A cutting control system for steel structure products

Abstract

The invention discloses a steel structure product cutting control system, which relates to the field of industrial manufacturing technology, including: performing three-dimensional stress field modeling on steel structure parts to generate stress distribution diagrams of steel structure parts; setting initial cutting parameters based on the stress distribution diagram to perform preliminary cutting path planning; real-time monitoring of temperature distribution data of steel structure parts, combining with feedback of adjusted cutting motion parameters to detect local overheating and thermal stress concentration phenomena; based on the detection results, automatically adjusting the injection parameters of coolant through a thermal stress control mechanism; combining real-time vibration data and temperature data to recalculate the stress distribution of steel structure parts and dynamically adjust the cutting path; through temperature monitoring and thermal stress calculation, local overheating areas can be detected in real time, and the injection parameters of coolant can be automatically adjusted based on the thermal stress control mechanism to prevent the negative impact of thermal stress concentration on cutting accuracy and material integrity.

Description

Technical Field

[0001] The invention relates to the technical field of industrial manufacturing, in particular to a steel structure product cutting control system. Background Art

[0002] With the continuous development of industrial manufacturing technology, precision cutting of steel structures has been widely used in the fields of construction, aerospace, heavy machinery, etc. Traditional steel structure cutting technologies mostly rely on pre-set cutting parameters and paths, which are usually based on static stress analysis and material properties. However, in the actual cutting process, due to the complex stress distribution of the material, the dynamic changes of thermal stress and the influence of vibration, problems such as reduced cutting accuracy, material deformation, and equipment wear often occur. In recent years, technologies such as three-dimensional stress field modeling, real-time vibration monitoring and temperature control have been gradually applied to steel structure cutting control systems. These technologies can effectively improve cutting accuracy and safety, but still face some limitations.

[0003] The shortcomings of existing technologies in stress field analysis and cutting path planning are mainly reflected in the lack of real-time and dynamic adjustment capabilities. First, traditional stress analysis methods are usually based on static models and cannot reflect the dynamic changes of stress during the cutting process, especially in areas of high stress concentration, which can easily lead to cutting errors or material damage. Secondly, although some systems have introduced vibration monitoring and temperature feedback control, the existing vibration data acquisition and temperature control mechanisms are relatively simple and cannot effectively combine stress distribution and cutting paths for real-time adjustments, resulting in a lack of flexibility and precision optimization space in the cutting process. Therefore, there is an urgent need for a comprehensive solution that can collect vibration and temperature data in real time and dynamically adjust cutting paths and parameters in combination with stress fields. Summary of the invention

[0004] In view of the above existing problems, the present invention is proposed.

[0005] Therefore, the present invention provides a steel structure product cutting control system to solve the problems of reduced cutting accuracy and material deformation caused by stress concentration, vibration and thermal stress changes during the cutting process of steel structure parts.

[0006] In order to solve the above technical problems, the present invention provides the following technical solutions:

[0007] In a first aspect, the present invention provides a steel structure product cutting control system, which comprises:

[0008] The three-dimensional stress field modeling module performs three-dimensional stress field modeling on steel structures and generates stress distribution diagrams of steel structures;

[0009] Parameter setting module, based on the stress distribution diagram, sets the initial cutting parameters and performs preliminary cutting path planning;

[0010] The monitoring and analysis module collects and analyzes vibration data during the cutting process in real time and dynamically adjusts cutting parameters;

[0011] The detection module monitors the temperature distribution data of steel structures in real time, and detects local overheating and thermal stress concentration phenomena in combination with the adjusted cutting motion parameter feedback;

[0012] A coolant control module that automatically adjusts the coolant injection parameters through a thermal stress control mechanism based on the detection results;

[0013] The stress adjustment module combines real-time vibration data and temperature data to recalculate the stress distribution of steel structures and dynamically adjust the cutting path.

[0014] As a preferred solution of the steel structure product cutting control system of the present invention, the three-dimensional stress field modeling of the steel structure part and the generation of the stress distribution diagram of the steel structure part include the following steps:

[0015] Use 3D scanning technology to obtain the 3D geometric model of steel structure parts and collect the material properties of the steel structure;

[0016] Set boundary conditions and external loads for steel structures based on geometric models and material properties;

[0017] After the boundary conditions and external load conditions are set, the finite element mesh is divided by finite element analysis technology;

[0018] Based on finite element analysis technology, the geometric features of the 3D geometric model are analyzed to identify the key areas in the model;

[0019] According to the complexity of the model and the needs of the user, select the corresponding mesh unit type and set the global mesh density to divide the mesh;

[0020] According to the global mesh division results, local mesh refinement is performed in key areas to generate a comprehensive mesh;

[0021] Perform mesh quality check on the generated comprehensive mesh, and generate a finite element mesh model after passing the check;

[0022] All material properties and external loads are assigned to each mesh unit of the finite element model, the stress field of the steel structure is solved, the stress, strain and displacement data of each mesh unit are obtained, and the stress distribution diagram of the steel structure is automatically generated.

[0023] As a preferred solution of the steel structure product cutting control system of the present invention, wherein: based on the stress distribution diagram, the initial cutting parameters are set and the preliminary cutting path planning is performed, including the following steps:

[0024] Based on the stress distribution diagram, the steel structure is analyzed as a whole, high stress concentration areas and low stress areas are identified, and areas suitable for cutting are divided;

[0025] Automatically recommend the starting and ending points of the cutting path based on the geometric shape and stress distribution of the area suitable for cutting;

[0026] After determining the starting and ending points of the cutting path, the stress distribution along the entire cutting path is analyzed again, and the initial cutting parameters are automatically recommended based on the stress values ​​in different areas;

[0027] Dynamically adjust the cutting plan for the high stress concentration areas that the initial cutting path passes through;

[0028] Integrate dynamic adjustment schemes for trunk lines and high stress concentration areas to generate global preliminary cutting paths;

[0029] Generate corresponding cutting parameters according to different path segments in the global preliminary cutting path;

[0030] Integrate all path information and cutting parameters to generate a preliminary cutting path file.

[0031] As a preferred solution of the steel structure product cutting control system of the present invention, the vibration data of the cutting process is collected in real time and analyzed, and the cutting parameters are dynamically adjusted, including the following steps:

[0032] Based on the stress distribution map and the stress concentration areas in the cutting path, the maximum bearing stress of each area is determined and converted into the corresponding vibration threshold;

[0033] Real-time collection of vibration acceleration data of tools and equipment;

[0034] The acceleration data is converted from the time domain to the frequency domain through Fourier transformation, the vibration energy at different frequencies is analyzed, and whether there is resonance frequency and abnormally high amplitude vibration is monitored;

[0035] Set a safety threshold for vibration acceleration, compare the vibration amplitude at each frequency with the set safety threshold for vibration acceleration, and determine whether the vibration amplitude exceeds the safety threshold;

[0036] Obtain the displacement data of each monitoring point, set the safety threshold of displacement, compare the displacement data with the safety threshold of displacement, and judge whether the slight deformation of steel during cutting exceeds the safety limit;

[0037] Combine the analysis results of acceleration and displacement data to determine whether the cutting parameters need to be further adjusted;

[0038] When it is determined that the cutting parameters need to be adjusted, a cutting parameter adjustment instruction is automatically generated to control the behavior of the cutting equipment and dynamically adjust the cutting parameters.

[0039] As a preferred solution of the steel structure product cutting control system of the present invention, the temperature distribution data of the steel structure is monitored in real time, and the detection of local overheating and thermal stress concentration phenomena is combined with the adjusted cutting motion parameter feedback, including the following steps:

[0040] The temperature distribution data of the cutting area is collected in real time through thermal imagers and temperature sensors;

[0041] Get the adjusted cutting speed, feed depth and path information in real time;

[0042] The overheating temperature threshold is set according to the physical properties of steel, and the real-time temperature data is compared with the overheating temperature threshold. When the real-time temperature of a certain area exceeds the overheating temperature threshold, it is determined that local overheating has occurred in the area and the area is marked;

[0043] The thermal stress in the area where local overheating occurs is calculated using the thermal stress equation, and the expression is:

[0044] ;

[0045] in, is the spatial coordinate position in the horizontal direction, is the spatial coordinate position in the vertical direction, is the spatial coordinate position in the depth direction, For time, is the thermal stress value, is the elastic modulus of the material, is the thermal expansion coefficient of the material, is the temperature difference in the area of ​​thermal stress concentration;

[0046] Compare thermal stress values ​​to the yield strength in the steel material properties to identify thermal stress concentrations.

[0047] As a preferred solution of the steel structure product cutting control system of the present invention, the automatic adjustment of the spray parameters of the coolant through the thermal stress control mechanism based on the detection results includes the following steps:

[0048] According to the thermal stress value, surface area, temperature difference and heat transfer coefficient of the overheated area, the injection flow rate of the coolant is calculated as follows:

[0049] ;

[0050] in, is the injection flow rate of the coolant, is the surface area of ​​the superheated region, is the heat transfer coefficient of the coolant, is the temperature difference in the overheated area, is the heat absorption capacity of the coolant;

[0051] Dynamically adjust the coolant injection flow rate based on the real-time changes in the temperature of the thermal stress concentration area;

[0052] According to the relative position of the coolant nozzle and the thermal stress concentration area, the injection angle is calculated as follows:

[0053] ;

[0054] in, is the spatial coordinate of the coolant nozzle, is the spatial coordinate of the thermal stress concentration area, is the injection angle;

[0055] Dynamically adjust the spray angle according to the movement of the cutting head and the real-time changes in the thermal stress concentration area;

[0056] The required cooling time is calculated based on the mass, specific heat capacity, temperature difference and coolant flow rate of the thermal stress concentration area. The expression is:

[0057] ;

[0058] in, is the required cooling time, is the mass of the thermal stress concentration area, is the specific heat capacity of the material, is the heat absorption capacity per unit volume of coolant;

[0059] Dynamically adjust the injection time according to the real-time changes in the temperature of the overheated area;

[0060] Use thermal imagers and temperature sensors to monitor the temperature changes in the cooling area in real time, and evaluate the cooling effect based on the temperature changes before and after cooling;

[0061] Based on the cooling feedback data, the relevant parameters in the cutting process are dynamically adjusted.

[0062] As a preferred solution of the steel structure product cutting control system of the present invention, the stress distribution of the steel structure is recalculated by combining the real-time vibration data and temperature data, and the cutting path is dynamically adjusted, including the following steps:

[0063] Real-time measurement of the three-dimensional stress distribution inside the steel and the temperature distribution on the surface and inside the steel;

[0064] Calculate the thermal stress at the current moment based on the thermal expansion coefficient and elastic modulus of the material;

[0065] The thermal stress is superimposed on the original mechanical stress to generate a dynamic stress field that changes with time;

[0066] Through real-time vibration data, the impact of vibration on mechanical stress is calculated, and the distribution of mechanical stress is adjusted according to the current cutting speed and feed depth;

[0067] According to the vibration and cutting parameters, the mechanical stress distribution of the material is recalculated and superimposed with the thermal stress to generate a new stress field;

[0068] Perform gradient analysis on the updated stress field and calculate the stress change rate in each direction;

[0069] The cutting path is dynamically adjusted based on the stress gradient calculation results.

[0070] In a second aspect, the present invention provides a computer device comprising a memory and a processor, wherein the memory stores a computer program, wherein: when the computer program is executed by the processor, any step of the steel structure product cutting control system as described in the first aspect of the present invention is implemented.

[0071] In a third aspect, the present invention provides a computer-readable storage medium having a computer program stored thereon, wherein: when the computer program is executed by a processor, any step of the steel structure product cutting control system as described in the first aspect of the present invention is implemented.

[0072] The beneficial effects of the present invention are as follows: by using three-dimensional scanning technology and finite element analysis technology, a three-dimensional stress distribution map of a steel structure is generated, which can fully reflect the internal stress distribution of the material and provide an accurate basis for the initial cutting parameter setting. Secondly, the system collects vibration data in real time during the cutting process and performs frequency domain analysis, and dynamically adjusts the cutting parameters in combination with the stress distribution map to avoid cutting errors caused by vibration. In addition, through temperature monitoring and thermal stress calculation, local overheating areas can be detected in real time, and the injection parameters of the coolant can be automatically adjusted based on the thermal stress control mechanism to prevent the negative impact of thermal stress concentration on cutting accuracy and material integrity. Combined with real-time vibration and temperature data, the system can recalculate the stress field and dynamically adjust the cutting path to ensure that the cutting process is carried out under stress-stable conditions and avoid material damage in stress concentration areas. BRIEF DESCRIPTION OF THE DRAWINGS

[0073] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative work.

[0074] Figure 1 This is a flow chart of the steel structure product cutting control system in Example 1.

[0075] Figure 2 This is a schematic diagram of the preliminary cutting path planning in Example 1. DETAILED DESCRIPTION

[0076] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the accompanying drawings.

[0077] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein, and those skilled in the art may make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0078] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The term "in one embodiment" that appears in different places in this specification does not necessarily refer to the same embodiment, nor does it refer to a separate or selective embodiment that is mutually exclusive with other embodiments.

[0079] Example 1, reference Figure 1 and Figure 2 , which is the first embodiment of the present invention, provides a steel structure product cutting control system, comprising the following steps:

[0080] S1. Carry out three-dimensional stress field modeling on steel structure parts and generate stress distribution diagrams of steel structure parts.

[0081] S1.1. Use 3D scanning technology to obtain the 3D geometric model of the steel structure and collect the material properties of the steel structure.

[0082] Specifically, the material properties of steel structures include the elastic modulus, Poisson's ratio, density, yield strength, thermal expansion coefficient, etc.

[0083] S1.2. Set the boundary conditions and external loads of the steel structure based on the geometric model and material properties.

[0084] Specifically, the boundary conditions include the fixing points and support positions of the steel structure, while the external loads include pressure loads, gravity loads, thermal loads, vibration loads, etc.

[0085] Furthermore, for pressure loads, users can choose to apply them to a specific node or surface area; for gravity loads, the system will automatically apply them evenly to all mesh elements; for thermal loads, users need to enter the temperature change value, and the system will calculate the thermal stress based on the thermal expansion coefficient of the geometric model and apply it to all mesh elements. During the load application process, the system will ensure that the direction and size of the load are accurate based on the geometric position and direction of each mesh element.

[0086] S1.3. After the boundary conditions and external load conditions are set, the finite element mesh is divided by finite element analysis technology; based on the finite element analysis technology, the geometric features of the three-dimensional geometric model are analyzed and the key areas in the model are identified.

[0087] Specifically, geometric features include corners, curved surfaces, holes, welding points, etc. of the structure; critical areas refer to stress concentration areas or parts with complex geometry.

[0088] S1.4. According to the complexity of the model and the needs of the user, select the corresponding grid unit type and set the global grid density to divide the grid.

[0089] Specifically, the mesh unit type refers to the three-dimensional unit that is usually used for steel structures. The most common mesh units include tetrahedral units and hexahedral units. If the geometry is complex and irregular, tetrahedral units are recommended because they can better adapt to complex surfaces; if the geometry is regular and flat, hexahedral units may be recommended because they have higher computational efficiency in regular areas.

[0090] The global mesh density determines the meshing accuracy of the steel structure as a whole. At this point, the user can enter a global mesh size, usually in millimeters or other length units. A smaller mesh size will generate more mesh elements, thereby improving the analysis accuracy, but it will also increase the computational cost; a larger mesh size will generate fewer mesh elements, improving computational efficiency, but may result in reduced accuracy. After the global mesh density is set, the system will preview the preliminary meshing effect and prompt the user whether to continue with local refinement.

[0091] S1.5. Based on the global grid division results, local grid refinement is performed on the key areas to generate a comprehensive grid.

[0092] Specifically, critical areas include stress concentration areas such as curved surfaces, holes, and welding points.

[0093] S1.6. Perform a mesh quality check on the generated comprehensive mesh, and generate a finite element mesh model after passing the check; assign all material properties and external loads to each mesh unit of the finite element model, solve the stress field of the steel structure, obtain the stress, strain and displacement data of each mesh unit, and automatically generate a stress distribution diagram of the steel structure.

[0094] Specifically, the process of solving the stress field of steel structures is as follows:

[0095] The initial stress state is calculated based on the material properties, external loads and boundary conditions of each mesh element. The initial stress state is usually obtained through a simple linear calculation as the starting point for subsequent nonlinear solutions. According to the geometry of the mesh element and the external force, the preliminary stress value and displacement state of each element are calculated; in finite element analysis, the key step in solving the stress field is to calculate the stress and strain of each mesh element under the action of external forces by solving the equilibrium equations of the structure; the finite element method is used to decompose the entire steel structure into many small units, and a linear equation system is constructed for each unit; by solving these equations, the system can calculate the stress, strain and displacement of each unit.

[0096] After the initial linear solution is completed, the nonlinear solution stage will begin. For many steel structures, especially those with complex geometries and multiple load conditions, nonlinear stress-strain relationships will occur, such as plastic deformation or local buckling in high stress areas. In this stage, nonlinear algorithms (such as the Newton-Raphson method) are used for iterative solutions to gradually approximate the true stress distribution of each mesh element. Nonlinear solutions usually require more computing resources because in each iteration, the system needs to update the material properties and load conditions of each element and recalculate the stress and strain.

[0097] During the nonlinear solution process, the convergence of the solution is monitored in real time. After each iteration, the system checks whether the current stress field distribution has stabilized according to the preset accuracy conditions. Convergence monitoring is usually judged by residual evaluation, that is, comparing the difference between the results of the current iteration and the previous iteration. If the difference is less than the set error tolerance, the solution is considered to have converged and the iteration is stopped; if the difference is large, the system will continue to iterate until the convergence condition is met or the maximum number of iterations is reached. While monitoring the convergence process, the stress, strain and displacement data of each iteration are recorded to ensure the accuracy of the analysis results.

[0098] When the iterative calculation reaches the convergence condition, the system will automatically stop solving and generate stress distribution results. At this time, the system will calculate the final stress, strain and displacement values ​​for each mesh element and store these values ​​in the result file. The stress distribution results are usually presented in the form of three-dimensional data, including the maximum principal stress, shear stress and equivalent stress of each mesh element under the external load. These data will serve as the basis for the subsequent generation of stress distribution diagrams.

[0099] S2. Based on the stress distribution diagram, set the initial cutting parameters and perform preliminary cutting path planning.

[0100] S2.1. Analyze the steel structure as a whole based on the stress distribution diagram, identify the high stress concentration areas and low stress areas, and divide the areas suitable for cutting.

[0101] Specifically, high stress concentration areas: stress values ​​approach or exceed the yield strength of the material, and plastic deformation or fracture may occur.

[0102] Low stress area: The stress value is much lower than the yield strength of the material, and the material is in the elastic range and suitable for cutting.

[0103] S2.2. According to the geometric shape and stress distribution of the area suitable for cutting, the starting point and end point of the cutting path are automatically recommended.

[0104] Specifically, the starting point should be selected in an area with low stress and easy to cut to reduce the load during the initial cutting. The end point should be selected in an area where the cutting path is relatively stable to avoid sudden material breakage or irregular cracks at the end of cutting.

[0105] S2.3. After determining the starting point and end point of the cutting path, analyze the stress distribution along the entire cutting path again, and automatically recommend initial cutting parameters based on the stress values ​​in different areas.

[0106] Specifically, cutting parameters include cutting speed, cutting depth, feed angle, cooling method, etc. In low stress areas, higher cutting speed and feed depth can be used because the material is more stable and easier to cut. In high stress areas, it is recommended to reduce the cutting speed and feed depth to avoid excessive cutting force causing material failure.

[0107] S2.4. Dynamically adjust the cutting plan for the high stress concentration area passed by the initial cutting path.

[0108] Specifically, the cutting scheme is as follows:

[0109] Reduce cutting speed: In high stress areas, reduce cutting force by reducing cutting speed to prevent sudden breakage of the material.

[0110] Reduced infeed depth: By reducing the infeed depth, high stress areas are cut gradually to avoid cutting too much material at one time.

[0111] Adjust the cooling solution: In high stress areas, increase the coolant flow or adjust the coolant spray angle to reduce the impact of thermal stress on cutting quality.

[0112] S2.5. Integrate the dynamic adjustment scheme of the trunk line and the high stress concentration area to generate a global preliminary cutting path; generate corresponding cutting parameters according to different path segments in the global preliminary cutting path; integrate all path information and cutting parameters to generate a preliminary cutting path file.

[0113] Specifically, the preliminary cutting path file includes:

[0114] Path geometry information: including the starting point, end point, and coordinate points of each path segment of the cutting path.

[0115] Cutting parameters: including cutting speed, feed depth, power, cooling parameters, etc. for each path segment.

[0116] Dynamic adjustment information: Dynamic adjustment solutions in areas of high stress concentration, such as reducing speed, adjusting feed depth, etc.

[0117] S3, real-time collection of vibration data during cutting and analysis, dynamic adjustment of cutting parameters includes the following steps:

[0118] Based on the stress distribution diagram and the stress concentration area in the cutting path, the maximum bearing stress of each area is determined and converted into the corresponding vibration threshold; the vibration acceleration data of the tool and equipment are collected in real time; the acceleration data is converted from the time domain to the frequency domain through Fourier transform, the vibration energy at different frequencies is analyzed, and whether there is resonance frequency and abnormally high amplitude vibration is monitored; the safety threshold of vibration acceleration is set, and the vibration amplitude at each frequency is compared with the set vibration acceleration safety threshold to determine whether the vibration amplitude exceeds the safety threshold; the displacement data of each monitoring point is obtained, the safety threshold of displacement is set, and the displacement data is compared with the displacement safety threshold to determine whether the slight deformation of the steel during the cutting process exceeds the safety limit; combined with the analysis results of acceleration and displacement data, it is determined whether the cutting parameters need to be further adjusted; when it is determined that the cutting parameters need to be adjusted, the cutting parameter adjustment instructions are automatically generated to control the behavior of the cutting equipment and dynamically adjust the cutting parameters.

[0119] Specifically, the analysis results of acceleration and displacement data are combined to determine whether the cutting parameters need to be further adjusted: if the acceleration data analysis results show that the vibration amplitude exceeds the threshold and a resonant frequency appears in the spectrum, the system will decide to adjust the cutting parameters. If the displacement data analysis results show that the displacement of the material exceeds the limit, the system will also trigger the adjustment of the cutting parameters to reduce stress release.

[0120] Decision logic: If the vibration amplitude exceeds the threshold, the system will prioritize adjusting the cutting speed to reduce the vibration of the tool and the material. If the displacement exceeds the limit, the system will prioritize adjusting the cutting depth to reduce the deformation of the material during the cutting process.

[0121] It should be noted that by combining stress distribution diagrams and vibration data, the vibration and displacement generated during the cutting process can be monitored in real time, abnormal conditions (such as resonant frequency and vibration with abnormally high amplitude) can be discovered in time, and cutting parameters can be dynamically adjusted according to the detection results to avoid equipment loss and cutting failure. Traditional cutting systems usually rely on preset fixed parameters for cutting and cannot be adjusted according to real-time vibration and deformation data. Once problems such as material deformation and tool vibration occur during the cutting process, manual adjustment or interruption of cutting is often required to recalibrate the equipment. Such a system is difficult to adapt to complex stress distribution or material changes, and the cutting accuracy and safety are low; the technology based on stress distribution diagrams usually relies on static stress analysis. Although it can identify high stress areas and preliminarily plan cutting paths and parameters, it cannot cope with real-time changes (such as vibration, material deformation, etc.) during the cutting process. This technical solution not only combines stress distribution diagrams, but also can dynamically adjust cutting parameters by real-time monitoring of vibration and displacement data. This dual monitoring and adjustment mechanism can cope with various real-time problems during the cutting process, ensuring that the cutting process is more flexible, safe and efficient. Ordinary vibration monitoring systems are usually only used to detect the vibration state of the equipment, and cannot be directly linked with the stress distribution and real-time cutting parameters during the cutting process. Adjustment. Even if abnormal vibration is detected, it is usually only an alarm or shutdown processing, and real-time automatic adjustment cannot be achieved. The present technical solution analyzes the vibration frequency domain characteristics through Fourier transform, which can identify the resonant frequency and abnormally high amplitude vibration, and automatically adjust the cutting parameters according to the vibration threshold set by the stress distribution diagram, thus avoiding unnecessary shutdowns and cutting failures and improving the intelligence and automation of the system.

[0122] S4. Real-time monitoring of the temperature distribution data of steel structures, combined with the adjusted cutting motion parameter feedback, to detect local overheating and thermal stress concentration phenomena includes the following steps:

[0123] The temperature distribution data of the cutting area is collected in real time through thermal imagers and temperature sensors; the adjusted cutting speed, feed depth and path information are obtained in real time; the overheating temperature threshold is set according to the physical properties of the steel, and the real-time temperature data is compared with the overheating temperature threshold. When the real-time temperature of a certain area exceeds the overheating temperature threshold, it is determined that local overheating has occurred in the area and the area is marked; the thermal stress of the area where local overheating has occurred is calculated through the thermal stress equation, and the expression is:

[0124] ;

[0125] in, is the spatial coordinate position in the horizontal direction, is the spatial coordinate position in the vertical direction, is the spatial coordinate position in the depth direction, For time, is the thermal stress value, is the elastic modulus of the material, is the thermal expansion coefficient of the material, is the temperature difference between the thermal stress area temperature and the initial temperature;

[0126] Compare thermal stress values ​​to the yield strength in the steel material properties to identify thermal stress concentrations.

[0127] Specifically, if the thermal stress in a certain area exceeds the yield strength, it is considered that there is a risk of thermal stress concentration in the area, and the area is marked as a thermal stress concentration area.

[0128] S5. Based on the detection results, automatically adjusting the injection parameters of the coolant through the thermal stress control mechanism includes the following steps:

[0129] According to the thermal stress value, surface area, temperature difference and heat transfer coefficient of the overheated area, the injection flow rate of the coolant is calculated as follows:

[0130] ;

[0131] in, is the injection flow rate of the coolant, is the surface area of ​​the superheated region, is the heat transfer coefficient of the coolant, is the temperature difference in the overheated area, is the heat absorption capacity of the coolant;

[0132] Dynamically adjust the coolant injection flow rate based on the real-time changes in the temperature of the thermal stress concentration area;

[0133] According to the relative position of the coolant nozzle and the thermal stress concentration area, the injection angle is calculated as follows:

[0134] ;

[0135] in, is the spatial coordinate of the coolant nozzle, is the spatial coordinate of the thermal stress concentration area, is the injection angle;

[0136] Dynamically adjust the spray angle according to the movement of the cutting head and the real-time changes in the thermal stress concentration area;

[0137] The required cooling time is calculated based on the mass, specific heat capacity, temperature difference and coolant flow rate of the thermal stress concentration area. The expression is:

[0138] ;

[0139] in, is the required cooling time, is the mass of the thermal stress concentration area, is the specific heat capacity of the material, is the heat absorption capacity per unit volume of coolant;

[0140] The injection time is dynamically adjusted according to the real-time temperature changes in the overheating area. The temperature changes in the cooling area are monitored in real time through thermal imagers and temperature sensors, and the cooling effect is evaluated based on the temperature changes before and after cooling. Based on the cooling feedback data, the relevant parameters in the cutting process are dynamically adjusted.

[0141] S6. Combining the real-time vibration data and temperature data, recalculating the stress distribution of the steel structure and dynamically adjusting the cutting path include the following steps:

[0142] S6.1. Real-time measurement of the three-dimensional stress distribution inside the steel and the temperature distribution on the surface and inside the steel; calculation of the thermal stress at the current moment based on the thermal expansion coefficient and elastic modulus of the material; superposition of the thermal stress with the original mechanical stress to generate a dynamic stress field that changes with time, expressed as:

[0143] ;

[0144] in, After the superposition of thermal stress and mechanical stress, at position ( ) Place, time The total stress at time, For mechanical stress.

[0145] S6.2. Calculate the influence of vibration on mechanical stress through real-time vibration data, and adjust the distribution of mechanical stress according to the current cutting speed and feed depth. The expression is:

[0146] ;

[0147] in, is the stress change caused by vibration, is the vibration acceleration, is the coefficient of inertia related to the material properties.

[0148] S6.3. Recalculate the mechanical stress distribution of the material according to the vibration and cutting parameters, and superimpose it with the thermal stress to generate a new stress field; perform gradient analysis on the updated stress field and calculate the stress change rate in each direction. The expression is:

[0149] ;

[0150] in, is the stress gradient vector, which indicates the rate of change of the total stress of the steel structure at different positions in three-dimensional space. Is the stress in the horizontal The rate of change in direction, is the stress in the vertical direction The rate of change in direction, is the stress at depth The rate of change in direction.

[0151] S6.4. Dynamically adjust the cutting path based on the stress gradient calculation results.

[0152] Specifically, a stress gradient threshold is set. If the stress gradient exceeds the threshold in a certain direction, the cutting path needs to avoid this area. In the path section where stress is concentrated, the cutting speed is appropriately reduced, or the amount of coolant sprayed is increased to relieve thermal stress.

[0153] It should be noted that traditional cutting technology is usually based on static stress analysis, that is, stress analysis of the material is performed before cutting, and the cutting path is planned based on the analysis results. However, this method cannot cope with the real-time stress distribution changes caused by factors such as temperature changes, vibrations, and cutting speed changes during the cutting process.

[0154] This solution measures and calculates the three-dimensional stress distribution and temperature distribution of steel in real time, combines the thermal expansion coefficient and elastic modulus of the material, and dynamically calculates the superposition effect of thermal stress and mechanical stress. In this way, the system can update the stress field in real time and dynamically adjust the cutting path during the cutting process to ensure the accuracy and safety of the cutting. In addition, the system can combine real-time vibration data to evaluate the impact of vibration on mechanical stress and further optimize the cutting parameters and paths. In traditional technology, processing is only performed through a one-time planned cutting path, and the path cannot be dynamically optimized during the cutting process. Even if temperature and vibration changes are monitored, these changes cannot be directly linked to changes in stress gradients, and the cutting path cannot be adjusted in time; this solution performs gradient analysis on the updated stress field and calculates the stress change rate in each direction. Changes in stress gradients can reflect the trend of stress concentration and distribution changes, thereby providing a basis for dynamic path adjustment.

[0155] This embodiment also provides a computer device suitable for the case of a steel structure product cutting control system, comprising: a memory and a processor; the memory is used to store computer executable instructions, and the processor is used to execute computer executable instructions to implement the steel structure product cutting control system proposed in the above embodiment.

[0156] The computer device may be a terminal, and the computer device includes a processor, a memory, a communication interface, a display screen and an input device connected through a system bus. Among them, the processor of the computer device is used to provide computing and control capabilities. The memory of the computer device includes a non-volatile storage medium and an internal memory. The non-volatile storage medium stores an operating system and a computer program. The internal memory provides an environment for the operation of the operating system and the computer program in the non-volatile storage medium. The communication interface of the computer device is used to communicate with an external terminal in a wired or wireless manner, and the wireless manner can be achieved through WIFI, an operator network, NFC (near field communication) or other technologies. The display screen of the computer device may be a liquid crystal display screen or an electronic ink display screen, and the input device of the computer device may be a touch layer covered on the display screen, or a key, trackball or touchpad provided on the housing of the computer device, or an external keyboard, touchpad or mouse, etc.

[0157] This embodiment also provides a storage medium on which a computer program is stored. When the program is executed by a processor, the steel structure product cutting control system proposed in the above embodiment is implemented; the storage medium can be implemented by any type of volatile or non-volatile storage device or a combination thereof, such as static random access memory (Static Random Access Memory, referred to as SRAM), electrically erasable programmable read-only memory (Electrically Erasable Programmable Read-Only Memory, referred to as EEPROM), erasable programmable read-only memory (Erasable Programmable Read Only Memory, referred to as EPROM), programmable read-only memory (Programmable Red-Only Memory, referred to as PROM), read-only memory (Read-Only Memory, referred to as ROM), magnetic storage, flash memory, magnetic disk or optical disk.

[0158] In summary, the present invention generates a three-dimensional stress distribution map of steel structures by utilizing three-dimensional scanning technology and finite element analysis technology, which can fully reflect the internal stress distribution of the material and provide an accurate basis for the initial cutting parameter setting. Secondly, the system collects vibration data in real time during the cutting process and performs frequency domain analysis, and dynamically adjusts the cutting parameters in combination with the stress distribution map to avoid cutting errors caused by vibration. In addition, through temperature monitoring and thermal stress calculation, local overheating areas can be detected in real time, and the injection parameters of the coolant can be automatically adjusted based on the thermal stress control mechanism to prevent the negative impact of thermal stress concentration on cutting accuracy and material integrity. Combined with real-time vibration and temperature data, the system can recalculate the stress field and dynamically adjust the cutting path to ensure that the cutting process is carried out under stress-stable conditions and avoid material damage in stress concentration areas.

[0159] Example 2, referring to Table 1, is the second example of the present invention. To further verify the technical solution of the present invention, experimental simulation data of a steel structure product cutting control system are provided.

[0160] The purpose of this example is to verify the advantages of the steel structure product cutting control system of the present invention over the prior art in terms of improving cutting accuracy, reducing material deformation and optimizing cutting efficiency. The test object is a 20mm thick steel structure plate made of high-strength low-alloy steel (HSLA), and the cutting equipment is a CNC plasma cutting machine. The implementation process is divided into two stages: the first stage uses the existing cutting technology, and the second stage uses the steel structure product cutting control system of the present invention, and the two are compared and tested under the same environmental conditions.

[0161] In the prior art, cutting parameters are usually based on a preset cutting path and static stress analysis. The cutting process only relies on a simple temperature monitoring and limit warning system provided by a vibration sensor. It lacks the ability to dynamically adjust the stress field in real time, resulting in low cutting accuracy and prone to deformation and thermal stress concentration in high stress areas.

[0162] The present invention uses a three-dimensional stress field modeling module to first perform a three-dimensional geometric scan on the steel structure to obtain its geometric model and material properties, divide the grid using finite element analysis technology, set boundary conditions and external loads, and generate a stress distribution map. The stress distribution map is used to identify high stress concentration areas and provide a basis for subsequent cutting path planning. On this basis, the parameter setting module automatically recommends the starting and end points of the cutting path, and generates initial cutting parameters according to the characteristics of different stress areas.

[0163] After the cutting process begins, the monitoring and analysis module collects the vibration acceleration data of the cutting tool in real time, and analyzes the vibration frequency and amplitude through Fourier transform. According to the changes in vibration data and stress distribution, the cutting parameters are dynamically adjusted to ensure that the error caused by vibration is reduced in high stress areas. In addition, the real-time temperature monitoring module monitors the temperature distribution of the cutting area through thermal imagers and temperature sensors, and calculates the thermal stress concentration phenomenon through the thermal stress equation. Combined with the coolant control module, it automatically adjusts the injection flow and angle of the coolant to prevent local overheating. During the cutting process, the system will also recalculate the current stress distribution based on the vibration and temperature data, and combine the stress field dynamic adjustment module to optimize the cutting path in real time.

[0164] The details are shown in Table 1 below:

[0165] Table 1 Experimental data record table

[0166]

[0167] By comparing the table data, it can be clearly seen that the present invention is significantly superior to the prior art in multiple key indicators. First, in terms of cutting speed, the system of the present invention can increase the cutting speed to 12 mm / s, while the prior art is only 10 mm / s. This is mainly due to the fact that the present invention can monitor and adjust the cutting parameters in real time, especially in areas of high stress concentration. Through the monitoring and analysis module, the system can dynamically adjust the cutting parameters in time when the vibration frequency reaches 20 Hz, reducing the impact of vibration on cutting accuracy. In the prior art, the vibration frequency is relatively high (50 Hz), and there is a lack of a corresponding adjustment mechanism, which limits the cutting speed.

[0168] Secondly, the cutting accuracy error of the present invention is only 0.2 mm, while the error of the prior art is as high as 0.6 mm. This difference is mainly reflected in the application of the stress adjustment module. By analyzing the vibration and temperature data in real time, the present invention can recalculate the stress distribution of the material and optimize the cutting path, thereby ensuring that the stress field during the cutting process remains stable and avoiding large deformation of the material during the cutting process. It can be seen from the table that the deformation of the material after cutting is only 0.8 mm in the present invention, while the deformation of the prior art is as high as 2.4 mm, which further verifies the advantage of the present invention in maintaining the shape stability of the steel structure.

[0169] In addition, the coordinated work of temperature monitoring and coolant control modules significantly reduces local overheating. In the embodiment of the present invention, the maximum temperature is 320°C and the local overheating area is 400 mm², while the maximum temperature of the prior art is 400°C and the local overheating area is 1500 mm². Effective temperature control not only reduces the concentration of thermal stress, but also greatly improves the cutting quality and avoids microstructural damage to the steel caused by overheating.

[0170] Finally, in terms of cutting efficiency, the present invention significantly shortens the total cutting time. Since the present invention can accurately plan the cutting path and optimize the cutting process through dynamic parameter adjustment, the total cutting time is 85 seconds, which is 15 seconds less than the 100 seconds of the prior art, which means that the production efficiency has been effectively improved.

[0171] In summary, the table data clearly shows the significant advantages of the present invention in terms of cutting accuracy, cutting speed, temperature control, material deformation and cutting efficiency. These beneficial effects not only reflect the innovation and novelty of the present invention in cutting steel structure products, but also solve the shortcomings of the prior art such as vibration monitoring lag, stress distribution cannot be adjusted in real time, and temperature control is not accurate, effectively improving the stability and quality of the cutting process.

[0172] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A steel structure product cutting control system, characterized in that: include, The three-dimensional stress field modeling module performs three-dimensional stress field modeling on steel structures and generates stress distribution diagrams of steel structures; Parameter setting module, based on the stress distribution diagram, sets the initial cutting parameters and performs preliminary cutting path planning; The monitoring and analysis module collects and analyzes vibration data during the cutting process in real time and dynamically adjusts cutting parameters; The detection module monitors the temperature distribution data of steel structures in real time, and detects local overheating and thermal stress concentration phenomena in combination with the adjusted cutting motion parameter feedback; A coolant control module that automatically adjusts the coolant injection parameters through a thermal stress control mechanism based on the detection results; The stress adjustment module combines real-time vibration data and temperature data to recalculate the stress distribution of steel structures and dynamically adjust the cutting path.

2. The steel structure product cutting control system according to claim 1, characterized in that: The three-dimensional stress field modeling of steel structure parts and the generation of stress distribution diagram of steel structure parts include the following steps: Use 3D scanning technology to obtain the 3D geometric model of steel structure parts and collect the material properties of the steel structure; Set boundary conditions and external loads for steel structures based on geometric models and material properties; After the boundary conditions and external load conditions are set, the finite element mesh is divided by finite element analysis technology; Based on finite element analysis technology, the geometric features of the 3D geometric model are analyzed to identify the key areas in the model; According to the complexity of the model and the needs of the user, select the corresponding mesh unit type and set the global mesh density to divide the mesh; According to the global mesh division results, local mesh refinement is performed in key areas to generate a comprehensive mesh; Perform mesh quality check on the generated comprehensive mesh, and generate a finite element mesh model after passing the check; All material properties and external loads are assigned to each mesh unit of the finite element model, the stress field of the steel structure is solved, the stress, strain and displacement data of each mesh unit are obtained, and the stress distribution diagram of the steel structure is automatically generated.

3. The steel structure product cutting control system according to claim 2, characterized in that: Based on the stress distribution diagram, set the initial cutting parameters and perform preliminary cutting path planning. The following steps are included: Based on the stress distribution diagram, the steel structure is analyzed as a whole, high stress concentration areas and low stress areas are identified, and areas suitable for cutting are divided; Automatically recommend the starting and ending points of the cutting path based on the geometric shape and stress distribution of the area suitable for cutting; After determining the starting and ending points of the cutting path, the stress distribution along the entire cutting path is analyzed again, and the initial cutting parameters are automatically recommended based on the stress values ​​in different areas; Dynamically adjust the cutting plan for the high stress concentration areas that the initial cutting path passes through; Integrate dynamic adjustment schemes for trunk lines and high stress concentration areas to generate global preliminary cutting paths; Generate corresponding cutting parameters according to different path segments in the global preliminary cutting path; Integrate all path information and cutting parameters to generate a preliminary cutting path file.

4. The steel structure product cutting control system according to claim 3, characterized in that: Real-time collection and analysis of vibration data during the cutting process and dynamic adjustment of cutting parameters include the following steps: Based on the stress distribution map and the stress concentration areas in the cutting path, the maximum bearing stress of each area is determined and converted into the corresponding vibration threshold; Real-time collection of vibration acceleration data of tools and equipment; The acceleration data is converted from the time domain to the frequency domain through Fourier transformation, the vibration energy at different frequencies is analyzed, and whether there is resonance frequency and abnormally high amplitude vibration is monitored; Set a safety threshold for vibration acceleration, compare the vibration amplitude at each frequency with the set safety threshold for vibration acceleration, and determine whether the vibration amplitude exceeds the safety threshold; Obtain the displacement data of each monitoring point, set the safety threshold of displacement, compare the displacement data with the safety threshold of displacement, and judge whether the slight deformation of steel during cutting exceeds the safety limit; Combine the analysis results of acceleration and displacement data to determine whether the cutting parameters need to be further adjusted; When it is determined that the cutting parameters need to be adjusted, a cutting parameter adjustment instruction is automatically generated to control the behavior of the cutting equipment and dynamically adjust the cutting parameters.

5. The steel structure product cutting control system according to claim 4, characterized in that: Real-time monitoring of the temperature distribution data of steel structures, combined with the adjusted cutting motion parameter feedback, detection of local overheating and thermal stress concentration phenomena includes the following steps: The temperature distribution data of the cutting area is collected in real time through thermal imagers and temperature sensors; Get the adjusted cutting speed, feed depth and path information in real time; The overheating temperature threshold is set according to the physical properties of steel, and the real-time temperature data is compared with the overheating temperature threshold. When the real-time temperature of a certain area exceeds the overheating temperature threshold, it is determined that local overheating has occurred in the area and the area is marked; The thermal stress in the area where local overheating occurs is calculated using the thermal stress equation, and the expression is: ； in, is the spatial coordinate position in the horizontal direction, is the spatial coordinate position in the vertical direction, is the spatial coordinate position in the depth direction, For time, is the thermal stress value, is the elastic modulus of the material, is the thermal expansion coefficient of the material, is the temperature difference in the area of ​​thermal stress concentration; Compare thermal stress values ​​to the yield strength in the steel material properties to identify thermal stress concentrations.

6. The steel structure product cutting control system according to claim 5, characterized in that: Based on the detection results, the injection parameters of the coolant are automatically adjusted through the thermal stress control mechanism, including the following steps: According to the thermal stress value, surface area, temperature difference and heat transfer coefficient of the overheated area, the injection flow rate of the coolant is calculated as follows: ； in, is the injection flow rate of the coolant, is the surface area of ​​the superheated region, is the heat transfer coefficient of the coolant, is the temperature difference in the overheated area, is the heat absorption capacity of the coolant; Dynamically adjust the coolant injection flow rate based on the real-time changes in the temperature of the thermal stress concentration area; According to the relative position of the coolant nozzle and the thermal stress concentration area, the injection angle is calculated as follows: ； in, is the spatial coordinate of the coolant nozzle, is the spatial coordinate of the thermal stress concentration area, is the injection angle; Dynamically adjust the spray angle according to the movement of the cutting head and the real-time changes in the thermal stress concentration area; The required cooling time is calculated based on the mass, specific heat capacity, temperature difference and coolant flow rate of the thermal stress concentration area. The expression is: ； in, is the required cooling time, is the mass of the thermal stress concentration area, is the specific heat capacity of the material, is the heat absorption capacity per unit volume of coolant; Dynamically adjust the injection time according to the real-time changes in the temperature of the overheated area; Use thermal imagers and temperature sensors to monitor the temperature changes in the cooling area in real time, and evaluate the cooling effect based on the temperature changes before and after cooling; Based on the cooling feedback data, the relevant parameters in the cutting process are dynamically adjusted.

7. The steel structure product cutting control system according to claim 6, characterized in that: Combining real-time vibration data and temperature data, recalculating the stress distribution of steel structures and dynamically adjusting the cutting path include the following steps: Real-time measurement of the three-dimensional stress distribution inside the steel and the temperature distribution on the surface and inside the steel; Calculate the thermal stress at the current moment based on the thermal expansion coefficient and elastic modulus of the material; The thermal stress is superimposed on the original mechanical stress to generate a dynamic stress field that changes with time; Through real-time vibration data, the impact of vibration on mechanical stress is calculated, and the distribution of mechanical stress is adjusted according to the current cutting speed and feed depth; According to the vibration and cutting parameters, the mechanical stress distribution of the material is recalculated and superimposed with the thermal stress to generate a new stress field; Perform gradient analysis on the updated stress field and calculate the stress change rate in each direction; Based on the stress gradient calculation results, the cutting path is dynamically adjusted.

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