Self-adaptive machining method, system and device for hole opening and groove of welded cylinder

Abstract

The invention relates to the technical field of numerical control milling machining and manufacturing, in particular to a welding barrel tapping and groove self-adaption machining method, system and device, and the method comprises the steps that based on an actual welding barrel, a simulation model of the welding barrel is built, and hole milling is conducted on the simulation model; the method comprises the steps that an actual to-be-machined hole and a peripheral contour area of the actual to-be-machined hole are scanned, point cloud data of the to-be-machined hole are obtained, a groove curved surface model is constructed based on the point cloud data, and a groove profiling machining tool path is generated according to the groove curved surface model; and the actual welding barrel is milled through the groove profiling machining tool path. By means of the method, errors in actual machining of holes and grooves of the welding barrel can be reduced, and the high-precision machining requirements of the grooves of different shapes and sizes are met.

Description

Technical Field

[0001] The invention relates to the technical field of numerical control milling processing and manufacturing, and in particular to a welding cylinder hole opening and groove adaptive processing method, system and device. Background Art

[0002] Large-scale cylinder hole opening and groove processing technology plays a vital role in the shield machine manufacturing industry, shipbuilding industry and large-scale infrastructure construction projects. So far, the traditional process methods of water jet cutting or flame cutting supplemented by manual fine grinding are widely used at home and abroad to meet this processing challenge. Although these traditional processes have been widely used in the manufacturing process of conventional products, they are often difficult to meet strict process specifications and quality standards when faced with specific application scenarios such as the introduction of new materials, extremely high requirements for hole opening and groove processing accuracy, and the pursuit of low residual stress.

[0003] In contrast, mechanical processing technology is gradually becoming an important development trend in the field of large cylinder processing with its unique advantages of high efficiency, high precision processing capabilities, and no adverse effects on the microstructure of materials. Especially for large cylinders with a diameter and height of more than 10 meters, since its parts are very likely to be significantly deformed during the processing and the structure is highly complex, if the bottom hole and groove are processed directly according to the theoretical design model, it is very easy to cause the relative position deviation between the bottom hole and the groove, which will have a negative impact on the subsequent welding assembly quality.

[0004] Actual data shows that if traditional methods are used to directly process based on theoretical models, the final offset between the groove and the bottom hole may be as high as 3 to 10 mm, which will directly affect the accuracy and effect of welding assembly, and may even lead to the scrapping of the entire large cylinder, resulting in significant material waste and manufacturing progress delays. Summary of the invention

[0005] In order to solve the technical problems raised in the above background technology, the present invention provides a method, system and device for self-adaptive processing of opening and groove of welding cylinder, and the method comprises the following steps:

[0006] S1: Based on the actual welded cylinder, a simulation model of the welded cylinder is constructed, and holes are milled on the simulation model;

[0007] S2: Scanning the actual hole to be processed and its surrounding contour area to obtain point cloud data of the hole to be processed, constructing a groove surface model based on the point cloud data, and generating a groove profiling tool path according to the groove surface model;

[0008] S3: performing milling processing on the actual welded cylinder through the groove profiling tool path.

[0009] In one embodiment of the present invention, in S1, the method for constructing a simulation model of a welded cylinder is as follows:

[0010] S11: Based on the actual welded cylinder, construct an initial simulation model of the welded cylinder, obtain the top center point and the bottom center point of the inner wall of the actual welded cylinder, and use these two points as reference points to adjust the position of the initial simulation model;

[0011] S12: Draw an outer generatrix of the initial simulation model, and based on the outer generatrix, draw contour lines on the lower outer circle, the upper outer circle and the top ring rib of the initial simulation model, and correct the Y-axis coordinate values ​​of all intersections between the same outer generatrix and the contour lines to be consistent;

[0012] S13: Obtaining the eccentricity value between the initial simulation model and the rotation center of the worktable, and correcting the center of the initial simulation model according to the eccentricity value to obtain a final simulation model of the welded cylinder.

[0013] In one embodiment of the present invention, in S13, the method for obtaining the eccentricity value between the initial simulation model and the rotation center of the worktable is:

[0014] Obtain the coordinate values ​​of the rotation center, the bottom center point, and any point on the zero-degree side busbar of the worktable in the machine tool coordinate system, and obtain a first vector from the bottom center point to any feature point on the zero-degree side busbar, and a second vector from the rotation center to any point on the zero-degree side busbar;

[0015] Based on the first vector and the second vector, an eccentricity value between the initial simulation model and the rotation center of the worktable is obtained.

[0016] In one embodiment of the present invention, in S1, the method for milling holes on the simulation model is as follows:

[0017] According to the hole positions of the actual welded cylinder, three-dimensional coordinate values ​​of the cross-line intersections of a plurality of holes to be processed are obtained on the simulation model;

[0018] After making the center axis of the simulation model consistent with the center axis of the rotary table, the three-dimensional coordinate value of the cross-line intersection is mapped to the machine tool coordinate system. Based on the three-dimensional coordinate value of the cross-line intersection in the machine tool coordinate system, the bottom hole contour line and the groove contour line of the hole to be processed are drawn to perform milling on the simulation model.

[0019] In one embodiment of the present invention, in S2, the method for generating the groove profiling tool path is as follows:

[0020] S21: obtaining a triangular mesh surface model of the groove based on the point cloud data of the hole to be processed, wherein the triangular mesh surface model is composed of a plurality of triangular surfaces;

[0021] S22: performing reverse processing on the triangular mesh surface model to obtain a free-form surface model, wherein the free-form surface model is used to adjust the shape and size of different parts by adjusting parameters;

[0022] S23: Based on the free-form surface model, different machining tool paths are designed for the bottom hole, outer groove, and inner groove areas of the groove.

[0023] In one embodiment of the present invention, the machining tool path includes tool type, tool path and cutting method, and the tool type includes an extended milling head, a right-angle milling head, a two-axis milling head and a horizontal rotary table.

[0024] In one embodiment of the present invention, the cutting methods include plunge milling, contour milling and spiral milling.

[0025] Based on the same inventive concept, the present invention also provides a welding cylinder hole opening and groove adaptive processing system, which is used to implement the steps of the welding cylinder hole opening and groove adaptive processing method. The welding cylinder hole opening and groove adaptive processing system includes the following modules:

[0026] A milling module is used to construct a simulation model of a welded cylinder based on an actual welded cylinder, and to perform milling on the simulation model;

[0027] The tool path planning module is used to scan the actual hole to be processed and its surrounding contour area to obtain point cloud data of the hole to be processed, build a groove surface model based on the point cloud data, and generate a groove profiling tool path according to the groove surface model;

[0028] The groove processing module is used to perform milling processing on the actual welded cylinder through the groove profiling tool path.

[0029] The present invention also provides a welding cylinder hole opening and groove adaptive processing device, including the welding cylinder hole opening and groove adaptive processing system.

[0030] The present invention also provides a computer storage medium, which stores a computer software product. The computer software product includes several instructions for enabling a computer device to execute the welding cylinder hole opening and groove adaptive processing method.

[0031] The above technical solution of the present invention has the following advantages compared with the prior art:

[0032] 1. High-precision processing: By constructing a simulation model of the welded cylinder and milling holes on it, the actual processing process can be accurately simulated to reduce errors. The groove surface model is constructed using point cloud data to more accurately reflect the actual shape of the hole to be processed and its surrounding contours, thereby improving processing accuracy.

[0033] 2. Strong adaptability: This method can construct a simulation model according to the shape and size of the actual welded cylinder, and has strong adaptability. By processing the point cloud data, it can automatically adapt to the groove processing requirements of different shapes and sizes without manual adjustment. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] In order to make the content of the present invention more clearly understood, the present invention is further described in detail below according to specific embodiments of the present invention in conjunction with the accompanying drawings, wherein:

[0035] Figure 1 It is a flow chart of a welding cylinder hole opening and groove adaptive processing method provided in the first embodiment of the present invention;

[0036] Figure 2 It is a flow chart of the method for constructing a simulation model and milling a hole in the first embodiment of the present invention;

[0037] Figure 3 It is a schematic diagram of the center of the welded cylinder in an uncorrected state;

[0038] Figure 4 is a flow chart of a method for generating a groove profiling tool path in Embodiment 1 of the present invention;

[0039] Figure 5 It is a schematic diagram of the structure of the welding cylinder hole opening and groove adaptive processing system provided in the second embodiment of the present invention;

[0040] Description of the accompanying drawings in the specification: 100, milling module; 200, tool path planning module; 300, groove processing module. DETAILED DESCRIPTION

[0041] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments so that those skilled in the art can better understand the present invention and implement it, but the embodiments are not intended to limit the present invention.

[0042] Embodiment 1

[0043] like Figure 1 As shown, the present invention provides a method for self-adaptive processing of holes and grooves of a welding cylinder, the method comprising the following steps:

[0044] S1: Based on the actual welded cylinder, a simulation model of the welded cylinder is constructed, and holes are milled on the simulation model;

[0045] S2: Scanning the actual hole to be processed and its surrounding contour area to obtain point cloud data of the hole to be processed, constructing a groove surface model based on the point cloud data, and generating a groove profiling tool path according to the groove surface model;

[0046] S3: performing milling processing on the actual welded cylinder through the groove profiling tool path.

[0047] It can be seen from the above technical scheme that the present invention can pre-plan and verify the processing process in the simulation environment by constructing a simulation model of the welded cylinder and performing milling simulation on it, thereby reducing errors in actual processing and improving processing accuracy; by scanning the actual hole to be processed and its surrounding contour area, accurate point cloud data is obtained, and a groove surface model is constructed based on this to generate a customized groove profiling tool path. This method can adapt to welded cylinders of different shapes and sizes, as well as complex groove requirements, realize the adaptability and flexibility of the processing process, and also improve processing efficiency.

[0048] In order to verify the intelligent hole opening process of the cylinder, an 8-meter diameter test cylinder is separately made as a pre-acceptance test piece. The overall dimensions of this test piece are: Φ8776mm×5525mm, weight: 45000kg, material: Q235B, divided into 3 sections: cylinder, right cone and oblique cone. Except that the diameter is slightly smaller than the original right cone and oblique cone cylinders, the rest of the appearance retains the original cylinder characteristics, and a total of 8 holes (specifically numbered 3, 4, 17, 18, 20, 27, 28, and 29 holes) are selected from the original two cylinders and placed on this test piece according to the original size and orientation.

[0049] like Figure 2 As shown, in step S1, based on the actual welded cylinder, the method for constructing the simulation model of the welded cylinder is as follows:

[0050] S11: Based on the actual welded cylinder (i.e., the test piece), an initial simulation model of the welded cylinder is constructed, and the top center point and the bottom center point of the inner wall of the actual welded cylinder are obtained. The position of the initial simulation model is adjusted using these two points as reference points;

[0051] S12: using a marking device to program the outer generatrix of the initial simulation model, and taking the outer generatrix as a reference, drawing contour lines on the lower outer circle, the upper outer circle and the top ring rib of the initial simulation model, and correcting the Y-axis coordinate values ​​of all intersections between the same outer generatrix and the contour lines to be consistent;

[0052] S13: Obtaining the eccentricity value between the initial simulation model and the rotation center of the worktable, and correcting the center of the initial simulation model according to the eccentricity value to obtain a final simulation model of the welded cylinder.

[0053] Further, in step S13, the method for obtaining the eccentricity value between the initial simulation model and the rotation center of the worktable is:

[0054] S131: Figure 3As shown, the coordinate values ​​of the rotation center, the bottom center point, and any point on the zero-degree side busbar of the worktable in the machine tool coordinate system are obtained to obtain a first vector α from the bottom center point to any feature point on the zero-degree side busbar, and a second vector β from the rotation center to any point on the zero-degree side busbar;

[0055] S132: Based on the first vector α and the second vector β, obtain the eccentricity value between the initial simulation model and the rotation center of the worktable

[0056] In step S1, the method for performing milling on the simulation model is as follows:

[0057] S14: According to the hole positions of the actual welded cylinder, on the simulation model, the visual measurement module measures the three-dimensional coordinate values ​​of the cross-line intersections of eight holes to be processed (specifically numbered as holes 3, 4, 17, 18, 20, 27, 28, and 29), and these coordinate values ​​represent the precise positions of the holes to be processed in the simulation model;

[0058] S15: Keeping the center axis of the simulation model consistent with the center axis of the rotary table is a key step to ensure the accuracy of subsequent processing. Afterwards, the three-dimensional coordinate value of the cross-line intersection is mapped to the machine tool coordinate system (such as G54). Based on the three-dimensional coordinate value of the cross-line intersection in the machine tool coordinate system, a dedicated programming software is used to automatically draw the bottom hole contour line and the groove contour line of the hole to be processed. In order to consider the amount of material removal and possible errors during the processing process, each contour line is offset 3mm outward according to the theoretical size to ensure that the actual processed hole and groove dimensions meet the design requirements.

[0059] It should be noted that in order to further improve the processing accuracy and increase the flexibility and controllability of the processing, the dedicated programming software uses the automatic marking program to mark the contour of the hole to be opened. The user can then intuitively view and confirm the position and shape of the contour line in the software interface, and then proceed with subsequent processing and measurement after ensuring that there are no errors.

[0060] The above-mentioned precision conditions that need to be guaranteed for milling are crucial for the welding cylinder hole opening and groove adaptive processing methods, which ensure the accuracy and reliability of the processing results. The following is a detailed description of these precision conditions:

[0061] 1) The tolerance requirement for the width of the outer groove is ±1mm; 2) The tolerance requirement for the depth of the outer groove is ±1mm; 3) The position of the processed hole is 0.5mm; 4) The error of the diameter of the processed hole is 0.2mm; 5) The error of the processed groove angle is 0.2°; 6) The deviation of the root position of the groove is 1mm; 7) The processing roughness is Ra6.3.

[0062] See also Figure 4As shown, in step S2, the actual hole to be processed and its surrounding contour area are scanned to obtain point cloud data of the hole to be processed, and a groove surface model is constructed based on the point cloud data. According to the groove surface model, a method for generating a groove profiling tool path is as follows:

[0063] S21: obtaining a triangular mesh surface model of the groove based on the point cloud data of the hole to be processed, wherein the triangular mesh surface model is composed of a plurality of triangular surfaces;

[0064] S22: using QJCAM software to reverse process the triangular mesh surface model to obtain a free-form surface model, which has the characteristics of being editable and processable. The QJCAM software is used to perform parametric modeling on the surface, and the shapes and sizes of different parts are adjusted by adjusting parameters to form an editable and programmable groove three-dimensional model;

[0065] S23: Based on the free-form surface model, different machining tool paths are designed for the bottom hole, outer groove, and inner groove areas of the groove.

[0066] The machining tool path includes tool type, tool path and cutting method. According to the structure of the cylinder and the shape of each hole, the tool type includes extended milling head, right-angle milling head, two-axis milling head and horizontal rotary table; the cutting method includes plunge milling, contour milling and spiral milling.

[0067] The above processing method also includes: for each hole type and the hole processing tool path and groove profiling tool path generated by it, a simulation test is implemented. This step is to strictly verify the accuracy of the tool path trajectory, the optimal state of the path (that is, to ensure maximum efficiency and no redundancy in the path), and the occurrence of no interference, so as to fully guarantee the reliability and accuracy of the processing process.

[0068] In addition, a post-processing module is constructed, which can receive and finely process tool path trajectory data. After precise processing by the post-processing module, the data will be directly converted into a digital control program (i.e., NC program), and then seamlessly transmitted to the numerical control system (CNC system) to drive the machine tool to perform efficient processing tasks. In this process, the post-processing module pays special attention to the precise offset of the workpiece center coordinate relative to the worktable center coordinate obtained in the "workpiece leveling and center coordinate offset measurement" link. This consideration ensures that in the actual hole opening processing and groove profiling processing, the preset processing path can be strictly followed, thereby achieving accurate and error-free processing results.

[0069] Embodiment 2

[0070] Based on the same inventive concept as that of the first embodiment, the present invention also provides a welding cylinder hole opening and groove adaptive processing system, which is used to implement the steps of the welding cylinder hole opening and groove adaptive processing method described in the first embodiment. Figure 5 As shown, the welding cylinder opening and groove adaptive processing system includes the following modules:

[0071] The milling module 100 is used to construct a simulation model of the welded cylinder based on the actual welded cylinder, and to perform milling on the simulation model;

[0072] The tool path planning module 200 is used to scan the actual hole to be processed and its surrounding contour area to obtain point cloud data of the hole to be processed, build a groove surface model based on the point cloud data, and generate a groove profiling tool path according to the groove surface model;

[0073] The groove processing module 300 is used to perform milling processing on the actual welded cylinder through the groove profiling tool path.

[0074] A welding cylinder hole opening and groove adaptive processing system proposed in this embodiment is used to implement the aforementioned welding cylinder hole opening and groove adaptive processing method. Therefore, the specific implementation method of the synchronous response single-point displacement monitoring system can be seen in the embodiment part of the aforementioned welding cylinder hole opening and groove adaptive processing method. For example, the milling module 100, the tool path planning module 200 and the groove processing module 300 are respectively used to correspond to the steps S1, S2 and S3 in the welding cylinder hole opening and groove adaptive processing method in embodiment one. Therefore, its specific implementation method can refer to the description of the corresponding each part of the embodiment. In order to avoid redundancy, it will not be repeated here.

[0075] Embodiment 3

[0076] The present invention also provides a welding cylinder hole opening and groove adaptive processing device, including the welding cylinder hole opening and groove adaptive processing system described in the above-mentioned embodiment 2.

[0077] Embodiment 4

[0078] The present invention also provides a computer storage medium, which stores a computer software product. The computer software product includes several instructions for enabling a computer device to execute the welding cylinder hole opening and groove adaptive processing method described in the above-mentioned embodiment one.

[0079] In summary, the present invention has certain versatility for opening welding holes and internal and external grooves of large cylinders that are easy to deform, have many ribs, and have complex internal structures. It can eliminate various processing errors during the processing of large cylinders and ensure the consistency of welding bottom holes and grooves.

[0080] Those skilled in the art will appreciate that the embodiments of the present application may be provided as methods, systems, or computer program products. Therefore, the present application may adopt the form of a complete hardware embodiment, a complete software embodiment, or an embodiment in combination with software and hardware. Moreover, the present application may adopt the form of a computer program product implemented in one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) that include computer-usable program code.

[0081] The present application is described with reference to the flowcharts and / or block diagrams of the methods, devices (systems), and computer program products according to the embodiments of the present application. It should be understood that each process and / or box in the flowchart and / or block diagram, as well as the combination of the processes and / or boxes in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing device to generate a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 A process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0082] These computer program instructions may also be stored in a computer-readable memory capable of directing a computer or other programmable data processing device to operate in a specific manner, so that the instructions stored in the computer-readable memory produce an article of manufacture comprising an instruction device, which implements the process Figure 1 A process or multiple processes and / or boxes Figure 1 A function specified in one or more boxes.

[0083] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operating steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions for implementing the process. Figure 1 A process or multiple processes and / or boxes Figure 1 The steps for the functions specified in one or more boxes.

[0084] Obviously, the above embodiments are merely examples for clear explanation and are not intended to limit the implementation methods. For those skilled in the art, other different forms of changes or modifications can be made based on the above description. It is not necessary and impossible to list all the implementation methods here. The obvious changes or modifications derived from them are still within the protection scope of the invention.

Claims

1. A method for self-adapting the opening and groove of a welding cylinder, characterized in that: The following steps are involved: S1: Based on the actual welded cylinder, a simulation model of the welded cylinder is constructed, and holes are milled on the simulation model; S2: Scanning the actual hole to be processed and its surrounding contour area to obtain point cloud data of the hole to be processed, constructing a groove surface model based on the point cloud data, and generating a groove profiling tool path according to the groove surface model; S3: performing milling processing on the actual welded cylinder through the groove profiling tool path.

2. The method for self-adapting hole and groove processing of welding cylinder according to claim 1, characterized in that: In S1, the method of constructing the simulation model of the welded cylinder is as follows: S11: Based on the actual welded cylinder, construct an initial simulation model of the welded cylinder, obtain the top center point and the bottom center point of the inner wall of the actual welded cylinder, and use these two points as reference points to adjust the position of the initial simulation model; S12: Draw an outer generatrix of the initial simulation model, and based on the outer generatrix, draw contour lines on the lower outer circle, the upper outer circle and the top ring rib of the initial simulation model, and correct the Y-axis coordinate values ​​of all intersections between the same outer generatrix and the contour lines to be consistent; S13: Obtaining the eccentricity value between the initial simulation model and the rotation center of the worktable, and correcting the center of the initial simulation model according to the eccentricity value to obtain a final simulation model of the welded cylinder.

3. The welding cylinder hole opening and groove adaptive processing method according to claim 2 is characterized in that: In S13, the method for obtaining the eccentricity value between the initial simulation model and the rotation center of the worktable is: S131: Obtain the coordinate values ​​of the rotation center, the bottom center point, and any point on the zero-degree side busbar of the worktable in the machine tool coordinate system, and obtain a first vector from the bottom center point to any feature point on the zero-degree side busbar, and a second vector from the rotation center to any point on the zero-degree side busbar; S132: Based on the first vector and the second vector, obtain the eccentricity value between the initial simulation model and the rotation center of the worktable.

4. The method for self-adapting hole and groove processing of welding cylinder according to claim 1, characterized in that: In S1, the method for performing milling on the simulation model is as follows: S14: according to the hole positions of the actual welded cylinder, obtaining the three-dimensional coordinate values ​​of the cross-line intersections of the plurality of holes to be processed on the simulation model; S15: After the center axis of the simulation model is made consistent with the center axis of the rotary table, the three-dimensional coordinate value of the cross-line intersection is mapped to the machine tool coordinate system, and based on the three-dimensional coordinate value of the cross-line intersection in the machine tool coordinate system, the bottom hole contour line and the groove contour line of the hole to be processed are drawn to perform milling on the simulation model.

5. The welding cylinder hole opening and groove adaptive processing method according to claim 1 is characterized in that: In S2, the method for generating the groove profiling tool path is as follows: S21: obtaining a triangular mesh surface model of the groove based on the point cloud data of the hole to be processed, wherein the triangular mesh surface model is composed of a plurality of triangular surfaces; S22: performing reverse processing on the triangular mesh surface model to obtain a free-form surface model, wherein the free-form surface model is used to adjust the shape and size of different parts by adjusting parameters; S23: Based on the free-form surface model, different machining tool paths are designed for the bottom hole, outer groove, and inner groove areas of the groove.

6. The welding cylinder hole opening and groove adaptive processing method according to claim 5 is characterized in that: The processing tool path includes tool type, tool path and cutting method, and the tool type includes extended milling head, right-angle milling head, two-coordinate milling head and horizontal rotating disk.

7. The welding cylinder hole opening and groove adaptive processing method according to claim 6 is characterized in that: The cutting methods include plunge milling, contour milling and spiral milling.

8. A welding cylinder hole opening and groove adaptive processing system, characterized in that: The method for realizing the method for self-adaptive processing of a hole and groove of a welding cylinder according to any one of claims 1 to 7, wherein the self-adaptive processing system for a hole and groove of a welding cylinder comprises the following modules: A milling module is used to construct a simulation model of a welded cylinder based on an actual welded cylinder, and to perform milling on the simulation model; The tool path planning module is used to scan the actual hole to be processed and its surrounding contour area to obtain point cloud data of the hole to be processed, build a groove surface model based on the point cloud data, and generate a groove profiling tool path according to the groove surface model; The groove processing module is used to perform milling processing on the actual welded cylinder through the groove profiling tool path.

9. A welding cylinder hole opening and groove adaptive processing device, characterized in that: It comprises the welding cylinder hole opening and groove adaptive processing system as described in claim 8.

10. A computer storage medium, characterized in that: The computer storage medium stores a computer software product, and the computer software product includes a number of instructions for enabling a computer device to execute the welding cylinder hole opening and groove adaptive processing method as described in any one of claims 1 to 7.

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