Self-adaptive control system and method of five-axis numerical control machine tool

Abstract

The invention relates to the technical field of control systems, and discloses a self-adaptive control system and method for a five-axis numerical control machine tool, machining data and a machining program are controlled through a simulation interaction module, and the state and the machining data of the machine tool are displayed in real time through an interaction display strategy; the sensing monitoring module obtains machining data in the machining process in real time and transmits the machining data to the path judgment module and the simulation interaction module through a data transmission strategy. The path judgment module judges the machining path of the five-axis numerical control machine tool according to the machining data through a path generation strategy, so that the machining efficiency and quality are improved; the motion control module generates a motion control instruction of the five-axis numerical control machine tool according to the machining program and the machining path of the five-axis numerical control machine tool through an instruction generation strategy, accurately drives the five-axis numerical control machine tool to move, and ensures the machining precision; the safety monitoring module monitors the state of the machine tool in real time, and if the five-axis numerical control machine tool is abnormal, an abnormity processing strategy is executed.

Description

Technical Field

[0001] The present invention relates to the technical field of control systems, and in particular to an adaptive control system and method for a five-axis CNC machine tool. Background Art

[0002] Five-axis CNC machine tools can simultaneously adjust the cutting position and direction of the tool relative to the workpiece, have higher cutting efficiency, and can complete multiple processes after one clamping. Through adaptive control systems, five-axis CNC machine tools can achieve high-precision parts processing. However, most of them have not solved how to determine the processing path of five-axis CNC machine tools through processing data, control the movement of five-axis CNC machine tools, and monitor the machine status to execute abnormal handling strategies.

[0003] For example, the Chinese patent application with the publication number CN117872962A discloses a CNC machine tool control system, including: a control terminal: the master control end of the system, used to issue execution commands; a power module, used to provide the power required by the machine tool, including AC power and DC power; an input module: used to convert the input digital signal into analog and output a controllable continuous voltage and current signal. The system provides a simpler structure, the whole system is more stable and reliable, the PLC has strong anti-interference ability, can adapt to various environments of industrial sites, and has a long life, can work stably for a long time, is suitable for the machine tool operating environment, meets the requirements of accuracy and speed, has good stability, small maintenance workload, fast response speed, and improves production efficiency, etc., so that the three axes and the main axis have the advantages of high accuracy, high speed, strong adaptability, good stability, fast acceleration and deceleration dynamic response and low energy consumption.

[0004] For example, a Chinese patent application with authorization announcement number CN114995291B discloses a CNC machine tool control system, including a control terminal for issuing execution commands; an input module for inputting the numerical value of the specification parameter of the machine tool processing parts of the system; a verification module for obtaining the numerical value of the specification parameter of the processing parts obtained by running the input module, and building a three-dimensional model of the processing parts with reference to the numerical value of the specification parameter of the processing parts; a design module for obtaining the three-dimensional model of the processing parts, and designing the machine tool running program command with reference to the three-dimensional model of the processing parts; during use, two different input methods are provided to obtain the parameter data of the required processing mechanical parts, thereby greatly enhancing the adaptability of the system in actual application, and the CNC machine tool can be applicable to the processing of various specifications of mechanical parts within a certain range.

[0005] The above technical solution has the problem raised by the background technology: it does not solve the problem of how to determine the processing path of the five-axis CNC machine tool through processing data, control the movement of the five-axis CNC machine tool, and monitor the machine tool status to execute the abnormality handling strategy. To solve this problem, the present invention proposes an adaptive control system and method for a five-axis CNC machine tool. Summary of the invention

[0006] In view of the above problems existing in the adaptive control system and method of the existing five-axis CNC machine tool, the present invention is proposed.

[0007] Therefore, the object of the present invention is to provide an adaptive control system and method for a five-axis CNC machine tool.

[0008] In order to solve the above technical problems, the present invention provides an adaptive control system for a five-axis CNC machine tool: a simulation interaction module, a sensor monitoring module, a path judgment module, a motion control module and a safety monitoring module; The simulation interaction module is used to control the processing data and processing program, and to display the machine tool status and processing data in real time through an interactive display strategy; The sensor monitoring module is used to obtain processing data in the processing process in real time, and transmit the processing data to the path judgment module and the simulation interaction module through a data transmission strategy; The path determination module is used to determine the processing path of the five-axis CNC machine tool according to the processing data through a path generation strategy, wherein the path generation strategy includes obtaining a workpiece model, cutting the workpiece according to the style of the workpiece model to form multiple processing layers, and dividing the initial processing path according to the processing layers; The motion control module is used to generate motion control instructions for the five-axis CNC machine tool according to the machining program and the machining path of the five-axis CNC machine tool through an instruction generation strategy, and drive the movement of the five-axis CNC machine tool; The safety monitoring module is used to monitor the status of the machine tool in real time. If an abnormality occurs in the five-axis CNC machine tool, an abnormality handling strategy is executed.

[0009] As a preferred solution of the adaptive control system of a five-axis CNC machine tool described in the present invention, the path generation strategy includes: Obtain a workpiece model, and cut the workpiece according to the style of the workpiece model to form multiple processing layers, and divide the initial processing path according to the processing layers; Establish a path prediction model based on processing data; Inputting real-time processing data into the path prediction model, adjusting the processing path according to the output result of the path prediction model, and feeding back to the graphical user interface; The machining path is continuously optimized and the optimized machining path is converted into G code.

[0010] As a preferred solution of the adaptive control system of a five-axis CNC machine tool described in the present invention, the strategy for optimizing the processing path includes: The optimization target of the processing path is given by optimizing the objective function, and the constraint conditions in the processing process are given. The optimized processing path is solved according to the optimization objective function and the constraint conditions, and the optimized processing path is displayed in real time on a graphical user interface.

[0011] As a preferred solution of the adaptive control system of a five-axis CNC machine tool described in the present invention, wherein: the motion control instructions include position instructions, speed instructions and tool change instructions; Instruction generation strategies include: Solve the optimized machining path, convert the machining path into G code recognizable by the five-axis CNC machine tool, parse the G code, obtain the path of the tool in the translation axis and the rotation axis according to the parsing result of the G code, generate a position command, calculate the spindle speed and feed speed at the same time, generate a speed command, and generate a tool replacement command according to the damage of the tool and the tool demand, perform speed planning according to the position command and speed command, and perform collision detection in the process of generating motion control commands. If a collision is detected, adjust the path of the tool in the translation axis and the rotation axis. If the collision cannot be eliminated after adjusting the path of the tool in the translation axis and the rotation axis, issue an alarm and stop the movement of the five-axis CNC machine tool, and safely exit the machining program. Receive the position feedback of the five-axis CNC machine tool in real time and compare it with the preset motion control command. If there is an error between the real-time position of the five-axis CNC machine tool and the position in the preset motion control command, adjust the position command, send the motion control command to the machining program, control the motor of the five-axis CNC machine tool, and drive the movement of the five-axis CNC machine tool.

[0012] As a preferred solution of the adaptive control system of a five-axis CNC machine tool described in the present invention, the exception handling strategy includes: monitoring the processing data in real time, configuring an upper data threshold and a lower data threshold, if the monitored processing data is greater than the upper data threshold or less than the lower data threshold, the five-axis CNC machine tool is abnormal, judging the authenticity of the abnormality of the five-axis CNC machine tool, if the five-axis CNC machine tool returns to normal after adjusting the processing data and the processing path, the abnormality of the five-axis CNC machine tool is false; If the five-axis CNC machine tool does not return to normal after adjusting the processing data and the processing path, the abnormality of the five-axis CNC machine tool is true, and an alarm is displayed on the graphical user interface and a voice prompt is given to prompt that the five-axis CNC machine tool has an abnormality. At the same time, the operation of the five-axis CNC machine tool is stopped, the abnormality of the five-axis CNC machine tool is diagnosed, and repair measures are taken until the processing program and the five-axis CNC machine tool are restarted after the repair, and the display of the five-axis CNC machine tool returns to normal.

[0013] As a preferred solution of the adaptive control system of a five-axis CNC machine tool described in the present invention, the interactive display strategy includes: Design a graphical user interface to display the machine status, processing data and processing path in real time on the graphical user interface, customize the interface layout, provide intelligent prompts for processing data adjustment according to the machine status, analyze the processing data in real time, simulate and display the processing path on the graphical user interface before starting the processing program, and set a safety stop button.

[0014] As a preferred solution of the adaptive control system of a five-axis CNC machine tool described in the present invention, wherein: the processing data includes tool posture, cutting force, workpiece temperature, machine vibration and process parameters; The processing data is transmitted to the path judgment module and the simulation interaction module through the data transmission strategy, and the data transmission strategy includes: Preprocessing the acquired processing data, converting the processing data into data packets, storing the data packets in a cache group, and not triggering data packet transmission if no processing event is detected; If a processing event is detected, data packet transmission is triggered, a timestamp is added to each transmitted data packet, and a priority is assigned to the data packet transmission, and the data packet is transmitted according to the priority.

[0015] As a preferred solution of the adaptive control system of a five-axis CNC machine tool described in the present invention, the method of dividing the initial processing path according to the processing layer includes: Establish multiple coordinate systems, including the workpiece clamping coordinate system, the tool head coordinate system and the machine tool coordinate system, set the tool detection strategy based on the multiple coordinate systems, and determine the initial processing path and processing parameters according to the tool detection strategy; Tool detection includes detection during the processing of a single processing layer, and detection of the processing position between layers when switching to processing on different processing layers; Determine the processing position according to the tool detection strategy, and compare whether the processing position in multiple coordinate systems is unique; When the processing position deviates, it is determined whether the tool has collided. If the processing position is a positive deviation, it indicates that the tool is not in place; If the machining position has a negative deviation, it indicates tool collision; When the tool collides, the tool is corrected.

[0016] An adaptive control method for a five-axis CNC machine tool, comprising: S1, controlling processing data and processing program, and displaying the machine tool status and processing data in real time through an interactive display strategy; S2, real-time acquisition of processing data during the processing; S3, determining a processing path of the five-axis CNC machine tool according to the processing data through a path generation strategy, wherein the path generation strategy includes obtaining a workpiece model, cutting the workpiece according to a style of the workpiece model to form a plurality of processing layers, and dividing the initial processing path according to the processing layers; S4, generating motion control instructions for the five-axis CNC machine tool according to the machining program and the machining path of the five-axis CNC machine tool through an instruction generation strategy, and driving the movement of the five-axis CNC machine tool; S5, real-time monitoring of machine tool status, if the five-axis CNC machine tool has an abnormality, execute the abnormality handling strategy; S6. Establish multiple coordinate systems, including the workpiece clamping coordinate system, the tool coordinate system and the machine tool coordinate system, execute the tool detection strategy, detect the tool processing position when switching between single processing layers and layers, determine whether the tool collides, and correct the tool.

[0017] The beneficial effects of the present invention are as follows: the present invention controls the processing data and processing program through the simulation interaction module, and displays the machine tool status and processing data in real time through the interactive display strategy, thereby enhancing the operator's control and monitoring capabilities over the processing process; the sensor monitoring module acquires the processing data during the processing process in real time, and transmits the processing data to the path judgment module and the simulation interaction module through the data transmission strategy, thereby ensuring accurate real-time data to support processing decisions and monitoring; the path judgment module determines the processing path of the five-axis CNC machine tool according to the processing data through the path generation strategy, thereby helping to improve processing efficiency and quality; the motion control module generates the motion control instructions of the five-axis CNC machine tool according to the processing program and the processing path of the five-axis CNC machine tool through the instruction generation strategy, and drives the motion of the five-axis CNC machine tool to ensure processing accuracy; the safety monitoring module monitors the machine tool status in real time, and if an abnormality occurs in the five-axis CNC machine tool, executes the abnormality handling strategy, thereby ensuring the safety of the five-axis CNC machine tool, the operator and the workpiece.

[0018] Through the combined action of the above modules, the control system can automatically receive motion control instructions, calculate the optimal processing path, and accurately control the movement of the five-axis CNC machine tool, reducing human intervention and improving production efficiency; the control system can dynamically adjust the processing data to adapt to changes in the processing process and ensure processing quality; the control system ensures the safety of the entire processing process and avoids potential equipment damage and personal injury; the control system can interact with the operator and obtain processing status information, improving the transparency and ease of use of the operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] 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 labor. Among them: Figure 1 A structural diagram of an adaptive control system for a five-axis CNC machine tool according to the present invention; Figure 2 A data transmission strategy flow chart of an adaptive control system of a five-axis CNC machine tool according to the present invention; Figure 3 A flow chart of an instruction generation strategy for an adaptive control system of a five-axis CNC machine tool according to the present invention; Figure 4 The present invention is a flow chart of an adaptive control method for a five-axis CNC machine tool. DETAILED DESCRIPTION

[0020] 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.

[0021] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention can also be implemented in other ways different from those described herein, and those skilled in the art can make similar generalizations without violating the connotation of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0022] 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.

[0023] Example 1 In this embodiment, Figure 1 As shown, an adaptive control system for a five-axis CNC machine tool includes a simulation interaction module, a sensor monitoring module, a path judgment module, a motion control module and a safety monitoring module.

[0024] The simulation interaction module is used to control the processing data and processing program, and display the machine tool status and processing data in real time through an interactive display strategy.

[0025] The machine tool status and processing data are displayed in real time through interactive display strategies, which include: Design a graphical user interface to display the machine status, processing data and processing path in real time on the graphical user interface, support customized interface layout, provide intelligent prompts for processing data adjustment according to the machine status, analyze the processing data input by the operator in real time, simulate and display the processing path on the graphical user interface before starting the processing program, and set a safety stop button.

[0026] This module allows the operator to interact with the control system. The operator can input or change processing data, start or stop the processing program. At the beginning of starting the processing program, the preset processing data can be input. When problems occur in the five-axis CNC machine during the processing, the problems can be corrected by changing the processing data.

[0027] A graphical user interface is designed, which is equipped with a machine tool status display area, a processing data display area, a processing path display area, a custom interface area, a processing data control area, a processing program control area and a safety stop button. Before starting the processing program, the operator needs to input the processing data in the processing data control area, and at the same time, the processing path generated according to the processing data is simulated and displayed in the processing path display area. After the input is completed, the processing program is started in the processing program control area, and the processing data is displayed. Through subsequent continuous monitoring of the status of the five-axis CNC machine tool, it is displayed in real time in the machine tool status display area. If an emergency occurs, the safety stop button can be used to quickly stop the operation of the five-axis CNC machine tool and safely exit the processing program, and intelligent prompts are given as to which processing data need to be adjusted.

[0028] The sensor monitoring module is used to obtain the processing data in real time during the processing, and transmit the processing data to the path judgment module and the simulation interaction module through the data transmission strategy.

[0029] Processing data includes tool posture, cutting force, workpiece temperature, machine vibration and process parameters.

[0030] The processing data is transmitted to the path judgment module and the simulation interaction module through the data transmission strategy. Figure 2 As shown, specifically including: Preprocess the acquired processing data, convert the processing data into data packets, and store the data packets in the cache group. If no processing event is detected, the data packet transmission is not triggered; If a processing event is detected, the data packet transmission is triggered, a timestamp is added to each transmitted data packet, and a priority is assigned to the data packet transmission. The data packet is transmitted according to the priority, and after being transmitted to the path judgment module and the simulation interaction module, the data packet is converted into processing data.

[0031] The processing data of the five-axis CNC machine tool during the processing is obtained in real time through sensors. Real-time monitoring of the tool posture can ensure the accurate execution of the processing path and avoid processing errors. The monitoring of the workpiece temperature can effectively prevent the deformation or damage of the workpiece caused by overheating. By monitoring the cutting force, the cutting force can be adjusted in real time to prevent tool breakage or workpiece damage. The machine tool vibration data can help identify and avoid vibration problems that may lead to a decrease in processing quality and optimize cutting conditions. The process parameters include spindle speed, feed speed, cutting speed and cutting depth, which are key factors in determining the processing effect and need to be precisely controlled according to different processing requirements.

[0032] The acquired processing data is preprocessed, including filtering, denoising and formatting, to reduce the amount of data transmission and improve the quality of data transmission. The processing data is compressed into data packets and divided into a memory space, which is defined as a cache group. The data packets are stored in the cache group before transmission. At the same time, it is detected whether a processing event occurs. The processing event is set according to the actual situation. Here, the processing event is set as the tool touching the workpiece. When a processing event is detected, the data packet transmission is triggered, and a timestamp is added to each transmitted data packet to ensure that the path judgment module and the simulation interaction module can correctly sort and synchronize the processing data according to the timestamp. At the same time, priority is assigned to the data packet transmission to ensure that the data packet can be transmitted first when the network load is heavy. After being transmitted to the path judgment module and the simulation interaction module, the data packet is decompressed into processing data for subsequent processing.

[0033] The path judgment module is used to judge the machining path of the five-axis CNC machine tool according to the machining data through the path generation strategy.

[0034] Through the path generation strategy, the processing path of the five-axis CNC machine tool is determined according to the processing data. The path generation strategy includes: Obtain a workpiece model, and cut the workpiece according to the style of the workpiece model to form multiple processing layers, and divide the initial processing path according to the processing layers; Establish a path prediction model based on processing data; Input the real-time processing data into the path prediction model, adjust the processing path according to the output result of the path prediction model, and feed back to the graphical user interface; Continuously optimize the machining path and convert the optimized machining path into G code.

[0035] Directly read the CAD model file to obtain the precise three-dimensional data of the workpiece model, analyze the shape, size and surface features of the workpiece model through image processing algorithms, determine the complexity of the workpiece model and key structural parts, and determine the reasonable layering thickness and layering method according to the pre-set processing technology rules and the shape, size and surface features of the workpiece model. For example, equal thickness layering is used for parts with regular shapes and uniform sizes, while variable thickness layering is used for parts with complex shapes and large curvature changes, to ensure the accuracy and efficiency of each processing layer, and identify the contours of the divided processing layers to generate the initial processing path, which is generally partitioned processing.

[0036] By accurately acquiring the data of the workpiece model, deeply analyzing the characteristics of the workpiece, and combining the processing technology rules, it is possible to achieve reasonable stratification of the workpiece, ensuring that each processing layer can not only meet the processing accuracy requirements but also improve the processing efficiency. The initial processing path is generated based on the stratification results, providing a basis for subsequent processing processes.

[0037] Suppose there is a complex impeller workpiece with complex blade shapes and large curvature variations. The traditional single processing method is difficult to ensure processing accuracy and efficiency. The above method is used to first obtain the precise model data of the impeller through three-dimensional scanning, and then use the image processing algorithm to analyze the shape characteristics of the blades, and determine to use a variable thickness layering method. For the thinner parts of the blades with large curvature variations, the thickness of the processing layer is set to be smaller. For parts with relatively regular shapes such as the root of the blade, the thickness of the processing layer is appropriately increased. For the contour of each processing layer, the initial processing path of partition processing is adopted.

[0038] Through reasonable stratification and initial processing path planning, the processing efficiency is improved, the processing time and tool wear are reduced, and the processing cost is reduced while ensuring the processing accuracy.

[0039] Methods for dividing the initial processing paths according to the processing layers include: Establish multiple coordinate systems, including the workpiece clamping coordinate system, the tool head coordinate system and the machine tool coordinate system, set the tool detection strategy based on the multiple coordinate systems, and determine the initial processing path and processing parameters according to the tool detection strategy; Tool detection includes detection during the processing of a single processing layer, and detection of the processing position between layers when switching to processing on different processing layers; Determine the processing position according to the tool detection strategy, and compare whether the processing position in multiple coordinate systems is unique; When the processing position deviates, it is determined whether the tool has collided. If the processing position is a positive deviation, it indicates that the tool is not in place; If the machining position has a negative deviation, it indicates tool collision; When the tool collides, the tool is corrected.

[0040] When the workpiece is clamped on the machine tool, the workpiece clamping coordinate system is established according to the positioning reference of the fixture to ensure that the position and posture of the workpiece on the machine tool can be accurately described; with the geometric center of the tool as the origin, a tool coordinate system related to the tool movement direction is established to describe the position and posture of the tool; and the machine tool coordinate system, as the fixed coordinate system of the machine tool, is the reference of other coordinate systems. All motion instructions and position feedback are converted and calculated based on the machine tool coordinate system.

[0041] During the tool processing process, sensors installed on the machine tool spindle or tool holder are used to detect the tool's processing position, posture, cutting force and machine tool vibration processing parameters in real time. For example, a force sensor is used to detect the cutting force, and whether the tool is cutting normally is determined by analyzing the changes in the cutting force. A vibration sensor is used to detect the tool's vibration. Abnormal vibration indicates tool wear or collision. At the same time, the tool's processing position is accurately measured before and after each processing layer, as well as when switching between layers. A laser measurement system or a contact measurement probe can be used to compare the tool's actual processing position with the target processing position.

[0042] Before the start of each layer of processing, not only is the processing position of the tool accurately measured, but the cutting edge of the tool is also visually inspected. High-definition cameras and image recognition technology are used to check whether the cutting edge of the tool is damaged, chipped, or has other defects. For some key processes, such as finishing and complex contour processing, the inspection frequency and inspection items are increased. At the same time, when switching between layers, in addition to measuring the processing position of the tool, the tool posture is calibrated and verified multiple times. Through the linkage of the rotating axis and the moving axis, the status of the tool at different angles and processing positions is checked to ensure the accuracy and stability of the tool when switching processing layers.

[0043] The tool processing position information is obtained according to the tool detection strategy. Combined with the conversion relationship between the three coordinate systems, the tool processing position in different coordinate systems is determined. The tool processing positions in different coordinate systems are compared to determine whether the processing position is unique. If there is a deviation, the size and direction of the deviation are calculated.

[0044] When judging whether the tool has collided, the tool's motion trajectory is adjusted according to the direction and size of the deviation. For example, if it is a positive deviation (the tool is not in place), the tool feed rate is increased. If it is a negative deviation (the tool has collided), the tool posture is adjusted or the tool is retracted to replan the processing path. During the correction process, the workpiece's processing parameters and the dynamic characteristics of the machine tool are combined to make corrections to ensure that the corrected processing can continue and the processing quality is guaranteed.

[0045] When a positive deviation is detected in the machining position of the tool (the tool is not in place), the feed amount of the tool in the direction of the corresponding coordinate axis is increased proportionally according to the specific value of the deviation. For example, when the deviation in the X-axis direction is 0.5mm, the system increases the X-axis feed amount by a certain proportion on the current basis, such as 10%, according to the pre-set correction coefficient, so that the tool can accurately reach the target machining position.

[0046] When a negative deviation (tool collision) is detected, the current processing action is stopped immediately to prevent further damage to the tool and workpiece, and the tool posture is adjusted according to the deviation direction. For example, if the deviation indicates that the tool collides in the YZ plane, the control system adjusts the angle of the tool in the plane by controlling the rotation axis of the machine tool to avoid the collision position. At the same time, based on the position of the collision point and the continuity of the processing path, the tool is re-planned after retreating a certain distance. The control system uses an optimization algorithm to generate a new safe processing path based on the current tool processing position, the shape of the remaining unprocessed part, and the kinematic constraints of the machine tool to ensure that subsequent processing can proceed smoothly.

[0047] During the processing after the tool is corrected, sensors are continuously used to monitor the tool status parameters in real time, including cutting force, vibration, temperature, etc. Once abnormal parameters are found, the tool processing position detection and deviation calculation are immediately performed again to determine whether further correction is needed. The corrected processing effect is fed back to the operator and control system in real time. The operator can manually intervene and adjust the processing process based on the feedback information.

[0048] In practical applications, when processing a mold with complex surfaces, the motion trajectory of the tool at different processing layers and different processing positions is complex, and collisions and deviations are prone to occur, affecting the processing accuracy and tool life. After the workpiece clamping coordinate system, tool coordinate system and machine tool coordinate system are established, the initial processing position of the tool is measured by a laser measurement system before processing each processing layer. During the processing, the tool status is monitored in real time by force sensors and vibration sensors. When switching from one processing layer to another, the actual processing position of the tool is measured again and compared with the target processing position; when a negative deviation is detected in the processing position of the tool at a certain processing layer, it is determined to be a tool collision, and the control system immediately stops processing, corrects the tool according to the deviation data, and restarts processing after adjusting the tool posture and motion trajectory; through real-time tool detection and correction, further damage to the tool is effectively avoided, the processing accuracy of the workpiece is guaranteed, the processing quality and production efficiency are improved, and the scrap rate is reduced.

[0049] The function expression of the path prediction model is as follows: ; In the formula, represents the predicted processing path, represents a multivariable function, They are respectively represented by tool posture, cutting force, workpiece temperature, machine vibration and process parameters. represents the error term.

[0050] The machining path is predicted by tool posture, cutting force, workpiece temperature, machine vibration and process parameters to adapt to the current machining process. Map multiple input variables including tool posture, cutting force, workpiece temperature, machine vibration and process parameters to predicted machining paths superior.

[0051] Analyze the CAD model of the workpiece, extract the workpiece features, determine the appropriate process parameters according to the workpiece features and workpiece requirements, including spindle speed, feed speed and cutting depth, generate the initial processing path, start the processing program, and perform rough processing on the workpiece in different areas to quickly remove excess material, and then perform fine processing based on rough processing to ensure processing accuracy and surface quality.

[0052] Strategies for optimizing machining paths include: The optimization target of the machining path is given by optimizing the objective function, and the constraints in the machining process are given. The optimized machining path is solved according to the optimization objective function and the constraints, and the optimized machining path is displayed in real time on the graphical user interface.

[0053] The expression of the optimization objective function is as follows: ; ; ; ; In the formula, represents the optimization target of the machining path, Indicates the minimum processing time, Indicates the maximum processing quality, represents the minimum prediction error, represents the constraints, Indicates that the process parameter is less than or equal to the process parameter threshold, Indicates that the prediction error of the path prediction model is less than or equal to the prediction error threshold. Indicates that the distance between the tool and the workpiece or machine tool is greater than or equal to the distance threshold.

[0054] It needs to be explained that: the process parameters need to be less than or equal to the maximum process parameters, the prediction error of the path prediction model needs to be less than or equal to the maximum prediction error, and the distance between the tool and the workpiece or machine tool needs to be greater than or equal to the minimum safety distance.

[0055] In the process of optimizing the machining path of a five-axis CNC machine tool, it is necessary to comprehensively consider the machining time, machining quality and prediction error of the path prediction model. The minimum machining time can improve production efficiency. The maximum machining quality is the key indicator for a five-axis CNC machine tool to produce high-quality workpieces. The minimum prediction error can improve machining accuracy. At the same time, process parameters, prediction errors and avoiding collisions between the tool and the workpiece or machine tool all have restrictions on the machining path. By optimizing the objective function and constraints, the optimal machining path can be found until a satisfactory machining effect is achieved, the workpiece quality is improved, and the optimal machining path is displayed in real time on the graphical user interface for operator monitoring and intervention, and converted into G code for easy recognition by the five-axis CNC machine tool.

[0056] The motion control module is used to generate motion control instructions for the five-axis CNC machine tool according to the machining program and the machining path of the five-axis CNC machine tool through the instruction generation strategy, and drive the movement of the five-axis CNC machine tool.

[0057] Through the instruction generation strategy, the motion control instructions of the five-axis CNC machine tool are generated according to the processing program and the processing path of the five-axis CNC machine tool. The motion control instructions include position instructions, speed instructions and tool change instructions. The instruction generation strategy is as follows: Figure 3 As shown, specifically including: Solve the optimized processing path, convert the processing path into G code recognizable by the five-axis CNC machine tool, parse the G code, and convert the parsed results into an internal data structure for subsequent processing. According to the parsed results of the G code, the path of the tool in the translation axis and the rotation axis is obtained, including the starting point, end point, intermediate point of the tool, the change of the tool posture and the angle change of the two rotation axes. Generate position instructions, including the positions of the translation axis and the rotation axis. At the same time, calculate the spindle speed and feed rate, generate speed instructions, and associate them with process parameters to affect processing efficiency and surface quality. Generate tool replacement instructions based on tool damage and tool requirements to use different tools for processing. Perform speed planning based on position instructions and speed instructions. The five-axis CNC machine tool starts from a stationary state and accelerates along a slope until it reaches the set maximum speed. Once the maximum speed is reached, the five-axis CNC machine tool will maintain this constant speed. , it is necessary to start decelerating when approaching the workpiece position until the five-axis CNC machine tool stops completely, ensuring smooth movement and not exceeding the dynamic limit of the five-axis CNC machine tool, reducing the acceleration of the five-axis CNC machine tool movement, and performing collision detection during the generation of motion control instructions to ensure that there is no interference between the tool, the workpiece and the five-axis CNC machine tool. If a collision is detected, the path of the tool in the translational axis and the rotational axis is adjusted. If the collision cannot be eliminated after adjusting the path of the tool in the translational axis and the rotational axis, an alarm is issued and the movement of the five-axis CNC machine tool is stopped, and the processing program is safely exited. The position feedback of the five-axis CNC machine tool is received in real time and compared with the preset motion control instruction. If there is an error between the real-time position of the five-axis CNC machine tool and the position in the preset motion control instruction, the position instruction is adjusted to eliminate the position error, and the motion control instruction is sent to the processing program to control the motor of the five-axis CNC machine tool to drive the movement of the five-axis CNC machine tool.

[0058] The calculation formula for the above spindle speed is as follows: ; In the formula, Indicates the spindle speed of the five-axis CNC machine tool in revolutions per minute. Indicates the cutting speed of the five-axis CNC machine tool in meters per minute. represents a constant, Indicates the tool diameter in millimeters.

[0059] The calculation formula for the above feed speed is as follows: ; In the formula, Indicates the feed rate of the five-axis CNC machine tool in millimeters per minute. It indicates the feed rate per revolution of a five-axis CNC machine tool, in millimeters per revolution.

[0060] The safety monitoring module is used to monitor the machine tool status in real time. If an abnormality occurs in the five-axis CNC machine tool, the abnormality handling strategy is executed.

[0061] Monitor the machine tool status in real time. If an abnormality occurs in the five-axis CNC machine tool, execute the abnormality handling strategy, which includes: Monitor the processing data in real time, configure the upper data threshold and the lower data threshold. If the monitored processing data is greater than the upper data threshold or less than the lower data threshold, it means that the five-axis CNC machine tool has an abnormality. Judge the authenticity of the abnormality of the five-axis CNC machine tool. If the five-axis CNC machine tool returns to normal after adjusting the processing data and processing path, it means that the abnormality of the five-axis CNC machine tool is false. If the five-axis CNC machine tool does not return to normal after adjusting the processing data and processing path, it means that the abnormality of the five-axis CNC machine tool is true, and an alarm is displayed on the graphical user interface and a voice prompt is given to inform the operator that the five-axis CNC machine tool has an abnormality. At the same time, the operation of the five-axis CNC machine tool is stopped to prevent further damage or accidents. The technician diagnoses the abnormality of the five-axis CNC machine tool, determines the specific cause of the abnormality, and takes corresponding repair measures, such as replacing damaged parts, etc., until the processing program and the five-axis CNC machine tool are restarted after the repair, and the five-axis CNC machine tool display returns to normal.

[0062] Example 2 In this embodiment, Figure 4 As shown, an adaptive control method for a five-axis CNC machine tool includes: S1, control processing data and processing program, and display machine tool status and processing data in real time through interactive display strategy; S2, real-time acquisition of processing data during the processing; S3, determining a processing path of the five-axis CNC machine tool according to the processing data through a path generation strategy, wherein the path generation strategy includes obtaining a workpiece model, cutting the workpiece according to a style of the workpiece model to form a plurality of processing layers, and dividing the initial processing path according to the processing layers; S4, generating motion control instructions for the five-axis CNC machine tool according to the machining program and the machining path of the five-axis CNC machine tool through an instruction generation strategy, and driving the movement of the five-axis CNC machine tool; S5, real-time monitoring of machine tool status, if the five-axis CNC machine tool has an abnormality, execute the abnormality handling strategy; S6. Establish multiple coordinate systems, including the workpiece clamping coordinate system, the tool coordinate system and the machine tool coordinate system, execute the tool detection strategy, detect the tool processing position when switching between single processing layers and layers, determine whether the tool collides, and correct the tool.

[0063] The specific contents of an adaptive control method for a five-axis CNC machine tool refer to an adaptive control system for a five-axis CNC machine tool, which will not be described in detail here.

Claims

1. An adaptive control system for a five-axis CNC machine tool, characterized in that: include: Simulation interaction module, sensor monitoring module, path judgment module, motion control module and safety monitoring module; The simulation interaction module is used to control the processing data and processing program, and to display the machine tool status and processing data in real time through an interactive display strategy; The sensor monitoring module is used to obtain processing data in the processing process in real time, and transmit the processing data to the path judgment module and the simulation interaction module through a data transmission strategy; The path determination module is used to determine the processing path of the five-axis CNC machine tool according to the processing data through a path generation strategy, wherein the path generation strategy includes obtaining a workpiece model, cutting the workpiece according to the style of the workpiece model to form multiple processing layers, and dividing the initial processing path according to the processing layers; The motion control module is used to generate motion control instructions for the five-axis CNC machine tool according to the machining program and the machining path of the five-axis CNC machine tool through an instruction generation strategy, and drive the movement of the five-axis CNC machine tool; The safety monitoring module is used to monitor the status of the machine tool in real time. If an abnormality occurs in the five-axis CNC machine tool, an abnormality handling strategy is executed.

2. The adaptive control system of a five-axis CNC machine tool according to claim 1, characterized in that: The path generation strategy includes: Obtain a workpiece model, and cut the workpiece according to the style of the workpiece model to form multiple processing layers, and divide the initial processing path according to the processing layers; Establish a path prediction model based on processing data; Inputting real-time processing data into the path prediction model, adjusting the processing path according to the output result of the path prediction model, and feeding back to the graphical user interface; The machining path is continuously optimized and the optimized machining path is converted into G code.

3. The adaptive control system of a five-axis CNC machine tool as claimed in claim 2, characterized in that: Strategies for optimizing the machining path include: The optimization target of the processing path is given by optimizing the objective function, and the constraints in the processing process are given. The optimized processing path is solved according to the optimization objective function and the constraints, and the optimized processing path is displayed in real time on a graphical user interface.

4. The adaptive control system of a five-axis CNC machine tool as claimed in claim 3, characterized in that: The motion control instructions include position instructions, speed instructions and tool change instructions; Instruction generation strategies include: Solve the optimized machining path, convert the machining path into G code recognizable by the five-axis CNC machine tool, parse the G code, obtain the path of the tool in the translation axis and the rotation axis according to the parsing result of the G code, generate a position command, calculate the spindle speed and feed speed at the same time, generate a speed command, and generate a tool replacement command according to the damage of the tool and the tool demand, perform speed planning according to the position command and the speed command, and perform collision detection in the process of generating the motion control command. If a collision is detected, adjust the path of the tool in the translation axis and the rotation axis. If the collision cannot be eliminated after adjusting the path of the tool in the translation axis and the rotation axis, issue an alarm and stop the movement of the five-axis CNC machine tool, and exit the machining program. Receive the position feedback of the five-axis CNC machine tool in real time and compare it with the preset motion control command. If there is an error between the real-time position of the five-axis CNC machine tool and the position in the preset motion control command, adjust the position command, send the motion control command to the machining program, control the motor of the five-axis CNC machine tool, and drive the movement of the five-axis CNC machine tool.

5. The adaptive control system of a five-axis CNC machine tool as claimed in claim 4, characterized in that: The exception handling strategy includes: monitoring the processing data in real time, configuring an upper data threshold and a lower data threshold, if the monitored processing data is greater than the upper data threshold or less than the lower data threshold, the five-axis CNC machine tool is abnormal, judging the authenticity of the abnormality of the five-axis CNC machine tool, if the five-axis CNC machine tool returns to normal after adjusting the processing data and the processing path, the abnormality of the five-axis CNC machine tool is false; If the five-axis CNC machine tool does not return to normal after adjusting the processing data and the processing path, the abnormality of the five-axis CNC machine tool is true, and an alarm is displayed on the graphical user interface and a voice prompt is given to prompt that the five-axis CNC machine tool has an abnormality. At the same time, the operation of the five-axis CNC machine tool is stopped, the abnormality of the five-axis CNC machine tool is diagnosed, and repair measures are taken until the processing program and the five-axis CNC machine tool are restarted after the repair, and the display of the five-axis CNC machine tool returns to normal.

6. The adaptive control system of a five-axis CNC machine tool as claimed in claim 5, characterized in that: The interactive display strategy includes: Design a graphical user interface to display the machine status, processing data and processing path in real time on the graphical user interface, customize the interface layout, provide intelligent prompts for processing data adjustment according to the machine status, analyze the processing data in real time, simulate and display the processing path on the graphical user interface before starting the processing program, and set a safety stop button.

7. The adaptive control system of a five-axis CNC machine tool according to claim 6, characterized in that: The processing data includes tool posture, cutting force, workpiece temperature, machine vibration and process parameters; The processing data is transmitted to the path judgment module and the simulation interaction module through the data transmission strategy, and the data transmission strategy includes: Preprocessing the acquired processing data, converting the processing data into data packets, storing the data packets in a cache group, and not triggering data packet transmission if no processing event is detected; If a processing event is detected, data packet transmission is triggered, a timestamp is added to each transmitted data packet, and a priority is assigned to the data packet transmission, and the data packet is transmitted according to the priority.

8. The adaptive control system of a five-axis CNC machine tool according to claim 7, characterized in that: Methods for dividing the initial processing paths according to the processing layers include: Establish multiple coordinate systems, including the workpiece clamping coordinate system, the tool head coordinate system and the machine tool coordinate system, set the tool detection strategy based on the multiple coordinate systems, and determine the initial processing path and processing parameters according to the tool detection strategy; Tool detection includes detection during the processing of a single processing layer, and detection of the processing position between layers when switching to processing on different processing layers; Determine the processing position according to the tool detection strategy, and compare whether the processing position in multiple coordinate systems is unique; When the processing position deviates, it is determined whether the tool has collided. If the processing position is a positive deviation, it indicates that the tool is not in place; If the machining position has a negative deviation, it indicates tool collision; When the tool collides, the tool is corrected.

9. An adaptive control method for a five-axis CNC machine tool, implemented based on an adaptive control system for a five-axis CNC machine tool according to any one of claims 1 to 8, characterized in that: include: S1, control processing data and processing program, and display machine tool status and processing data in real time through interactive display strategy; S2, real-time acquisition of processing data during the processing; S3, determining a processing path of the five-axis CNC machine tool according to the processing data through a path generation strategy, wherein the path generation strategy includes obtaining a workpiece model, cutting the workpiece according to a style of the workpiece model to form a plurality of processing layers, and dividing the initial processing path according to the processing layers; S4, generating motion control instructions for the five-axis CNC machine tool according to the machining program and the machining path of the five-axis CNC machine tool through an instruction generation strategy, and driving the movement of the five-axis CNC machine tool; S5, real-time monitoring of machine tool status, if the five-axis CNC machine tool has an abnormality, execute the abnormality handling strategy; S6. Establish multiple coordinate systems, including the workpiece clamping coordinate system, the tool coordinate system and the machine tool coordinate system, execute the tool detection strategy, detect the tool processing position when switching between single processing layers and layers, determine whether the tool collides, and correct the tool.

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