A PCD tool machining control system and control method thereof

Abstract

The present invention discloses a processing control system and a control method for PCD tools, and relates to the technical field of tool production. The present invention includes: a power unit including a multi-section robotic arm and connecting parts; the connecting parts are all equipped with servo motors and reducers; the control unit is an X86 general platform, which is used to send operating instructions to the power unit to complete the path tracking and positioning of the robotic arm; the multi-sensor unit includes a laser radar and an ultrasonic probe, which are used to detect and build the robotic arm movement environment and detect the rotation position and speed of the robotic arm; the human-computer interaction unit includes a mouse and a keyboard as an input platform, which is used to input interactive information and control the movement of the robotic arm. The present invention sets the processing parameters of the PCD tool through the human-computer interaction unit, and the control unit positions the robotic arm and the grinding wheel on the robotic arm based on a neural network, and tracks and understands the travel route of the grinding wheel during the welding process in real time, thereby improving the processing efficiency and accuracy of the PCD tool.

Description

Technical Field

[0001] The present invention belongs to the technical field of tool production, and in particular relates to a processing control system and a control method of a PCD tool. Background Art

[0002] With the continuous improvement of power electronics technology, high-frequency induction welding machines have also been continuously developed, their functions have been changing with each passing day, and their application areas have been continuously expanding. The professional requirements of high-frequency induction welding machines are also getting higher and higher, and different dedicated models have emerged for different application fields.

[0003] PCD insert welding is a key technology in PCD tool manufacturing. Welding quality directly impacts the lifespan of PCD tools and the machining accuracy of the resulting PCD tool. The carbide substrate of PCD inserts has poor wettability, and its thermal expansion coefficient differs significantly from that of the toolholder, easily generating welding stress and causing weld defects. Furthermore, welding is currently still largely manual, resulting in low efficiency and a high risk of defective products, impacting the stability of production quality. Summary of the Invention

[0004] The purpose of the present invention is to provide a processing control system and control method for PCD tools, which independently controls the robotic arm of the grinder through a human-machine interaction unit and uses a multi-sensor unit to achieve precise positioning of the robotic arm, thereby solving the problems of low efficiency and proneness to defective products in existing manual operations.

[0005] To solve the above technical problems, the present invention is achieved through the following technical solutions:

[0006] The present invention is a PCD tool processing control system, comprising a power unit, a control unit, a multi-sensor unit, a human-computer interaction unit, a power management system and a detection system;

[0007] The power unit includes a plurality of robotic arms and connecting components between each robotic arm; the connecting components are each equipped with a servo motor and a reducer; the servo motor is electrically connected to a servo driver and a control unit in turn; the control unit controls the servo driver via a CAN and RS485 interface; and the servo driver controls the servo motor;

[0008] The control unit is an X86 general platform; the control unit communicates with the driver through the CAN bus and is used to send operating instructions to the power unit to complete the path tracking and positioning of the robot arm;

[0009] The multi-sensor unit includes a laser radar and an ultrasonic probe for detecting the motion environment of the robotic arm and detecting the rotation position and speed of the robotic arm;

[0010] The human-computer interaction unit includes a mouse and a keyboard as input platforms for inputting interaction information and controlling the movement of the robotic arm.

[0011] As a preferred technical solution, an electric rotary tool holder is provided at the end of the robotic arm; the electric rotary tool holder is used to install a grinding wheel when performing PCD tool processing.

[0012] As a preferred technical solution, the robotic arm includes a first section, a second section and a third section; the first section operates in a joint plane, and the operating plane of the robotic arm is made perpendicular to the PCD tool by rotation; the second section operates in a joint space, and the spatial position and pitch parameters of the robotic arm are adjusted by rotation; the third section operates in a joint plane, and the roll parameter angle is adjusted by rotating the robotic arm to achieve predetermined operations on the PCD tool.

[0013] As a preferred technical solution, the first section of the robotic arm rotates so that the operating plane of the second section of the robotic arm is perpendicular to the PCD tool; the second section of the robotic arm rotates so that the second section of the robotic arm approaches and faces the PCD tool; the third section of the robotic arm rotates to adjust the predetermined roll parameter angle to achieve position operation in three-dimensional space.

[0014] The present invention is a PCD tool processing control method, comprising the following steps:

[0015] Step S1: performing pre-processing operations on the PCD tool to be processed;

[0016] Step S2: Fix the processed PCD tool directly under the robotic arm and install the grinding wheel on the robotic arm;

[0017] Step S3: The user sets the processing parameters of the PCD tool through the human-computer interaction unit;

[0018] Step S4: The control unit positions the robotic arm based on the neural network;

[0019] Step S5: The CNC grinder controls the robot arm to perform predetermined operations on the PCD tool.

[0020] As a preferred technical solution, in step S1, the pretreatment operation of the PCD tool includes:

[0021] Step S11, degreasing and cleaning: cleaning the PCD tool to remove oil stains, and drying the cleaned PCD tool with nitrogen;

[0022] Step S12, rough machining: quenching the PCD tool; during the heat treatment process, not only should the PCD tool be given an appropriate hardness, but the internal stress should also be well controlled;

[0023] Step S13, grinding: performing constant temperature grinding on the PCD tool using a grinding wheel;

[0024] There are generally three types of grinding machines for grinding: surface grinders, internal and external cylindrical grinders, and tool grinders. Be extremely careful during the grinding process to avoid deformation of the PCD tool during the grinding process. In order to avoid deformation, it is necessary to ensure a smaller fine grinding feed, the coolant meets the needs, and parts with a dimensional tolerance within 0.01mm should be ground at a constant temperature as much as possible. At the same time, pay attention to whether the grinding wheel has been passivated, and maintain the grinding wheel regularly, because a passivated grinding wheel will leave wear marks on the surface of the PCD tool during grinding, thereby damaging the PCD tool. When performing fine grinding, the corresponding grinding wheel should be selected according to the specific conditions of different molds;

[0025] Step S14, electrical machining: The PCD tool is clamped on the electrode and subjected to electrical discharge machining (EDM). EDM processes are generally divided into wire cutting and electrical discharge machining. It can process PCD tools of various shapes or materials with high hardness. Before wire cutting, a series of inspections must be performed, such as the use of the grinder, whether the purity of the dedicated emulsion meets the standard, and whether the water temperature meets the processing requirements, to ensure high-precision cutting.

[0026] Step S15, Surface Treatment: The PCD tool surface is inspected and further inspected after machining. Pay special attention to any cracks or wear marks on the PCD tool surface. These are signs of stress concentration and are potential sources of future cracks. Therefore, to prevent cracks, the PCD tool surface is ground and strengthened by benchwork after machining.

[0027] As a preferred technical solution, in step S3, the processing parameters of the PCD tool need to be calibrated. During calibration, each model of PCD tool is tested multiple times on each model of CNC grinding machine, and the dimensional accuracy grade, shape accuracy grade and position accuracy grade of the PCD tool are measured each time, and the average accuracy grade is calculated. The calibration is repeated until the PCD tool reaches the preset accuracy grade.

[0028] As a preferred technical solution, in step S4, the neural network is a three-layer network structure consisting of an input layer, a hidden layer, and an output layer; the neural network is composed of input nodes to form an input layer; the input layer directly connects the network to the external environment and transmits the input signal x to the hidden layer; the hidden layer is used to transmit the input layer signal to the hidden node radial basis function in the hidden layer for nonlinear transformation, and the transformation here needs to be transformed through the radial basis function in the hidden node in the hidden layer, and the radial basis function is used to generate a local response to the input signal x.

[0029] As a preferred technical solution, in step S4, when positioning the robotic arm, the rectangular coordinates of the end of the first section of the robotic arm are set to , the angular position of the joint point is , then the rectangular coordinates of the robotic arm are expressed as:

[0030] ;

[0031] Where, Indicates the angle between the second section of the robot arm and the x-axis, It represents the angle between the first section of the robot arm and the second section of the robot arm. Indicates the length of the second section of the robotic arm, Indicates the length of the first section of the robotic arm;

[0032] The dynamic characteristic expression of the second section of the robotic arm is:

[0033] ;

[0034] Where, is represented as a vector of robot arm joint angles, It is expressed as the torque vector given to the robot arm, represents the inertia matrix of the second section of the robotic arm, is represented as the damping vector, Represented as the gravity vector.

[0035] The present invention has the following beneficial effects:

[0036] The present invention sets the processing parameters of the PCD tool through a human-computer interaction unit. The control unit positions the robotic arm and the grinding wheel on the robotic arm based on a neural network, and tracks the movement path of the grinding wheel during the welding process in real time, thereby improving the processing efficiency and accuracy of the PCD tool.

[0037] Of course, any product implementing the present invention does not necessarily need to achieve all of the advantages described above at the same time. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0039] Figure 1 This is a flow chart of a PCD tool processing control method of the present invention;

[0040] Figure 2This is a schematic structural diagram of a PCD tool processing control system of the present invention. DETAILED DESCRIPTION

[0041] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.

[0042] In addition, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0043] In order to make the purpose, technical solutions and advantages of this application more clear, the following Figure 1-2 It should be understood that the specific embodiments described herein are only used to explain the present application and are not intended to limit the present application.

[0044] Example 1

[0045] Based on the usage of conventional CNC grinding machines both domestically and internationally, CNC turning machining primarily utilizes conventional grinding machines. During CNC turning, workers randomly install the required grinding wheels onto the CNC grinder's electric rotary toolholder. The installed tools do not have a defined machining coordinate system relative to the part being machined. Before machining begins, tool alignment (note: each tool required for the part being machined) must be performed to determine the coordinate position of each turning tool within the machining coordinate system. This results in low efficiency, poor precision, and inconsistent quality.

[0046] See also Figure 1 As shown, the present invention is a PCD tool processing control system method, comprising the following steps:

[0047] Step S1: performing pre-processing operations on the PCD tool to be processed;

[0048] Step S2: Fix the processed PCD tool directly under the robotic arm and install the grinding wheel on the robotic arm;

[0049] Step S3: The user sets the processing parameters of the PCD tool through the human-computer interaction unit;

[0050] Step S4: The control unit positions the robotic arm based on the neural network;

[0051] Step S5: The CNC grinder controls the robot arm to perform predetermined operations on the PCD tool.

[0052] In step S1, the pre-processing operation of the PCD tool includes:

[0053] Step S11, degreasing and cleaning: cleaning the PCD tool to remove oil stains, and drying the cleaned PCD tool with nitrogen;

[0054] Step S12, rough machining: quenching the PCD tool; during the heat treatment process, not only should the PCD tool be given an appropriate hardness, but the internal stress should also be well controlled;

[0055] Step S13, grinding: performing constant temperature grinding on the PCD tool using a grinding wheel;

[0056] There are generally three types of grinding machines for grinding: surface grinders, internal and external cylindrical grinders, and tool grinders. Be extremely careful during the grinding process to avoid deformation of the PCD tool during the grinding process. In order to avoid deformation, it is necessary to ensure a smaller fine grinding feed, the coolant meets the needs, and parts with a dimensional tolerance within 0.01mm should be ground at a constant temperature as much as possible. At the same time, pay attention to whether the grinding wheel has been passivated, and maintain the grinding wheel regularly, because a passivated grinding wheel will leave wear marks on the surface of the PCD tool during grinding, thereby damaging the PCD tool. When performing fine grinding, the corresponding grinding wheel should be selected according to the specific conditions of different molds;

[0057] Step S14, electrical machining: The PCD tool is clamped on the electrode and subjected to electrical discharge machining (EDM). EDM processes are generally divided into wire cutting and electrical discharge machining. It can process PCD tools of various shapes or materials with high hardness. Before wire cutting, a series of inspections must be performed, such as the use of the grinder, whether the purity of the dedicated emulsion meets the standard, and whether the water temperature meets the processing requirements, to ensure high-precision cutting.

[0058] Step S15, Surface Treatment: The PCD tool surface is inspected and further inspected after machining. Pay special attention to any cracks or wear marks on the PCD tool surface. These are signs of stress concentration and are potential sources of future cracks. Therefore, to prevent cracks, the PCD tool surface is ground and strengthened by benchwork after machining.

[0059] In step S3, the processing parameters of the PCD tool need to be calibrated. During calibration, each model of PCD tool is tested multiple times on each model of CNC grinding machine, and the dimensional accuracy level, shape accuracy level and position accuracy level of the PCD tool are measured each time, and the average accuracy level is calculated. The calibration is repeated until the PCD tool reaches the preset accuracy level.

[0060] In step S4, the neural network is a three-layer network structure of an input layer, a hidden layer, and an output layer; the neural network is composed of input nodes to form an input layer; the input layer directly connects the network to the external environment and transmits the input signal x to the hidden layer; the hidden layer is used to transmit the input layer signal to the hidden node radial basis function in the hidden layer for nonlinear transformation. The transformation here needs to be transformed by the radial basis function in the hidden node in the hidden layer, and the radial basis function is used to generate a local response to the input signal x.

[0061] In step S4, when positioning the robot arm, the rectangular coordinates of the end of the first section of the robot arm are set to , the angular position of the joint point is , then the rectangular coordinates of the robotic arm are expressed as:

[0062] ;

[0063] Where, Indicates the angle between the second section of the robot arm and the x-axis, It represents the angle between the first section of the robot arm and the second section of the robot arm. Indicates the length of the second section of the robotic arm, Indicates the length of the first section of the robotic arm;

[0064] The dynamic characteristic expression of the second section robot arm is:

[0065] ;

[0066] Where, is represented as a vector of robot arm joint angles, It is expressed as the torque vector given to the robot arm, represents the inertia matrix of the second section of the robotic arm, is represented as the damping vector, Represented as the gravity vector.

[0067] Example 2

[0068] See Figure 2 As shown, the present invention is a PCD tool processing control system, which can be used to execute the method of Example 1 of the present invention, including: a power unit, a control unit, a multi-sensor unit, a human-computer interaction unit, a power management system and a detection system;

[0069] The power unit includes multiple sections of the robotic arm and connecting components between each section of the robotic arm; the connecting components are equipped with servo motors and reducers; the servo motors are electrically connected to the servo drivers and control units in turn; the control unit controls the servo drivers through CAN and RS485 interfaces; and the servo drivers control the servo motors;

[0070] The control unit is an X86 general-purpose platform. It communicates with the driver through the CAN bus and sends operating instructions to the power unit to complete the path tracking and positioning of the robot arm.

[0071] The multi-sensor unit includes a lidar and an ultrasonic probe, which are used to detect the motion environment of the robot arm and the rotation position and speed of the robot arm;

[0072] The human-computer interaction unit includes a mouse and keyboard as input platforms for inputting interactive information and controlling the movement of the robotic arm.

[0073] An electric rotary tool holder is provided at the end of the robotic arm; the electric rotary tool holder is used to install the grinding wheel when performing PCD tool processing.

[0074] The robotic arm consists of the first section, the second section and the third section. The first section operates in the joint plane, and the operating plane of the robotic arm is made perpendicular to the PCD tool by rotation. The second section operates in the joint space, and the spatial position and pitch parameters of the robotic arm are adjusted by rotation. The third section operates in the joint plane, and the roll parameter angle is adjusted by rotating the robotic arm to achieve the predetermined operation of the PCD tool.

[0075] The first section of the robotic arm rotates so that the operating plane of the second section of the robotic arm is perpendicular to the PCD tool; the second section of the robotic arm rotates so that the second robotic arm approaches and faces the PCD tool; the third section of the robotic arm rotates to adjust the predetermined roll parameter angle to achieve position operation in three-dimensional space.

[0076] It is worth noting that in the above system embodiment, the various units included are only divided according to functional logic, but are not limited to the above division, as long as the corresponding functions can be achieved; in addition, the specific names of the functional units are only for the convenience of distinguishing each other, and are not used to limit the scope of protection of the present invention.

[0077] In addition, those skilled in the art will appreciate that all or part of the steps in the above-mentioned embodiments can be accomplished by instructing related hardware through a program, and the corresponding program can be stored in a computer-readable storage medium.

[0078] The preferred embodiments of the present invention disclosed above are intended only to help illustrate the present invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the present invention to the specific embodiments described. Obviously, many modifications and variations are possible based on the content of this specification. These embodiments are selected and described in detail in this specification to better explain the principles and practical applications of the present invention, thereby enabling those skilled in the art to better understand and utilize the present invention. The present invention is limited only by the claims and their full scope and equivalents.

Claims

1. A PCD tool processing control system, comprising a power unit, a control unit, a multi-sensor unit, a human-machine interaction unit, a power management system, and a detection system, characterized in that: The power unit includes a plurality of robotic arms and connecting components between each robotic arm; the connecting components are each equipped with a servo motor and a reducer; the servo motor is electrically connected to a servo driver and a control unit in turn; the control unit controls the servo driver via a CAN and RS485 interface; and the servo driver controls the servo motor; The robotic arm comprises a first section, a second section and a third section; the first section operates in a joint plane, and the operating plane of the robotic arm is made perpendicular to the PCD tool by rotation; the second section operates in a joint space, and the spatial position and pitch parameters of the robotic arm are adjusted by rotation; the third section operates in a joint plane, and the roll parameter angle is adjusted by rotating the robotic arm to achieve predetermined operations on the PCD tool; The control unit is an X86 general platform; the control unit communicates with the driver through the CAN bus and is used to send operating instructions to the power unit to complete the path tracking and positioning of the robot arm; When positioning the robotic arm, the rectangular coordinates of the end of the first section of the robotic arm are set to , the angular position of the joint point is , then the rectangular coordinates of the robotic arm are expressed as: ； Where, Indicates the angle between the second section of the robot arm and the x-axis, It represents the angle between the first section of the robot arm and the second section of the robot arm. Indicates the length of the second section of the robotic arm, Indicates the length of the first section of the robotic arm; The dynamic characteristic expression of the second section of the robotic arm is: ； Where, is represented as a vector of robot arm joint angles, It is expressed as the torque vector given to the robot arm, represents the inertia matrix of the second section of the robotic arm, is represented as the damping vector, Expressed as gravity vector; The multi-sensor unit includes a laser radar and an ultrasonic probe for detecting the motion environment of the robotic arm and detecting the rotation position and speed of the robotic arm; The human-computer interaction unit includes a mouse and a keyboard as input platforms for inputting interaction information and controlling the movement of the robotic arm.

2. A PCD tool processing control system according to claim 1, characterized in that: An electric rotary tool holder is provided at the end of the robotic arm; the electric rotary tool holder is used to install a grinding wheel when performing PCD tool processing.

3. A PCD tool processing control system according to claim 2, characterized in that: The first section of the robotic arm rotates so that the operating plane of the second section of the robotic arm is perpendicular to the PCD tool; the second section of the robotic arm rotates so that the second section of the robotic arm is close to and facing the PCD tool; the third section of the robotic arm rotates to adjust a predetermined roll parameter angle to achieve position operation in three-dimensional space.

4. A method for controlling the processing of a PCD tool according to a processing control system of a PCD tool according to any one of claims 1 to 3, characterized in that: The steps include: Step S1: performing pre-processing operations on the PCD tool to be processed; Step S2: Fix the processed PCD tool directly under the robotic arm and install the grinding wheel on the robotic arm; Step S3: The user sets the processing parameters of the PCD tool through the human-computer interaction unit; Step S4: The control unit positions the robotic arm based on the neural network; Step S5: The CNC grinder controls the robot arm to perform predetermined operations on the PCD tool.

5. The PCD tool processing control method according to claim 4, characterized in that: In step S1, the pre-processing operation of the PCD tool includes: Step S11, degreasing and cleaning: cleaning the PCD tool to remove oil stains; Step S12, rough machining: quenching the PCD tool; Step S13, grinding: performing constant temperature grinding on the PCD tool using a grinding wheel; Step S14, electrical machining: clamping the PCD tool on the electrode to perform electrical discharge machining; Step S15: Surface treatment: inspecting the surface of the PCD tool.

6. The PCD tool processing control method according to claim 5, characterized in that: In step S3, the processing parameters of the PCD tool need to be calibrated. During calibration, each model of PCD tool is tested multiple times on each model of CNC grinding machine, and the dimensional accuracy level, shape accuracy level and position accuracy level of the PCD tool are measured each time, and the average accuracy level is calculated. The calibration is repeated until the PCD tool reaches the preset accuracy level.

7. The PCD tool processing control method according to claim 6, characterized in that: In step S4, the neural network is a three-layer network structure consisting of an input layer, a hidden layer, and an output layer; the neural network is composed of input nodes to form an input layer; the input layer directly connects the network to the external environment and transmits the input signal x to the hidden layer; the hidden layer is used to transmit the input layer signal to the hidden node radial basis function in the hidden layer for nonlinear transformation, and the transformation here needs to be transformed through the radial basis function in the hidden node in the hidden layer, and the radial basis function is used to generate a local response to the input signal x.

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