A method for realizing automatic numerical control machining of positive type of orthosis and prosthetic socket

Abstract

The present invention discloses a method for realizing automated numerical control machining of positive orthotics and prosthetic sockets, and belongs to the technical field of manufacturing auxiliary devices for rehabilitation engineering. First, select the input model in the plug-in, load various three-dimensional model files of orthotics and prosthetic sockets, and at the same time, the plug-in establishes a coordinate system according to the model type, loads the blank, safety rod and target model, establishes a dedicated tool and determines the machining strategy; then click to start the calculation, and the software processes the model according to the set parameters; then perform a machining safety check, and ensure machining safety through automatic collision checks, etc.; finally, output the machining program file to the milling machine, and a single machine can be selected for sequential or multiple machines for parallel machining. The present invention provides an efficient, precise and automated solution for machining positive orthotics and prosthetic sockets, and promotes the development of the technical field of manufacturing auxiliary devices for rehabilitation engineering.

Description

Technical Field

[0001] The invention belongs to the technical field of manufacturing auxiliary appliances of rehabilitation engineering, and in particular relates to a digital automated processing method for positive types of orthoses and prosthetic receiving cavities. Background Art

[0002] In the traditional production of orthotics and prosthetic sockets, the molding stage mainly relies on plaster bandages. The technician needs to carefully wrap the patient's torso with a plaster bandage soaked in water, and after the plaster bandage solidifies, a negative mold (mold cavity) is obtained. Subsequently, plaster slurry is poured into the negative mold cavity, and after the plaster slurry solidifies, a positive mold with a size similar to that of the patient's torso is obtained. Then, the prosthetic technician or orthopedic technician performs mold repair on the positive mold, and finally obtains a prosthetic / orthotic positive mold that can be worn by the patient. However, this traditional process has many problems. First, in terms of the working environment, the use of a large amount of plaster makes the workplace dirty and messy, and the dust pollution generated seriously threatens the health of the orthotist. Secondly, from a technical point of view, the determination of the entire manufacturing process parameters mainly relies on human experience, lacks the assistance of digital means, and is difficult to conduct accurate inspection and verification. Furthermore, the management of patient data is almost blank, and patient data cannot be effectively saved, which brings great difficulties to the subsequent traceability and tracking work, and is not conducive to the improvement and improvement of product quality. In addition, in terms of efficiency, since each production step is time-consuming and the steps cannot be performed concurrently, the overall work efficiency is low, which makes it difficult to meet the requirements of modern rehabilitation medicine for the production efficiency and quality of orthotics and prosthetic sockets.

[0003] With the advancement of science and technology, digital technology has begun to emerge in the field of orthosis and prosthetic socket processing. At present, it is possible to obtain a three-dimensional model of the body, including the trunk, ankle, foot, and limb stump, through a three-dimensional scanner, which is a great improvement compared to the traditional plaster bandage molding. After obtaining the three-dimensional model, with the help of computer-aided software (CAD), operations such as force position and force line adjustment, pressure / release module design under the principle of biomechanical correction, etc. can be performed, and a three-dimensional file can be output. However, the three-dimensional files designed and output by CAD software cannot be directly used for CNC processing. The reason is that due to the influence of many factors such as format, position, and processing method, these three-dimensional files cannot be directly converted into instructions that can be used to produce positive types, and thus the subsequent assembly of orthoses and prosthetic sockets cannot be carried out smoothly. This shows that although digital technology has been applied in the front-end design link, there are still obvious shortcomings in the connection with the subsequent processing link, which needs to be solved urgently.

[0004] In the field of CNC machining, blank is an important concept. It is the original material or initial workpiece shape before CNC machining. Although its shape and size are close to the target drawing, it still needs to remove excess material (such as cutting, milling, drilling and other operations) or further finish machining (such as heat treatment, polishing, etc.) to achieve the final drawing model. In addition, the safety rod is indispensable in the CNC machining process. It is a fixed connecting rod or support rod when the blank is clamped on the CNC milling machine. On the one hand, it plays a role in firmly supporting the blank. On the other hand, it can effectively prevent the tool from colliding with the blank or other components during machining, thereby ensuring machining safety. The present invention aims to solve the problem of poor connection between existing digital technology and CNC machining, and implement it through innovative methods.

[0005] With the extension of human life span and the continuous development of clinical medicine and rehabilitation medicine, patients have increasingly higher technical requirements for orthotics and prosthetic sockets. As an important part of rehabilitation medicine and rehabilitation engineering, the assembly of orthotics requires close cooperation among patients, clinicians, prosthetists, rehabilitation therapists and other personnel. The various shortcomings of traditional processing technology have been unable to meet the growing demand. There is an urgent need for a new processing method to improve product quality, increase production efficiency, achieve precise personalized customization, and ensure the traceability and stability of the entire processing process. The emergence of digital automated processing technology has made it possible to solve these problems. The present invention came into being in this context, and is expected to fill the gaps in the prior art and promote technological innovation in the field of orthosis and prosthetic socket processing. Summary of the invention

[0006] In view of the shortcomings in the current technical field, the present invention focuses on solving the key technical problems faced in the current processing of orthotics and prosthetic socket positive molds, that is, the core problem that the three-dimensional files output by CAD software design cannot be directly used for CNC processing. Due to the constraints of various factors such as format, location, and processing methods, it is difficult to convert three-dimensional files into executable production positive instructions, which hinders the smooth development of subsequent finished product assembly work.

[0007] To this end, the present invention is committed to providing a method for realizing the automated numerical control machining of the positive type of orthosis and prosthetic socket through a series of automated and digitalized technical means to break through the bottleneck of existing technologies. It aims to achieve the following goals: establish a complete conversion mechanism that can automatically handle the format and position of three-dimensional files, so that it can be seamlessly connected with numerical control machining equipment, ensure the accurate generation of machining instructions, and smoothly realize the transformation from three-dimensional design to positive production.

[0008] Optimize the processing technology, standardize and intelligently integrate the processing methods, so that CNC processing equipment can automatically select the appropriate processing strategy based on the 3D file, such as accurately setting the various parameters of point projection processing or spiral finishing, improving the processing accuracy and surface quality, and meeting the strict requirements of orthotics and prosthetic sockets for precision and adaptability.

[0009] Improve the efficiency of the entire processing flow, realize automated operations from drawing input to final product delivery, reduce manual intervention, reduce errors caused by human factors, and significantly shorten the production cycle through parallel processing and other methods, thereby improving product production efficiency and consistency.

[0010] To ensure the reliability of product quality, through the synergy of software and hardware, automatic processing accuracy control and safety inspection are carried out to ensure that every positive product can meet high quality standards and can be directly used for the assembly of orthotics and prosthetic sockets without secondary testing, thereby improving the product's qualification rate and stability.

[0011] The present invention aims to fill the gap in the prior art, provide an efficient, precise and automated solution for the processing of positive types of orthoses and prosthetic sockets, and promote the development of the field of auxiliary device manufacturing technology in rehabilitation engineering in a more advanced and reliable direction.

[0012] To achieve the above-mentioned purpose, the technical solution adopted by the present invention is: a method for realizing automatic numerical control machining of positive type of orthosis and prosthetic socket, comprising the following steps:

[0013] Step S1: Input the drawing file and operate through the plug-in to prepare the data and model required for processing, including selecting the processing type, loading the model file and related models to the corresponding coordinate system, and supporting the addition of new processing types to prepare for subsequent processing;

[0014] Step S2: Start calculation. After the plug-in confirms the model, the calculation process is started. The plug-in processes the model according to the preset parameters and strategies, determines the processing path parameters, displays the status information during the calculation, and displays the results and updates the model status after completion.

[0015] Step S3: Processing safety check: the plug-in performs safety inspection before processing, calculates the tool trajectory through automatic collision check and compares it with the relevant model, sets safety clearance and warning, and determines the subsequent operation based on the results to ensure processing safety;

[0016] Step S4: Output the processing program file, select the output method in the plug-in, and process on one or more milling machines. When there are multiple milling machines, the milling machine parameters need to be set to ensure that the processing is started after the execution program is correctly received to achieve flexible processing arrangements.

[0017] Furthermore, in step S1, the plug-in operation specifically includes at least:

[0018] Step S11: In the plug-in, click the input model function button to start the model input process;

[0019] Step S12: After clicking to input the model, in the selection menu that appears containing a variety of orthotic and prosthetic socket types, select the corresponding type according to actual needs. You can choose to load a single model or multiple models. You can directly click to start the calculation for a single model. Multiple models need to be selected before clicking to start the calculation. Adding a new model requires calculation after a specific button operation. At the same time, after selecting the relevant logo, the plug-in automatically loads the corresponding type of blank and safety rod, and supports later added types.

[0020] Step S13: The plug-in establishes two spatial coordinate systems according to the type of three-dimensional model, places the blank, safety rod and target processing model in the corresponding coordinate system, establishes a dedicated tool that fully matches the actual CNC milling machine tool, and determines two processing strategies and their respective detailed parameters.

[0021] Furthermore, a dedicated tool that fully matches the actual CNC milling machine tool is established, and two processing strategies and their respective detailed parameters are determined, including the following:

[0022] The parameters that need to be determined for the point projection processing strategy include: spatial coordinate system, blank and safety bar, tool, processing limit, which is used to define the maximum limit of each axial processing, the projection reference line style is spiral and clockwise, the angle increment is 0.5 degrees, which is used to control the processing accuracy, the tool moves down this angle for each circle of processing, the tool start and end processing direction, automatic collision check, including setting the safety gap and warning before collision during processing, tool axis inclination, processing start and end points, feed and speed settings, spindle speed 12000 rpm, cutting feed rate 8000 mm / min, downcut feed rate 2000 mm / min, skimming feed rate specific value mm / min, cooling method is standard air cooling;

[0023] The parameters that need to be determined for the spiral finishing strategy include: spatial coordinate system, blank and safety bar, tool, machining limit, which is used to define the maximum limit of each axial machining, spiral reference line style is spiral and clockwise, machining line spacing is 1mm to 3mm, which can be freely set according to the model type to control the machining accuracy, tool start and end machining direction, automatic collision check including setting the safety gap and warning before collision during machining, tool axis inclination, machining start and end points, feed and speed settings, spindle speed of 12000 rpm, cutting feed rate of 8000 mm / min, downcut feed rate of 2000 mm / min, specific value of skimming feed rate of mm / min, and standard air cooling; this step ensures the comprehensiveness and accuracy of machining preparation work, laying the foundation for subsequent high-quality machining.

[0024] Further, in step S2, starting the calculation process after confirming the model based on the plug-in specifically includes:

[0025] Step S21: Carefully confirm the various models available for calculation and their file paths on the plug-in interface to ensure that the selected model is accurate;

[0026] Step S22: Click the Start Calculation button to trigger the plug-in to perform calculations on the selected model. The software performs complex calculations based on the parameters and strategies set in the previous steps, including establishing a coordinate system, placing related models, calling tools, loading target models, and calculating key parameters such as machining paths, tool axis inclinations, feeds, and speeds according to the selected machining strategies. During the calculation process, the status bar at the bottom of the plug-in interface displays the calculation progress and related information in real time, including displaying the status when calculating a specific model. After the calculation is completed, the interface may display the calculation results, the generated tool path trajectory, and the estimated machining time. At the same time, the status column of the model changes from "Uncalculated" to "Calculated", providing an accurate basis for subsequent processing.

[0027] Furthermore, in step S3, the plug-in is subjected to safety inspection before processing, specifically including:

[0028] Step S31: The plug-in is running in the background. For the selected processing strategy, including point projection processing or spiral finishing, the automatic collision check function is started. The motion trajectory of the tool during the processing is accurately calculated according to the set processing limits, the starting and ending processing directions of the tool, and the tool axis inclination parameters. The motion trajectory is carefully compared with the three-dimensional model of the blank and the safety rod to comprehensively check whether there is a collision risk.

[0029] Step S32: The plug-in sets a safety gap before collision during machining. When the tool approaches the safety gap, a warning message is issued in time, including displaying the relevant status in the status bar. Based on the inspection result, if it is normal, the plug-in continues to the next machining operation, including generating the final machining tool path. If a collision risk is found, the plug-in suspends the current operation and prompts the user to make adjustments on the interface. The user may need to recheck and adjust the machining parameters, including one or more of the tool parameters, machining limits and machining strategies, until the safety check is passed before continuing the machining.

[0030] Furthermore, in step S4, selecting an output mode in the plug-in specifically includes:

[0031] Step S41: In the plug-in, find and select the corresponding processing program file output mode setting option to determine whether to use a single milling machine for sequential processing or multiple milling machines for parallel processing to meet different production scenarios and needs;

[0032] Step S42: If multiple milling machines are selected for parallel processing, each milling machine needs to be fully set up, including ensuring that the milling machines are correctly connected and reasonably configuring various parameters to ensure that each milling machine can accurately receive and execute the corresponding processing program; after completing the settings, the plug-in outputs the processing program file to the milling machine in the selected method, and the milling machine can start the processing operation after receiving the program file.

[0033] The present invention adopts the above technical solution, which has at least the following beneficial effects:

[0034] 1. Solve key technical problems, achieve seamless connection and accurate generation of instructions: In view of the problem that the three-dimensional files output by CAD software design cannot be directly used for CNC processing, the present invention has established a perfect conversion mechanism. Through the plug-in, in the step of inputting drawings, two spatial coordinate systems are automatically established according to the type of three-dimensional model, and the blank, safety rod and target processing model are accurately placed in the corresponding coordinate system. At the same time, a dedicated tool that fully matches the actual CNC milling machine tool is established, solving problems such as format and position, so that the three-dimensional file can be seamlessly connected with the CNC processing equipment. This ensures the accurate generation of processing instructions, successfully breaks through the bottleneck of existing technologies, and smoothly realizes the transformation from three-dimensional design to positive production, laying a solid foundation for subsequent processing.

[0035] 2. Optimize the processing technology and improve the processing accuracy and surface quality: standardize and intelligently integrate the processing methods. When establishing the tool path processing strategy, it is divided into two strategies: point projection processing and spiral finishing according to different models, and various parameters are set accurately. For example, the angle increment in the point projection processing strategy is 0.5 degrees, and the processing line spacing in the spiral finishing strategy can be freely set from 1mm to 3mm according to the model type. At the same time, the processing limits, tool start and end directions, automatic collision checks, tool axis inclination, feed and speed and other parameters are carefully set. These measures enable CNC processing equipment to automatically select the appropriate processing strategy based on the three-dimensional file, greatly improving the processing accuracy and surface quality, effectively meeting the strict requirements of orthotics and prosthetic sockets for precision and adaptability, and improving the performance and quality of the product.

[0036] 3. Improve the efficiency of the processing process, shorten the production cycle and enhance consistency: realize the automated operation from drawing input to the final delivery of the finished product. In the entire processing process, each step is closely connected and highly automated. For example, when inputting drawings, you can flexibly select various models and automatically complete the relevant preparations. After selecting "Start Calculation", the software automatically performs complex calculations, and the processing safety check is automatically performed and intelligently processed according to the results. When outputting the processing program file, you can select a single or multiple milling machines for parallel processing according to needs and automatically complete the settings. It reduces the manual intervention links and the errors caused by human factors. At the same time, the production cycle is greatly shortened through parallel processing and other methods. For example, multiple milling machines can process multiple models at the same time in parallel, which significantly improves the efficiency compared to the traditional single machine processing. The automation of the entire process ensures the efficiency and consistency of product production, and improves the production capacity and market competitiveness of the enterprise.

[0037] 4. Ensure product quality reliability, ensure high-quality delivery and improve stability: Ensure product quality through the synergy of software and hardware. During the processing, the software automatically controls the processing accuracy, such as automatically adjusting the processing parameters to adapt to different products and process requirements, and the processing parameters have been integrated in the software and verified in practice, without the need for secondary testing. At the same time, in terms of hardware, through the design of safety bars and other aspects and automatic collision checks in processing safety inspections, pre-collision safety gaps and warnings are set to ensure that the processing process is safe and free of collision risks. This synergy ensures that every positive product can meet high quality standards and can be directly used for the assembly of orthotics and prosthetic sockets without secondary testing, which improves the product's qualification rate and stability, reduces production costs, provides patients with more reliable and higher-quality products, and promotes the overall improvement of industry product quality.

[0038] 5. Promote the development of industry technology, fill the gap in technology and lead the direction of progress: This invention fills the gap in the existing technology in the automated CNC processing of orthotics and prosthetic sockets. It provides an efficient, accurate and automated solution for the industry, integrating digital technology and CNC processing links, and optimizing the entire process from design to finished products. Its innovative technical means and concepts have set a new benchmark for the field of assistive device manufacturing technology in rehabilitation engineering, leading the industry to develop in a more advanced and reliable direction, helping to promote further research and application of related technologies, and injecting strong impetus into the continuous innovation and development of the industry. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. 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 paying creative work.

[0040] Figure 1 It is a flow chart of the implementation method of the present invention;

[0041] Figure 2 It is a schematic diagram of the plug-in input model of the present invention;

[0042] Figure 3 It is a schematic diagram of the plug-in loading interface of the present invention;

[0043] Figure 4 It is a schematic diagram of the interface for starting calculation of the plug-in of the present invention. DETAILED DESCRIPTION

[0044] Exemplary embodiments will be described in detail herein, examples of which are shown in the accompanying drawings. When the following description refers to the drawings, the same numbers in different drawings represent the same or similar elements unless otherwise indicated. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the present invention. Instead, they are merely examples of devices and methods consistent with some aspects of the present invention as detailed in the appended claims.

[0045] Embodiment 1

[0046] like Figure 1 As shown, the present invention provides a method for realizing automatic numerical control machining of a positive type of an orthosis and a prosthetic receiving cavity, comprising the following steps:

[0047] Step S1: Input the drawing file and operate through the plug-in to prepare the data and model required for processing, including selecting the processing type, loading the model file and related models to the corresponding coordinate system, and supporting the addition of new processing types to prepare for subsequent processing;

[0048] Step S2: Start calculation. After the plug-in confirms the model, the calculation process is started. The plug-in processes the model according to the preset parameters and strategies, determines the processing path parameters, displays the status information during the calculation, and displays the results and updates the model status after completion.

[0049] Step S3: Processing safety check: the plug-in performs safety inspection before processing, calculates the tool trajectory through automatic collision check and compares it with the relevant model, sets safety clearance and warning, and determines the subsequent operation based on the results to ensure processing safety;

[0050] Step S4: Output the processing program file, select the output method in the plug-in, and process on one or more milling machines. When there are multiple milling machines, the milling machine parameters need to be set to ensure that the processing is started after the execution program is correctly received to achieve flexible processing arrangements.

[0051] Furthermore, in step S1, the plug-in operation specifically includes at least:

[0052] Step S11: In the plug-in, click the input model function button to start the model input process;

[0053] Step S12: After clicking to input the model, in the selection menu that appears containing a variety of orthotic and prosthetic socket types, select the corresponding type according to actual needs. You can choose to load a single model or multiple models. You can directly click to start the calculation for a single model. Multiple models need to be selected before clicking to start the calculation. Adding a new model requires calculation after a specific button operation. At the same time, after selecting the relevant logo, the plug-in automatically loads the corresponding type of blank and safety rod, and supports later added types.

[0054] Step S13: The plug-in establishes two spatial coordinate systems according to the type of three-dimensional model, places the blank, safety rod and target processing model in the corresponding coordinate system, establishes a dedicated tool that fully matches the actual CNC milling machine tool, and determines two processing strategies and their respective detailed parameters.

[0055] Furthermore, a dedicated tool that fully matches the actual CNC milling machine tool is established, and two processing strategies and their respective detailed parameters are determined, including the following:

[0056] The parameters that need to be determined for the point projection processing strategy include: spatial coordinate system, blank and safety bar, tool, processing limit, which is used to define the maximum limit of each axial processing, the projection reference line style is spiral and clockwise, the angle increment is 0.5 degrees, which is used to control the processing accuracy, the tool moves down this angle for each circle of processing, the tool start and end processing direction, automatic collision check, including setting the safety gap and warning before collision during processing, tool axis inclination, processing start and end points, feed and speed settings, spindle speed 12000 rpm, cutting feed rate 8000 mm / min, downcut feed rate 2000 mm / min, skimming feed rate specific value mm / min, cooling method is standard air cooling;

[0057] The parameters that need to be determined for the spiral finishing strategy include: spatial coordinate system, blank and safety bar, tool, machining limit, which is used to define the maximum limit of each axial machining, spiral reference line style is spiral and clockwise, machining line spacing is 1mm-3mm, which can be freely set according to the model type to control the machining accuracy, tool start and end machining direction, automatic collision check including setting the safety gap and warning before collision during machining, tool axis inclination, machining start and end points, feed and speed settings, spindle speed of 12000 rpm, cutting feed rate of 8000 mm / min, downcut feed rate of 2000 mm / min, specific value of skimming feed rate of mm / min, and standard air cooling; this step ensures the comprehensiveness and accuracy of machining preparation work, laying the foundation for subsequent high-quality machining.

[0058] Further, in step S2, starting the calculation process after confirming the model based on the plug-in specifically includes:

[0059] Step S21: Carefully confirm the various models available for calculation and their file paths on the plug-in interface to ensure that the selected model is accurate;

[0060] Step S22: Click the Start Calculation button to trigger the plug-in to perform calculations on the selected model. The software performs complex calculations based on the parameters and strategies set in the previous steps, including establishing a coordinate system, placing related models, calling tools, loading target models, and calculating key parameters such as machining paths, tool axis inclinations, feeds, and speeds according to the selected machining strategies. During the calculation process, the status bar at the bottom of the plug-in interface displays the calculation progress and related information in real time, including displaying the status when calculating a specific model. After the calculation is completed, the interface may display the calculation results, the generated tool path trajectory, and the estimated machining time. At the same time, the status column of the model changes from "Uncalculated" to "Calculated", providing an accurate basis for subsequent processing.

[0061] Furthermore, in step S3, the plug-in is subjected to safety inspection before processing, specifically including:

[0062] Step S31: The plug-in is running in the background. For the selected processing strategy, including point projection processing or spiral finishing, the automatic collision check function is started. The motion trajectory of the tool during the processing is accurately calculated according to the set processing limits, the starting and ending processing directions of the tool, and the tool axis inclination parameters. The motion trajectory is carefully compared with the three-dimensional model of the blank and the safety rod to comprehensively check whether there is a collision risk.

[0063] Step S32: The plug-in sets a safety gap before collision during machining. When the tool approaches the safety gap, a warning message is issued in time, including displaying the relevant status in the status bar. Based on the inspection result, if it is normal, the plug-in continues to the next machining operation, including generating the final machining tool path. If a collision risk is found, the plug-in suspends the current operation and prompts the user to make adjustments on the interface. The user may need to recheck and adjust the machining parameters, including one or more of the tool parameters, machining limits and machining strategies, until the safety check is passed before continuing the machining.

[0064] Furthermore, in step S4, selecting an output mode in the plug-in specifically includes:

[0065] Step S41: In the plug-in, find and select the corresponding processing program file output mode setting option to determine whether to use a single milling machine for sequential processing or multiple milling machines for parallel processing to meet different production scenarios and needs;

[0066] Step S42: If multiple milling machines are selected for parallel processing, each milling machine needs to be fully set up, including ensuring that the milling machines are correctly connected and reasonably configuring various parameters to ensure that each milling machine can accurately receive and execute the corresponding processing program; after completing the settings, the plug-in outputs the processing program file to the milling machine in the selected method, and the milling machine can start the processing operation after receiving the program file.

[0067] Embodiment 2

[0068] Step 1: Input the drawing file, which is the 3D model file designed by CAD software

[0069] like Figure 2 As shown, select the "Input Model" function, and then select various types of orthoses and prosthetic sockets to be processed, such as V66 for spinal orthoses, prosthetic sockets for prosthetic sockets, and children's foot braces for ankle-foot orthoses, etc.; and relevant processing types and modes can be added at any time.

[0070] This is a screenshot of the software interface called AutoFormer, which is software used for automated CNC machining of orthotics and prosthetic socket positons.

[0071] Function selection: In the software interface, click the "Input Model" function button. This button is located in the upper left corner of the interface, with a blue background and white text.

[0072] Select the processing type: After clicking "Input Model", a selection menu will appear, containing various types of orthotics and prosthetic sockets to be processed. For example:

[0073] V66: stands for spinal orthosis.

[0074] Prosthetic socket: stands for prosthetic socket.

[0075] Children's foot support: stands for ankle-foot orthosis.

[0076] Users can choose the corresponding type according to actual needs.

[0077] Add new types: The software supports adding relevant processing types and modes at any time. This means that if there is a new type of orthosis or prosthesis that needs to be processed, the corresponding processing mode can be easily added in the software.

[0078] The purpose of this step is to import the 3D model file designed by the CAD software into the AutoFormer software to prepare for subsequent CNC machining. By selecting different types of orthotics and prostheses, the software can set and process corresponding machining parameters according to their characteristics.

[0079] like Figure 3As shown, one or more orthotics and prosthetic socket male types are selected to be loaded;

[0080] This is a screenshot of the software interface called AutoFormer, which shows the relevant operations for inputting models.

[0081] There are currently three models in the list:

[0082] The first model is "V66 Spine", the corresponding file path is "D:\useccase\V66 Spine.stl", and the status is "Not Calculated".

[0083] The second model is "Children's Foot Support", the corresponding file path is "D:\useccase\AFO.stl", and the status is "Not Calculated".

[0084] The third model is the "prosthetic socket", the corresponding file path is "D:\useccase\socket.stl", and the status is "Not calculated".

[0085] Operation steps: If you want to select one or more orthotics and prosthetic socket positives to load, you can follow the steps below:

[0086] Select a single model to load: For example, if you only need to load the "V66 Spine" model, you can directly click the "Start Calculation" button (located in the middle of the top of the interface, a blue button), and the software will calculate the model.

[0087] Select multiple models to load: If you need to load multiple models at the same time, such as "Children's Foot Support" and "Prosthetic Socket", you can first select the rows corresponding to these two models (you can select them by clicking the row number or model icon), and then click the "Start Calculation" button. The software will calculate the selected multiple models in turn.

[0088] Add new model: If you need to add a new orthosis or prosthetic socket model, you can use the "Input Model" button (located on the top left of the interface, the blue button) to add a new model file and then perform the calculation operation.

[0089] The main function of this software interface is to calculate and process the input orthotic and prosthetic socket positive models for subsequent CNC machining operations. By selecting and loading different models, the automated machining of various orthotics and prosthetic sockets can be achieved.

[0090] In this operation, the relevant functional steps running in the background of the patented method include:

[0091] Two spatial coordinate systems are established according to different 3D model types; support is provided for later addition of more types.

[0092] Place the 3D model of the blank and the 3D model of the safety rod in the corresponding coordinate system. When "inputting drawings", select relevant labels such as V66, prosthetic socket, and children's foot support, and then load the corresponding type of blank and safety rod.

[0093] Create your own tool

[0094] Type: Ball-end cutter

[0095] Length:200mm

[0096] id:1-1-1-1

[0097] Number of slots: 1

[0098] Diameter:20mm

[0099] Extend: 200mm

[0100] Gauge length: 350mm

[0101] It must completely match the tool actually assembled on the CNC milling machine.

[0102] The three-dimensional model corresponding to the loaded drawing, i.e. the target processing model, is placed in the same spatial coordinate system as the blank and the safety rod.

[0103] Establish toolpath processing strategy, divided into two processing strategies according to different models: point projection processing and spiral finishing. Support later addition of more types.

[0104] The steps to establish a point projection processing strategy are as follows:

[0105] Space coordinate system; blank and safety rod; tool;

[0106] Processing limits, which define the maximum limits of each axial processing;

[0107] Define the style of the projection reference line as spiral and the direction as clockwise;

[0108] The angle increment is 0.5 degrees. The angle at which the knife moves down after each processing is controlled to control the processing accuracy.

[0109] Define the direction of tool start and end processing;

[0110] Automatic collision check, safety clearance before collision during processing, and early warning;

[0111] The inclination angle of the knife axis;

[0112] Processing start and end points;

[0113] Feed and speed settings, spindle speed: 12000 rpm, cutting feed rate 8000 mm / min, downcut feed rate 2000 mm / min, skimming feed rate mm / min;

[0114] Cooling method: standard air cooling;

[0115] The steps to establish the spiral finishing strategy are as follows, which determine the following:

[0116] Space coordinate system; blank and safety rod; tool;

[0117] Processing limits, which define the maximum limits of each axial processing;

[0118] Define the spiral reference line style as spiral and direction as clockwise;

[0119] The processing line spacing of 1mm-3mm can be freely set according to the model type to control the processing accuracy;

[0120] Define the direction of tool start and end processing;

[0121] Automatic collision check, safety clearance before collision during processing, and early warning;

[0122] The inclination angle of the knife axis;

[0123] Processing start and end points;

[0124] Feed and speed settings, spindle speed: 12000 rpm, cutting feed rate 8000 mm / min, downcut feed rate 2000 mm / min, skimming feed rate mm / min;

[0125] Cooling method: standard air cooling;

[0126] Step 2: If Figure 4 As shown, select "Start Calculation"

[0127] When you select "Start Calculation", the software will calculate the selected model. The following are the specific steps and possible situations:

[0128] 1. Operation steps

[0129] Confirm model selection;

[0130] There are currently three models available for calculation on the interface:

[0131] V66 spine, the file path is "D:\useccase\V66 spine.stl"

[0132] Children's foot support, the file path is "D:\useccase\AFO.stl"

[0133] Prosthetic socket, the file path is "D:\useccase\socket.stl"

[0134] Click the "Start Calculation" button;

[0135] The "Start Calculation" button is located in the middle of the upper part of the interface, with a blue background and white text. After clicking this button, the software will start calculating the selected model.

[0136] 2. Possible operations in the background

[0137] Model processing;

[0138] The software will process the model according to the previously set parameters and strategies. For example:

[0139] Depending on the type of 3D model, establish two spatial coordinate systems (if not already established).

[0140] Place the 3D model of the blank itself and the 3D model of the safety rod itself in the corresponding coordinate system (if they have not been placed yet).

[0141] Call the established exclusive tool (type, length, diameter and other parameters have been determined).

[0142] Load the target processing model (such as V66 spine, children's foot support, prosthetic socket) into the same spatial coordinate system.

[0143] Machining strategy execution; select the corresponding machining strategy (point projection machining or spiral finishing machining) according to different models: If it is a point projection machining strategy, the software will calculate according to the following parameters: spatial coordinate system, blank and safety bar, tool and other basic elements. Machining limits. The projection reference line style is spiral and the direction is clockwise, and the angle increment is 0.5 degrees. The starting and ending machining directions of the tool. Automatic collision check parameters. Tool axis inclination. Machining start and end points. Feed and speed settings (spindle speed 12000 rpm, cutting feed rate 8000 mm / min, downcut feed rate 2000 mm / min, etc.). Cooling method (standard air cooling). If it is a spiral finishing machining strategy, the software will calculate according to the following parameters: the same spatial coordinate system, blank and safety bar, tool and other basic elements. Machining limits. The spiral reference line style is spiral and the direction is clockwise, and the machining line spacing 1-3mm can be set according to the model type. The starting and ending machining directions of the tool.

[0144] Automatic collision check parameters. Tool axis inclination. Processing start and end points. Feed and speed settings (spindle speed 12000 rpm, cutting feed rate 8000 mm / min, downcut feed rate 2000 mm / min, etc.). Cooling method (standard air cooling).

[0145] 3. Interface Display

[0146] Calculation status display

[0147] The status bar at the bottom of the interface will display the calculation progress and related information. For example, when calculating the V66 spine, the status bar will display "Status: [V66 Spine] Calculating toolpath", indicating that the software is calculating the toolpath for the V66 spine model.

[0148] Calculation results

[0149] After the calculation is completed, the interface may display the calculation results, such as the generated toolpath trajectory, machining time estimate, etc., and the "Status" column of the model may change from "Not Calculated" to "Calculated" or display other relevant status information.

[0150] In short, selecting "Start Calculation" is a key step in the entire machining process. It will trigger the software to perform a series of complex calculation operations on the model to generate the final machining plan.

[0151] Step 3: Processing safety inspection

[0152] This is a screenshot of the AutoFormer software interface. After "start calculation", it is very important to perform a processing safety check.

[0153] 1. The importance of processing safety inspection: During CNC machining, processing safety inspection can prevent the tool from colliding with the workpiece, safety rod, etc., avoid equipment damage and processing failure, and ensure the safety of operators.

[0154] 2. Processing safety check in AutoFormer: automatic collision check

[0155] In the background running function of the software, both the point projection processing strategy and the spiral finishing strategy include the key link of automatic collision check. The software will pre-calculate the movement trajectory of the tool during the processing process according to the set processing limits, the starting and ending processing directions of the tool, the tool axis inclination and other parameters. By comparing with the three-dimensional model of the blank and the safety bar, check whether there is a collision risk. Safety clearance and warning; the software will set a safety clearance before collision during processing. When the distance between the tool and other parts is close to this safety clearance, the software will issue a warning. For example, relevant safety check status information may be displayed in the status bar. The status bar at the bottom of the current interface shows "Status: [V66 Spine] Tool Path Safety Check", which indicates that the software is performing a safety check on the processing tool path of the V66 spine model.

[0156] 3. Possible inspection results and subsequent treatment:

[0157] The inspection results are normal; if the machining safety inspection results are normal, the software can proceed to the next machining operation, such as generating the final machining tool path and sending it to the CNC milling machine for actual machining.

[0158] The inspection result is abnormal; if a collision risk is found, the software may pause the current operation and prompt the user to make adjustments on the interface.

[0159] The user may need to recheck and adjust machining parameters, such as tool parameters, machining limits, machining strategies, etc., until the safety check passes before continuing machining.

[0160] In short, processing safety inspection is an important part of ensuring the smooth progress of CNC processing and equipment safety. AutoFormer software ensures the safety of the processing process through a series of parameter settings and background calculations.

[0161] Step 4: After the calculation is completed, the processing program file is output to a milling machine for sequential processing, or it can be output to multiple milling machines for parallel processing.

[0162] This is the AutoFormer software interface, showing that the calculations for the three models (V66 spine, children's foot support, and prosthetic socket) have been completed.

[0163] 1. Output processing program file

[0164] Single milling machine processing;

[0165] When selecting a single milling machine for sequential processing: the software will output the calculated processing program files to the selected milling machine one by one in order. For example, the processing program of the V66 spine is output first, and after the processing is completed, the processing program of the children's foot support is output, and finally the processing program of the prosthetic socket is output.

[0166] This method is suitable for situations where the number of milling machines is limited. The operation is relatively simple, but the processing efficiency may be low because it is necessary to wait for the processing of one model to be completed before starting the processing of the next model.

[0167] Multiple milling machines parallel processing: If multiple milling machines are selected for parallel processing: the software can output the processing program files of different models to multiple milling machines for simultaneous processing. For example, the processing program of the V66 spine can be output to milling machine A, the processing program of the children's foot support can be output to milling machine B, and the processing program of the prosthetic socket can be output to milling machine C, and then these three milling machines can start processing at the same time.

[0168] This method can significantly improve processing efficiency and shorten the overall processing time, but it requires the availability of multiple milling machines and the reasonable arrangement of the allocation and coordination of the milling machines to ensure the smooth progress of the processing process.

[0169] 2. Operation steps:

[0170] Select output method: There may be corresponding setting options on the software interface (although not shown in the figure) to choose whether to process sequentially on a single milling machine or in parallel on multiple milling machines.

[0171] Milling machine settings: If multiple milling machines are used for parallel processing, each milling machine needs to be set up, including the connection and parameter configuration of the milling machine, to ensure that each milling machine can correctly receive and execute the corresponding processing program.

[0172] File output and processing start;

[0173] After completing the above settings, the software will output the processing program file to the milling machine in the selected way. After the milling machine receives the program file, it can start the processing operation and start processing the orthosis and prosthetic socket positive mold.

[0174] The specific implementation provided in this embodiment has at least the following advantages:

[0175] Simplified process: The software and automated control system of the invention tightly integrate the originally scattered design, programming, processing and finished product delivery links to form a continuous and efficient workflow. For example, in traditional processes, design, programming and processing may be completed by different people using different tools, and data transmission and conversion are prone to errors. However, the present invention achieves seamless data flow through high integration and reduces the cumbersome operations in the intermediate links.

[0176] Improve overall coordination: All links can be automatically coordinated and connected, avoiding delays and errors caused by poor communication or operational errors. For example, in the conversion process from design to processing, the software can automatically identify and process relevant data without manual adjustment and intervention, greatly improving work efficiency.

[0177] Automatically generate processing plans:

[0178] Advantages: Automatically generate corresponding processing plans, precision, surface roughness and processes according to different body parts (such as ankles, feet, trunk, head, etc.), reducing the tedious process of manually determining processing plans. In traditional methods, engineers need to manually determine these parameters based on the workpiece design drawings, which is not only time-consuming, but also prone to inaccurate plans due to differences in personal experience. The present invention ensures that the personalized requirements of each product are accurately implemented through software automation, and improves the scientificity and consistency of the processing plan.

[0179] Automated programming and simulation: Advantages: The dedicated software integrates CNC programming functions, and can input multiple 3D files at one time to automatically realize CNC programming and simulation. Compared with the traditional method of relying on engineers to manually write G codes and manually optimize and simulate, it saves a lot of time and reduces the possibility of manual errors. The programming instructions automatically generated by the software are more accurate and efficient, and the simulation function can also detect potential problems in advance, avoid errors in actual processing, and improve the success rate and quality of processing.

[0180] Automatic adjustment of processing parameters: Advantages: The system automatically adjusts the processing accuracy and parameters according to different product and process requirements, and the processing parameters have been integrated in the software and verified in practice. In traditional processing, the selection of processing accuracy and parameters depends on manual experience, and it is often necessary to adjust and re-test multiple times during the processing, which increases labor costs and time costs. The automatic adjustment function of the present invention ensures the consistency and high precision of processing quality, and can achieve the ideal processing effect without secondary testing, thereby improving production efficiency.

[0181] Automatic parallel processing: Advantages: Through the central control system, a host computer can distribute the calculation results to multiple devices for parallel processing. The traditional CNC machine tool has low single-machine operation efficiency, while the parallel processing method of the present invention greatly improves production efficiency, allowing a large number of products to be processed simultaneously, shortening the production cycle, and better meeting market demand, especially in the large-scale production of orthotics and prosthetic sockets.

[0182] Optimized material and fixture design: Advantages: The size and shape of the selected "hard foam" material are pre-set, which provides a basis for automated processing, effectively reduces material waste and improves processing stability. The fixture and tool are specially designed and embedded in the CNC machine tool, which can be automatically matched and adjusted without manual tool setting and coordinate system setting. In traditional processes, the selection and installation of fixtures and tools require manual operation, and manual adjustment according to the shape of the workpiece and processing requirements is inefficient and prone to errors. The optimized design of the present invention saves man-hours and improves the degree of automation and precision of processing.

[0183] Compared with traditional CNC milling machines, the comprehensive advantages are as follows: Improved processing accuracy: The automatic adjustment of processing parameters, automated programming and simulation, and optimized material and fixture design and other innovative points work together to significantly improve processing accuracy. For example, the software accurately controls the tool motion trajectory and processing parameters, avoiding the instability of manual operation, and can process high-precision orthotics and prosthetic socket positives that better meet design requirements.

[0184] Improved efficiency: Automatic generation of processing plans, automated programming and simulation, and automatic parallel processing have greatly shortened the processing cycle. All links from design to finished product delivery have been automated and optimized, reducing manual intervention and waiting time. Compared with traditional CNC milling machines, more products can be processed in a shorter time.

[0185] Improved product quality: Improved processing accuracy directly leads to improved product quality, while optimized material and fixture design also help ensure product stability and consistency. Reducing manual intervention and errors further reduces the probability of product quality problems, making the final orthosis and prosthetic sockets have better performance in terms of dimensional accuracy, surface quality and adaptability, improving patient comfort and safety.

[0186] The above description is only a preferred embodiment of the present invention and is not intended to limit the invention. Although the present invention is described in detail with reference to the aforementioned embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or replace some of the technical features therein by equivalents. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A method for realizing automated numerical control machining of positive-shaped orthotic and prosthetic sockets, characterized in that: The following steps are involved: Step S1: Input the drawing file and operate through the plug-in to prepare the data and model required for processing, including selecting the processing type, loading the model file and related models to the corresponding coordinate system, and supporting the addition of new processing types to prepare for subsequent processing; Step S2: Start calculation. After the plug-in confirms the model, the calculation process is started. The plug-in processes the model according to the preset parameters and strategies, determines the processing path parameters, displays the status information during the calculation, and displays the results and updates the model status after completion. Step S3: Processing safety check: the plug-in performs safety inspection before processing, calculates the tool trajectory through automatic collision check and compares it with the relevant model, sets safety clearance and warning, and determines the subsequent operation based on the results to ensure processing safety; Step S4: Output the processing program file, select the output method in the plug-in, and process on one or more milling machines. When there are multiple milling machines, the milling machine parameters need to be set to ensure that the processing is started after the execution program is correctly received to achieve flexible processing arrangements.

2. The method according to claim 1, characterized in that: In step S1, the plug-in operation specifically includes at least: Step S11: In the plug-in, click the input model function button to start the model input process; Step S12: After clicking to input the model, in the selection menu that appears containing a variety of orthotic and prosthetic socket types, select the corresponding type according to actual needs. You can choose to load a single model or multiple models. You can directly click to start the calculation for a single model. Multiple models need to be selected before clicking to start the calculation. Adding a new model requires calculation after a specific button operation. At the same time, after selecting the relevant logo, the plug-in automatically loads the corresponding type of blank and safety rod, and supports later added types. Step S13: The plug-in establishes two spatial coordinate systems according to the type of three-dimensional model, places the blank, safety rod and target processing model in the corresponding coordinate system, establishes a dedicated tool that fully matches the actual CNC milling machine tool, and determines two processing strategies and their respective detailed parameters.

3. The method according to claim 2, characterized in that: Create a dedicated tool that fully matches the actual CNC milling machine tool, and determine two processing strategies and their respective detailed parameters, including the following: The parameters that need to be determined for the point projection processing strategy include: spatial coordinate system, blank and safety bar, tool, processing limit, which is used to define the maximum limit of each axial processing, the projection reference line style is spiral and clockwise, the angle increment is 0.5 degrees, which is used to control the processing accuracy, the tool moves down this angle for each circle of processing, the tool start and end processing direction, automatic collision check, including setting the safety gap and warning before collision during processing, tool axis inclination, processing start and end points, feed and speed settings, spindle speed 12000 rpm, cutting feed rate 8000 mm / min, downcut feed rate 2000 mm / min, skimming feed rate specific value mm / min, cooling method is standard air cooling; The parameters that need to be determined for the spiral finishing strategy include: spatial coordinate system, blank and safety bar, tool, machining limit, which is used to define the maximum limit of each axial machining, spiral reference line style is spiral and clockwise, machining line spacing is 1mm-3mm, which can be freely set according to the model type to control the machining accuracy, tool start and end machining direction, automatic collision check including setting the safety gap and warning before collision during machining, tool axis inclination, machining start and end points, feed and speed settings, spindle speed of 12000 rpm, cutting feed rate of 8000 mm / min, downcut feed rate of 2000 mm / min, specific value of skimming feed rate of mm / min, and standard air cooling; this step ensures the comprehensiveness and accuracy of machining preparation work, laying the foundation for subsequent high-quality machining.

4. The method according to claim 3, characterized in that: In step S2, starting the calculation process after confirming the model based on the plug-in specifically includes: Step S21: Carefully confirm the various models available for calculation and their file paths on the plug-in interface to ensure that the selected model is accurate; Step S22: Click the Start Calculation button to trigger the plug-in to perform calculations on the selected model. The software performs complex calculations based on the parameters and strategies set in the previous steps, including establishing a coordinate system, placing related models, calling tools, loading target models, and calculating key parameters such as machining paths, tool axis inclinations, feed and speed according to the selected machining strategy. During the calculation process, the status bar at the bottom of the plug-in interface displays the calculation progress and related information in real time, including displaying the status when calculating a specific model. After the calculation is completed, the interface may display the calculation results, including the generated tool path trajectory and machining time estimate. At the same time, the status column of the model changes from "Uncalculated" to "Calculated", providing an accurate basis for subsequent processing.

5. The method according to claim 4, characterized in that: In step S3, the plug-in is subjected to safety inspection before processing, specifically including: Step S31: The plug-in is running in the background. For the selected processing strategy, including point projection processing or spiral finishing, the automatic collision check function is started. The motion trajectory of the tool during the processing is accurately calculated according to the set processing limits, the starting and ending processing directions of the tool, and the tool axis inclination parameters. The motion trajectory is carefully compared with the three-dimensional model of the blank and the safety rod to comprehensively check whether there is a collision risk. Step S32: The plug-in sets a safety gap before collision during machining. When the tool approaches the safety gap, a warning message is issued in time, including displaying the relevant status in the status bar. Based on the inspection result, if it is normal, the plug-in continues to the next machining operation, including generating the final machining tool path. If a collision risk is found, the plug-in suspends the current operation and prompts the user to make adjustments on the interface. The user may need to recheck and adjust the machining parameters, including one or more of the tool parameters, machining limits and machining strategies, until the safety check is passed before continuing the machining.

6. The method according to claim 5, characterized in that: In step S4, selecting an output mode in the plug-in specifically includes: Step S41: In the plug-in, find and select the corresponding processing program file output mode setting option to determine whether to use a single milling machine for sequential processing or multiple milling machines for parallel processing to meet different production scenarios and needs; Step S42: If multiple milling machines are selected for parallel processing, each milling machine needs to be fully set up, including ensuring that the milling machines are correctly connected and reasonably configuring various parameters to ensure that each milling machine can accurately receive and execute the corresponding processing program; after completing the settings, the plug-in outputs the processing program file to the milling machine in the selected method, and the milling machine can start the processing operation after receiving the program file.

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