the milling cutter and load the scripts into the channels corresponding to each processing station; PLC, used to control the operation and synchronization of each channel according to the script, and realize the dynamic configuration of the channel axis according to the rotation angle of the turntable; Data module, used to store and calculate the processing model, grinding parameters and error compensation data of the milling cutter; The data module establishes a processing model according to key geometric parameters of the milling cutter, and calculates an estimated grinding parameter according to the processing model; the data module also uses a dichotomy method to adjust the grinding parameter according to the difference between the measurement result returned by the detection device and the target size, and transmits the adjusted grinding parameter to the PLC; If there is an error between the measurement result and the target size that exceeds the accuracy range, the error value is recorded, and the grinding parameters of the corresponding size are found according to the processing model in the data module, and the grinding parameters are modified according to the preset step size. If the measurement result and the target size are within the accuracy range, the processing is completed; The PLC selects the corresponding channel axis dynamic configuration scheme according to the rotation angle of the turntable, and rewrites the physical axis number of the rotating axis according to the chuck corresponding to each channel in the scheme; wherein the channel axis dynamic configuration scheme refers to determining the correspondence between the chuck corresponding to each channel and the physical axis number j of the rotating axis according to the rotation angle θ of the turntable and the chuck number i, that is, j=f(θ,i); the physical axis number of the rotating axis refers to the number used to identify the storage position and operating status of the rotating axis in the PLC; the error compensation value refers to the calculation of the increment or decrement ò required to adjust the grinding parameters according to the error δ between the measurement result returned by the detection device and the target size, that is, ò=g(δ); The PLC also controls the speed v, position x, and acceleration a parameters of the grinding wheel motion axis of each channel according to the grinding parameters and error compensation values; When modifying the grinding parameters, the dichotomy method is used to adjust the step size, specifically: If the error between the measurement result and the target size is a positive value, it means that the grinding is too deep and the grinding parameters need to be reduced; if the error between the measurement result and the target size is a negative value, it means that the grinding is not deep enough and the grinding parameters need to be increased; After each modification of the grinding parameters, the current step length Δ is recorded and the step length is halved, that is, Δ 修改 =Δ / 2; If the error between the measured result and the target size is within the accuracy range, stop modifying the grinding parameters; if the error between the measured result and the target size is still beyond the accuracy range, continue to modify the grinding parameters until the accuracy requirement is met or the minimum step length is reached.

2. The eight-station control system according to claim 1, characterized in that: The detection device includes a high-power electron microscope and an image processing module, wherein the high-power electron microscope is used to magnify and photograph the milling cutter after processing, and transmit the image to the image processing module; the image processing module is used to process the image, extract the key geometric dimensions of the milling cutter, and compare the measurement results with the target dimensions.

3. The eight-station control system according to claim 2, characterized in that: The image processing module uses an algorithm based on edge detection and Hough transform to perform binarization, filtering, edge extraction, and straight line fitting operations on the milling cutter image, thereby obtaining the milling cutter's helix angle α, front angle β, back angle γ, core thickness h, and radius r parameters.

4. An eight-station control method for milling cutter grinding using an eight-station control system for milling cutter grinding as claimed in any one of claims 1 to 3, characterized in that: The following steps are involved: S1. Input the processing requirements of the milling cutter on the touch screen, including the number of blades n, helix angle α, rake angle β, back angle γ, core thickness h, and radius r parameters; S2, the controller calls the processing model in the data module according to the processing requirements of the milling cutter, calculates the estimated value of the grinding parameters, and displays the estimated value on the touch screen; S3. Select the processing chuck on the touch screen and click the processing button. The controller starts the channel operation function. Each channel controls the movement of the grinding wheel motion axis and the cylinder according to the loaded script. S4, the current processing station action is completed, after switching the processing station, the IO port operation designed in the script is executed to change the reconfiguration register state; S5. The controller scans and finds that the register state has changed, that is, it receives a reconfiguration command, selects the corresponding configuration scheme according to the current turntable angle, rewrites the physical axis number of the rotating axis according to the chuck corresponding to each channel in the scheme, and recalculates the axis coordinates; S6. After completing the dynamic configuration of the channel axis, restore the reconfiguration register state and start executing the processing action; S7. When a chuck completes the processing of six stations in sequence starting from the loading and unloading and step difference stations, it means that the processing of a milling cutter is completed. The detection device performs image measurement and analysis on the processed milling cutter and compares the measurement result with the target size. S8. If there is an error beyond the accuracy range between the measurement result and the target size, the error value is recorded, and the grinding parameters of the corresponding size are found according to the processing model in the data module, and the grinding parameters are modified according to the preset step length, and step S7 is repeated; the number of repetitions does not exceed 3 times, and if it exceeds 3 times, it will be treated as a defective product; S9. If the measurement result and the target size are within the accuracy range, the processing is completed; When modifying the grinding parameters, the dichotomy method is used to adjust the step size, specifically: If the error between the measurement result and the target size is a positive value, it means that the grinding is too deep and the grinding parameters need to be reduced; if the error between the measurement result and the target size is a negative value, it means that the grinding is not deep enough and the grinding parameters need to be increased; After each modification of the grinding parameters, the current step length Δ is recorded and the step length is halved, that is, Δ 修改 =Δ / 2; If the error between the measurement result and the target size is within the accuracy range, stop modifying the grinding parameters; if the error between the measurement result and the target size is still beyond the accuracy range, continue to modify the grinding parameters until the accuracy requirement is met or the minimum step length is reached; After completing the dynamic configuration of the channel axis, the following sub-steps are included: The controller calculates the number of blades n, helix angle α, rake angle β, back angle γ, core thickness h, and radius r of the milling cutter in the current chuck according to the turntable rotation angle θ and the chuck number i, and displays these parameters on the touch screen; The controller calls the error compensation value ò in the data module according to the parameters of the milling cutter in the current chuck, and corrects the grinding parameters according to the error compensation value.

5. The eight-station control method according to claim 4, characterized in that: In the step S2, after the grinding parameter estimation is calculated, the following sub-steps are also included: Display the estimated grinding parameters on the touch screen and provide modification options, allowing users to adjust the grinding parameters according to their own experience or needs; After the user confirms the grinding parameters, the grinding parameters are transmitted to the PLC, and the processing progress and status are displayed on the touch screen.

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