Balance correction method for compressor crankshaft finish machining

Abstract

The invention discloses a balance correction method for compressor crankshaft finish machining, and belongs to the technical field of crankshaft finish machining. The invention discloses a balance correction method for compressor crankshaft finish machining. The balance correction method comprises the following steps: step 1, a data acquisition stage; 2, an analysis and calculation stage; step 3, a counter weight adjusting stage: according to a calculation result, adding or removing a counter weight with corresponding mass at a specified position of the crankshaft so as to eliminate the amount of unbalance; and step 4, a verification stage. According to the balance correction method for compressor crankshaft finish machining provided by the invention, more detailed data can be obtained by using a high-precision non-contact measurement tool, so that the accuracy of analysis and calculation is improved; through integrated process management, tedious manual adjustment steps in a traditional method are reduced, the correction speed is increased, the application of automatic and intelligent technologies reduces the requirement for manual intervention, and the working efficiency is improved.

Description

Technical Field

[0001] The invention relates to the technical field of crankshaft finishing, in particular to a balancing correction method for finishing a compressor crankshaft. Background Art

[0002] In the compressor production process, the crankshaft is one of the key components, and its dynamic balance directly affects the operating stability and life of the compressor. The traditional crankshaft balancing correction method often requires repeated measurements and adjustments, which is not only inefficient, but also difficult to achieve high-precision requirements. Therefore, it is particularly necessary to develop a new balancing correction method for crankshaft finishing. Summary of the invention

[0003] The purpose of the present invention is to provide a balancing correction method for finishing a compressor crankshaft. By using a high-precision non-contact measuring tool, more detailed data can be obtained, thereby improving the accuracy of analysis and calculation; through integrated process management, the cumbersome manual adjustment steps in the traditional method are reduced, the correction speed is accelerated, and the problems raised in the above-mentioned background technology are solved.

[0004] To achieve the above object, the present invention provides the following technical solution: a balancing correction method for finishing a compressor crankshaft, comprising the following steps:

[0005] Step 1: Data collection stage: Use the instrument to perform a full-scale scan of the crankshaft that has not been balanced, obtain the actual dimensional parameters of each part of the crankshaft, and record the initial imbalance;

[0006] Step 2, analysis and calculation stage: import the collected data into special software, use computer-aided design and finite element analysis tools to simulate the dynamic response of the crankshaft at different speeds, and calculate the optimal counterweight position and weight through algorithms;

[0007] Step 3: Counterweight adjustment stage: according to the calculation results, add or remove the corresponding mass of counterweight blocks at the specified position of the crankshaft to eliminate the imbalance;

[0008] Step 4, Verification stage: After completing the counterweight adjustment, use precision instruments to check the balance state of the crankshaft again to ensure that it meets the relevant standard requirements.

[0009] Preferably, the method in the data collection stage is as follows:

[0010] Select the appropriate measuring tool and set the appropriate measurement range and resolution according to the size and shape of the crankshaft; install the crankshaft to be measured on a dedicated fixture to ensure that it does not move or vibrate during rotation; start a full-scale scan of the crankshaft to collect data on various parts of the crankshaft, including but not limited to diameter, length, weight distribution and other information. For parts that are difficult to reach, it may be necessary to scan from multiple angles to ensure the integrity of the data.

[0011] Preferably, in the data acquisition stage, the measuring equipment is calibrated before the formal measurement to ensure its accuracy, and standard parts are used for calibration. The measurement results are compared with the standard values, and the equipment parameters are adjusted. For known system errors, compensation parameters are set in the software in advance. If it is known that a certain measuring device has a fixed offset in a certain direction, it is corrected during data processing. When using multiple sensors, data fusion technology is used to integrate data from different sensors to improve measurement accuracy. Laser scanning data and contact measurement data are combined to complement their respective advantages.

[0012] Preferably, the analysis and calculation stage includes data import, data format conversion, data preprocessing, data integration and determination of crankshaft imbalance, ensuring that the original data format is compatible with the data analysis software used, and performing format conversion if necessary, for example, converting point cloud data into STL or OBJ format for subsequent processing.

[0013] Preferably, the specific method of data preprocessing is as follows: use a visualization tool to view the scanned data, mark points that are obviously deviated from normal data points, use an algorithm to automatically identify outliers, delete marked noise points, use an interpolation algorithm to fill in the empty area for local data missing due to occlusion and other reasons, use the average value or trend value of neighboring points to estimate the missing part of the data, and use a smoothing algorithm to reduce data fluctuations to make the crankshaft surface smoother;

[0014] Calculate the standard deviation and mean of the data set, and consider those points that are more than a certain number of standard deviations away from the mean as outliers; use the Z-score or IQR method to identify and remove outliers.

[0015] Preferably, the data integration is to stitch together the data scanned from different angles to form a complete three-dimensional model, and use software tools to smooth the data to ensure that the model surface is smooth and free of noise. The specific method is as follows:

[0016] Use 3D modeling software to import multiple data files scanned from different angles, preview the imported data in the software, check whether there is obvious noise or abnormal points, use the alignment tool provided by the software to align the scan segments, use feature matching, ICP (Iterative Closest Point) algorithm and other automatic alignment tools to align the data, stitch the aligned data together to form a complete 3D model, pay attention to check whether there are obvious gaps or overlaps at the joints, use the smoothing tool of the software to smooth the surface of the model, control the degree of smoothing, and avoid excessive smoothing leading to loss of details. If there are holes in the model, use the filling tool of the software to fill them to ensure the continuity and consistency of the model after filling. Use the denoising tool to remove small noise or irregular points on the surface of the model. You can use the denoising function in the software or manually select and delete noise points. Check whether the model has residual noise or splicing errors, and make necessary optimizations, such as adjusting the mesh density of the model to ensure that the model is neither too dense nor too sparse. After completing all preprocessing steps, export the processed 3D model and select the appropriate file format for subsequent use.

[0017] Preferably, the specific method for determining the unbalance amount of the crankshaft is as follows:

[0018] Import the integrated 3D model into professional software for imbalance calculation, set the crankshaft parameters, use the built-in functions of the software to calculate the center of gravity position and mass distribution of the crankshaft, simulate the dynamic response of the crankshaft during rotation through the software, automatically calculate the degree of center of gravity deviation and specific values ​​of imbalance, and export the calculation results, including key data such as center of gravity position and imbalance.

[0019] Preferably, the crankshaft parameters include material properties, density, and elastic modulus.

[0020] Preferably, the specific method of the counterweight adjustment stage is as follows:

[0021] Prepare the required counterweight materials. The selection of counterweight materials needs to consider their density, strength and compatibility with the crankshaft material. Prepare counterweight blocks of different specifications based on the calculation results to ensure that the position and weight of the counterweight can be flexibly adjusted. According to the optimal counterweight position determined in the analysis and calculation stage, use tools to mark the specified position on the crankshaft, adjust the counterweight at the marked position, and ensure that the counterweight achieves the desired effect. If necessary, repeatedly adjust the counterweight until the optimal balance is achieved. After the counterweight adjustment is completed, conduct a comprehensive inspection to ensure that all indicators of the crankshaft meet the standards and record the final counterweight configuration information for future maintenance and reference.

[0022] Preferably, the counterweight for adjusting the marked position includes adding counterweight and reducing counterweight. To add counterweight, the prepared counterweight block is installed at the marked position. For larger counterweight blocks, welding or high-strength adhesive may be required for fixation. For reducing counterweight, milling, drilling and the like are used to reduce the mass of a specific area. After installing or removing the counterweight, the balance of the crankshaft is rechecked.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] The present invention uses high-precision non-contact measurement tools to obtain more detailed data, thereby improving the accuracy of analysis and calculation; through integrated process management, the cumbersome manual adjustment steps in traditional methods are reduced, the correction speed is accelerated, and the application of automation and intelligent technology reduces the need for manual intervention and improves work efficiency; CAD / CAE tools can help designers better understand the dynamic response of the crankshaft under actual working conditions and ensure the effectiveness of the counterweight solution. Accurate simulation and calculation reduce the number of trial and error and improve the reliability of the final result; simulation tools can easily adjust parameters and facilitate customized balancing correction for crankshafts of different models or specifications. The data-driven method facilitates adjustment according to actual conditions, increasing the flexibility of the solution. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is a diagram showing the installation state of a crankshaft during balancing correction for finishing of a compressor crankshaft according to the present invention.

[0026] In the figure: 1. Balance frame; 2. Clamp; 3. Drive device; 4. Scanner. DETAILED DESCRIPTION

[0027] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. 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 creative work are within the scope of protection of the present invention.

[0028] In order to solve the problem that the existing traditional crankshaft balancing correction method often requires repeated measurement and adjustment, which is not only inefficient but also difficult to achieve high precision requirements, please refer to Figure 1 , this embodiment provides the following technical solutions:

[0029] A balancing correction method for finishing a compressor crankshaft comprises the following steps:

[0030] Step 1: Select a 3D scanner 4 equipped with a high-precision laser head. This device can accurately capture the details of the surface of an object and has the ability to scan quickly. Place the crankshaft on a special balancing frame 1. The balancing frame 1 has an adjustable clamp 2. The clamp 2 clamps and fixes the two ends of the crankshaft. The balancing frame 1 is also provided with a driving device 3. The driving device 3 is connected to one end of the crankshaft to control the rotation of the crankshaft. At the same time, the clamp 2 ensures that the crankshaft does not produce unnecessary shaking during the rotation process. The balancing frame 1 is equipped with a scanner 4. Set the working parameters of the scanner 4, such as scanning speed, resolution, etc., to ensure that sufficiently detailed crankshaft surface information can be obtained. Start the scanner 4 and scan from one end of the crankshaft to the other end. During this period, the position of the scanner 4 is continuously adjusted to ensure that all important parts of the crankshaft are covered.

[0031] Step 2: After scanning, import all collected data into the computer and use professional data analysis software to integrate and process the data. Make sure that the original data format is compatible with the data analysis software used. If necessary, perform format conversion, for example, convert the point cloud data into STL or OBJ format for subsequent processing.

[0032] Use data cleaning tools to remove noise points in the scanned data, use 3D modeling software to view the scanned data, mark points that obviously deviate from normal data points, use the DBSCAN clustering algorithm to automatically identify outliers, delete marked noise points, and use interpolation algorithms to fill in empty areas for local data missing due to occlusion and other reasons. Use the average or trend value of neighboring points to estimate the missing data, and use the moving average method to reduce data fluctuations to make the crankshaft surface smoother.

[0033] Calculate the standard deviation and mean of the data set, and consider those points that are more than a certain standard deviation away from the mean, such as 3 standard deviations, as outliers; use the Z-score or IQR method to identify and remove outliers.

[0034] Use the 3D modeling software Autodesk Meshmixer to import multiple data files scanned from different angles, preview the imported data in the software, check whether there is obvious noise or abnormal points, use the alignment tool provided by the software to align the scan segments, use feature matching and ICP algorithm automatic alignment tools to perform data registration, stitch the aligned data together to form a complete 3D model, pay attention to check whether there are obvious gaps or overlaps at the joints, use the Smooth function in Meshmixer to smooth the model surface, control the degree of smoothing, and avoid excessive smoothing that causes loss of details. If there are holes in the model, use the Hole Filling Brush software filling tool to fill them to ensure the continuity and consistency of the filled model. Use the denoising tool to remove small noise or irregular points on the model surface. You can use the denoising function in the software or manually select and delete noise points. Check whether the model has residual noise or splicing errors, and perform necessary optimization, such as adjusting the mesh density of the model to ensure that the model is neither too dense nor too sparse. After completing all preprocessing steps, export the processed 3D model and select a suitable file format, such as STL, OBJ, etc., for subsequent use.

[0035] Import the integrated 3D model into ANSYS Mechanical, a professional software for imbalance calculation, and set the crankshaft parameters, including material properties, density, and elastic modulus. Use the built-in functions of the software to calculate the center of gravity and mass distribution of the crankshaft. The software simulates the dynamic response of the crankshaft during rotation, automatically calculates the degree of center of gravity deviation and the specific value of imbalance, and exports the calculation results, including key data such as center of gravity position and imbalance. Finally, a detailed report is output, which includes key information such as the crankshaft's 3D model, center of gravity position, and imbalance.

[0036] Step three: prepare the required counterweight materials. The selection of counterweight materials needs to consider their density, strength and compatibility with the crankshaft material. Prepare counterweight blocks of different specifications according to the calculation results to ensure that the position and weight of the counterweight can be flexibly adjusted; according to the optimal counterweight position determined in the analysis and calculation stage, use a magnetic drill, electric welder, etc. to mark the specified position of the crankshaft and adjust the counterweight at the marked position. The counterweight at the marked position includes adding counterweight and reducing counterweight. Adding counterweight will install the prepared counterweight block to the marked position. For larger counterweight blocks, welding or high-strength adhesive may be required to fix them. For reducing counterweight, milling, drilling and other methods are used to reduce the mass of specific areas to ensure that the counterweight achieves the desired effect. If necessary, repeatedly adjust the counterweight until the optimal balance is achieved. After the counterweight adjustment is completed, conduct a comprehensive inspection to ensure that all indicators of the crankshaft meet the standards and record the final counterweight configuration information for future maintenance and reference.

[0037] Step 4, Verification stage: After completing the counterweight adjustment, use precision instruments to check the balance state of the crankshaft again to ensure that it meets the relevant standard requirements.

[0038] In summary: the present invention proposes a balancing correction method for finishing a compressor crankshaft. The present invention integrates the process of data collection, analysis and calculation, counterweight adjustment to final verification. A high-precision laser rangefinder or a non-contact sensor is used for all-round scanning. Compared with the traditional contact measurement method, this method can reduce the damage to the crankshaft surface and obtain more detailed data. The CAD / CAE technology is used for simulation and analysis, which can more accurately predict the behavior of the crankshaft under different working conditions, thereby optimizing the counterweight scheme. The entire process tends to a higher level of automation, and algorithm optimization is introduced in the calculation stage to improve the efficiency and accuracy of the counterweight adjustment.

[0039] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0040] While the embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that many changes, modifications, substitutions and variations can be made to the embodiments without departing from the principles and spirit of the invention.

Claims

1. A balancing correction method for finishing a compressor crankshaft, characterized in that: The following steps are involved: Step 1: Data collection stage: Use the instrument to perform a full-scale scan of the crankshaft that has not been balanced, obtain the actual dimensional parameters of each part of the crankshaft, and record the initial imbalance; Step 2, analysis and calculation stage: import the collected data into special software, use computer-aided design and finite element analysis tools to simulate the dynamic response of the crankshaft at different speeds, and calculate the optimal counterweight position and weight through algorithms; Step 3: Counterweight adjustment stage: according to the calculation results, add or remove the corresponding mass of counterweight blocks at the specified position of the crankshaft to eliminate the imbalance; Step 4, Verification stage: After completing the counterweight adjustment, use precision instruments to check the balance state of the crankshaft again to ensure that it meets the relevant standard requirements.

2. The balancing correction method for finishing a compressor crankshaft according to claim 1, characterized in that: The method of the data collection stage is as follows: Select the appropriate measuring tool and set the appropriate measurement range and resolution according to the size and shape of the crankshaft; install the crankshaft to be measured on a dedicated fixture; start scanning the crankshaft in all directions and collect data from all parts of the crankshaft.

3. The balancing correction method for finishing a compressor crankshaft according to claim 2, characterized in that: In the data acquisition stage, before the formal measurement, the measuring equipment is calibrated using standard parts, the measurement results are compared with the standard values, the equipment parameters are adjusted, and for known system errors, compensation parameters are pre-set in the software.

4. The balancing correction method for finishing a compressor crankshaft according to claim 1, characterized in that: The analysis and calculation stage includes data import, data format conversion, data preprocessing, data integration and determination of the unbalance amount of the crankshaft.

5. The balancing correction method for finishing a compressor crankshaft according to claim 4, characterized in that: The specific method of data preprocessing is as follows: use a visualization tool to view the scanned data, mark the points that obviously deviate from the normal data points, use an algorithm to automatically identify the outliers, delete the marked noise points, use an interpolation algorithm to fill the empty areas for local data missing due to occlusion, use the average value or trend value of the neighboring points to estimate the missing data, and use a smoothing algorithm to reduce data fluctuations to make the crankshaft surface smoother; Calculate the standard deviation and mean of the data set, and consider those points that are more than a certain number of standard deviations away from the mean as outliers; use the Z-score or IQR method to identify and remove outliers.

6. The balancing correction method for finishing a compressor crankshaft according to claim 4, characterized in that: The data integration is to stitch together the data scanned from different angles to form a complete 3D model, and use software tools to smooth the data to ensure that the model surface is smooth and free of noise. The specific method is as follows: Use 3D modeling software to import multiple data files scanned from different angles, use the alignment tool provided by the software to align the scan segments, use feature matching, ICP algorithm and other automatic alignment tools to perform data registration, splice the aligned data to form a 3D model, use the software's smoothing tool to smooth the model surface and control the degree of smoothness. If there are holes in the model, use the software's filling tool to fill them, use the denoising tool to remove small noise or irregular points on the model surface, check the model for residual noise or splicing errors, and optimize it. After completing all preprocessing steps, export the processed 3D model.

7. The balancing correction method for finishing a compressor crankshaft according to claim 4, characterized in that: The specific method for determining the unbalance amount of the crankshaft is as follows: Import the integrated 3D model into professional software for imbalance calculation, set the crankshaft parameters, use the built-in functions of the software to calculate the center of gravity position and mass distribution of the crankshaft, simulate the dynamic response of the crankshaft during rotation through the software, automatically calculate the degree of center of gravity deviation and specific values ​​of imbalance, and export the calculation results, including center of gravity position and imbalance data.

8. The balance correction method for finishing a compressor crankshaft according to claim 7, characterized in that: The crankshaft parameters include material properties, density, and elastic modulus.

9. The balancing correction method for finishing a compressor crankshaft according to claim 1, characterized in that: The specific method of the counterweight adjustment stage is as follows: Prepare the required counterweight materials and prepare counterweight blocks of different specifications according to the calculation results; use tools to mark the designated position of the crankshaft according to the optimal counterweight position determined in the analysis and calculation stage, adjust the counterweight at the marked position, and after the counterweight adjustment is completed, conduct a comprehensive inspection to ensure that all indicators of the crankshaft meet the standards.

10. The balance correction method for finishing a compressor crankshaft according to claim 9, characterized in that: The method of adjusting the counterweight at the marked position includes adding the counterweight and reducing the counterweight. To add the counterweight, the prepared counterweight block is installed at the marked position. To reduce the counterweight, milling or drilling is used to reduce the mass of a specific area. After installing or removing the counterweight, the balance state of the crankshaft is rechecked.

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