Copying edge milling machining equipment and machining method for long and straight structural part

Abstract

The invention relates to long and straight structural part profiling edge milling machining equipment and a machining method. A displacement sensor is adopted for monitoring the displacement amount between a workpiece and a milling power head in real time, and the displacement amount is input into a PLC control system in an analog quantity mode; according to the product drawing size requirement, the displacement median is calculated, a control program is programmed, the Y-direction displacement of the workpiece is judged through the PLC, a forward and reverse rotation instruction is sent to the servo motor, the Y-direction position of the edge milling machine walking trolley is controlled, the machining amount is adjusted to meet the size requirement, and profiling machining is achieved. The problems that in the prior art, in profiling edge milling machining of long and straight structural parts, especially airfoil grooves of C-shaped structural beams, due to the straightness deviation of workpieces, an existing machining technology cannot achieve real-time automatic profiling machining, the groove size control precision is poor, the machining efficiency is low, and the machining cost is high are solved.

Description

Technical Field

[0001] The invention belongs to the field of automobile parts processing, and in particular relates to a long straight structural part profiling edge milling processing equipment and a processing method. Background Art

[0002] At present, some special automobile beams are welded with C-shaped channel steel. This structure has the characteristics of long longitudinal dimension, short transverse dimension, large plate thickness and high welding difficulty. Beveling is required before welding to meet welding requirements. The conventional beveling method is milling machine processing. The traditional automatic milling machine, after setting the Y-direction (transverse) displacement, walks on the X-direction (longitudinal) fixed track and cannot dynamically adjust the Y-direction displacement. For roll-formed profiles with large longitudinal dimensions, the wing surface often has straightness deviation. After beveling along the fixed Y-direction displacement, the blunt edge size accuracy is poor. After welding, it is easy to produce local gaps that are too large and cause welding leakage problems, which leads to rework. If the operator manually adjusts the Y-direction position during the beveling process, the accuracy can also be improved, but this method will lead to reduced processing efficiency, high requirements on the operator's operating level, and is not conducive to automated production. Summary of the invention

[0003] The invention provides a long straight structural member profiling edge milling processing device and a processing method, which solves the problems of poor groove size control accuracy, low processing efficiency and high processing cost in the existing long straight structural member, especially the wing surface groove profiling edge milling processing of C-shaped structural beams, due to the straightness deviation of the workpiece itself, the existing processing technology cannot realize real-time automatic profiling processing.

[0004] The present invention is achieved by adopting the following technical solutions:

[0005] On one hand, the present invention provides an online profiling and edge milling processing device for long straight structural parts, including a milling power head, a workpiece distance measuring device, a PLC control system, and a servo motor control system;

[0006] The milling power head is connected to the lifting column, and the Z-direction movement of the milling power head is realized by the top motor and Z-direction lead screw arranged in the lifting column; the bottom of the lifting column is connected to the traveling trolley, and the Y-direction movement of the milling power head and the lifting column as a whole is realized by the Y-direction lead screw arranged in the traveling trolley; the traveling trolley is arranged on the workbench guide rail, and the X-direction movement is realized by the travel trolley's own motor moving along the workbench guide rail;

[0007] The servo motor control system includes a servo motor driver, a servo motor, and a Y-axis lead screw connected to the servo motor. The servo motor driver drives the Y-axis lead screw through the servo motor to control the Y-axis displacement of the lifting column and the milling power head.

[0008] The PLC control system includes a PLC controller, which is connected to the touch screen through a touch screen transmission harness and connected to the displacement sensor through a sensor transmission harness to receive signals; the PLC controller is connected to the servo motor by connecting to the servo motor driver to transmit signals and control the servo motor, thereby controlling the Y-direction displacement of the milling power head;

[0009] The top motor, the motor of the trolley, and the motor of the milling power head cutter are all ordinary motors, and their respective inverters are controlled by the touch screen to realize their start and stop, forward and reverse rotation, thereby realizing the Z-direction displacement of the milling power head, the X-direction movement of the trolley, and the control of the milling power head cutter head self-rotation milling processing;

[0010] The workpiece distance measuring device comprises a displacement sensor arranged between the workpiece and the milling power head. The displacement sensor is fixed on the lifting column and monitors the distance between the workpiece and the milling power head in real time.

[0011] As a further explanation of the present invention: the workpiece distance measuring device realizes real-time monitoring of the distance between the milling power head and the workpiece through a displacement sensor, and realizes the transmission of distance parameters by outputting analog quantities;

[0012] The PLC controller receives data from the touch screen and the displacement sensor, and sends forward and reverse rotation instructions to the servo motor of the servo motor system through program control;

[0013] The servo motor control system controls the Y-direction displacement of the milling power head in real time by receiving instructions from the PLC controller, thereby realizing the profiling processing of the workpiece.

[0014] Preferably, the workbench has a convex cross-section, and the workpiece is fixed on the top of the workbench; workbench guide rails are provided on both side ends of the workbench.

[0015] Preferably, the PLC controller and servo motor driver are arranged on the inner side of the traveling trolley base.

[0016] The present invention also provides an online profiling and edge milling processing method for long straight structural parts, which is processed by the processing equipment; the displacement sensor is used to monitor the displacement between the workpiece and the milling power head in real time, and input it into the PLC control system and touch screen display in the form of analog quantity; according to the size requirements of the product drawing, the displacement median is determined by manual control of the initial touch screen and a control program is compiled, the real-time Y-direction displacement of the workpiece during the processing is judged by the PLC controller, and forward and reverse rotation instructions are sent to the servo motor to control the Y-direction position of the milling power head in real time, adjust the processing amount to the size requirements, and realize real-time profiling processing.

[0017] As a further explanation of the present invention: the method has two control modes, the first one is the touch screen control mode, in the early stage of processing, the milling power head motor is started on the touch screen, and the preset Y and Z displacement values ​​are input. The PLC control system receives the Y-direction parameter of the touch screen to control the servo motor control system to realize the control and adjustment of the Y-direction displacement of the milling power head, and the Z-direction displacement of the milling power head is adjusted and controlled by the top motor. Under the joint action of the servo motor and the top motor, the milling power head starts the initial milling process until the groove size of the workpiece meets the requirements of the drawing. The indication of the displacement sensor at this time is recorded as the median displacement and input into the touch screen; the other is the displacement sensor profiling control mode, which is enabled after determining the median displacement of the processing. During processing, the sensor monitors and transmits the distance signal to the PLC control system, and compares the real-time displacement value with the median displacement through program control, and then outputs the forward and reverse instructions to the servo motor control system to control the real-time profiling change of the Y-direction displacement of the milling power head.

[0018] As a further explanation of the present invention: the processing method comprises the following steps:

[0019] S1: Fix the workpiece on the worktable, start the power supply of the milling power head motor, use the touch screen control mode, input the Y and Z displacement, adjust the position of the milling power head, start feeding processing, until the groove meets the requirements of the drawing, lock the displacement sensor reading at this time as the displacement median value, and record it on the touch screen;

[0020] S2: Switch the displacement sensor control mode; start the X-direction feed motor power of the trolley on the touch screen, and the trolley drives the milling power head to start X-direction feed processing;

[0021] S3: In the displacement sensor control mode, the displacement sensor monitors the distance between the workpiece and the milling power head in real time, and transmits it to the PLC controller and the touch screen display. The PLC controller compares and judges the real-time displacement with the displacement median data through the internal program, and outputs the forward and reverse rotation instructions to the servo motor control system; the servo motor system receives the forward and reverse rotation instructions of the PLC controller, and adjusts the Y displacement of the milling power head by rotating the Y-axis lead screw until the Y displacement returns to the displacement median range, the servo motor stops, and the displacement is locked;

[0022] S4: Execute step S3 repeatedly until the edge milling of the workpiece is completed, and then turn off the X-axis feed power supply.

[0023] Preferably, in step S1,

[0024] Use the touch screen control mode to input the Y-axis and Z-axis displacements to adjust the position of the milling power head to the position under the groove blunt edge size required by the drawing. Define the measurement data of the sensor at this time as the displacement median A0, and set the tolerance A0±d. Lock the displacement median at this time through the touch screen.

[0025] Preferably, in step S3,

[0026] The sensor measures the distance A between the milling power head and the workpiece in real time and transmits it to the PLC control system in analog form. The program makes a judgment on A. When A is within the tolerance range A0±d of the median displacement, the servo motor does not work and the Y-direction displacement does not change.

[0027] When the A value exceeds the range of the median displacement, the PLC control system sends forward and reverse commands to the servo motor control system to control the Y-axis displacement of the milling power head and make real-time adjustments until A is within the range of the median displacement A0 again. The servo motor stops and the Y-axis displacement is locked. This step is repeated until the processing is completed.

[0028] Preferably, in step S3, the adjustment process is specifically as follows:

[0029] When the sensor measures in real time that the distance A between the milling power head and the workpiece is greater than A0±d, the PLC control system sends a forward rotation command to the servo motor control system, and the servo motor works to control the Y-direction displacement of the milling power head to decrease until A enters the tolerance range A0±d of the median displacement again;

[0030] When the sensor measures in real time that the distance A between the milling power head and the workpiece is less than A0±d, the PLC control system sends a reverse command to the servo motor control system, and the servo motor works to control the Y-direction displacement of the milling power head to increase until A enters the tolerance range A0±d of the median displacement again.

[0031] Compared with the prior art, the present invention has the following beneficial effects:

[0032] The present invention solves the problems of poor groove size control accuracy, low processing efficiency and high processing cost caused by the existing processing technology that cannot realize real-time automatic profiling processing in the existing long straight structural parts, especially the wing surface groove of C-shaped structural beams due to the straightness deviation of the workpiece itself. The present invention realizes real-time profiling milling processing, and the processing accuracy is improved by 50% and the processing efficiency is improved by 30%. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Attached Figure 1 It is a framework diagram of the control principle of the profiling process of the present invention;

[0034] Attached Figure 2 It is a structural schematic diagram of the profiling processing equipment of the present invention (the edge milling machine, power travel trolley and other components are hidden);

[0035] Attached Figure 3 It is a structural layout diagram of the profiling processing equipment of the present invention;

[0036] Attached Figure 4 It is a flow chart of the profiling edge milling processing method of the present invention;

[0037] In the figure, 1. displacement sensor; 2. PLC controller; 3. touch screen; 4. servo motor driver; 5. servo motor; 6. workpiece; 7. touch screen connection harness; 8. sensor transmission harness; 9. servo motor transmission harness; 10. Y-axis lead screw; 11. walking trolley; 12. lifting column; 13. milling power head; 14. worktable guide rail; 15. Z-axis lead screw; 16. worktable; 17. top motor. DETAILED DESCRIPTION

[0038] In order to enable those skilled in the art to better understand the technical solutions in the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present invention.

[0039] Embodiment 1:

[0040] Combination Figure 1-3 As shown, the online profiling and milling processing equipment and method for long straight structural parts of the present invention comprises four modules: a milling power head 13, a workpiece distance measuring device, a PLC control system, and a servo motor control system.

[0041] The workpiece distance measuring device realizes real-time monitoring of the distance between the milling power head 13 and the workpiece 6 through the displacement sensor 1, and transmits the distance parameter by outputting analog quantity to the PLC controller 2;

[0042] The PLC controller 2 receives data from the touch screen 3 and the displacement sensor 1, and sends forward and reverse rotation instructions to the servo motor driver 4 of the servo motor system through program control;

[0043] The servo motor control system receives the forward and reverse rotation instructions of the PLC controller 2 through the servo motor driver 4, controls the servo motor 5, and controls and adjusts the Y-direction displacement of the milling power head 13 in real time to achieve the profiling of the workpiece.

[0044] The milling power head 13 is connected to the lifting column 12, and the Z-direction movement of the milling power head 13 is realized by the top motor 17 and the Z-direction lead screw 15 provided in the lifting column 12; the bottom of the lifting column 12 is connected to the traveling trolley 11, and the Y-direction lead screw 10 provided in the traveling trolley 11 realizes the overall Y-direction movement of the milling power head 13 and the lifting column 12; the traveling trolley 11 is arranged on the workbench guide rail 14, and the X-direction movement is realized by the traveling trolley's own motor moving along the workbench guide rail 14;

[0045] The workpiece distance measuring device includes a displacement sensor 1 disposed between the workpiece 6 and the milling power head 13. The displacement sensor 1 is fixed on the lifting column 12, monitors the distance between the workpiece 6 and the milling power head 13 in real time, and transmits it to the PLC control system and the touch screen 3 in real time;

[0046] The PLC control system receives the data signals from the displacement sensor 1 and the touch screen 3 and sends the forward and reverse rotation instructions to the servo motor system through the control program;

[0047] The servo motor control system receives the instruction of the PLC controller and drives the Y-direction lead screw 10 in real time through the servo motor 5 to control the Y-direction displacement of the lifting column 12 and the milling power head 13;

[0048] For the contour milling of the wing surface groove of the C-shaped structural beam, the milling equipment is arranged as follows: Figure 3 shown.

[0049] The workbench 16 has a convex cross-section, and the workpiece 6 is fixed on the top of the workbench 16 ; workbench guide rails 14 are provided at both side ends of the workbench 16 .

[0050] The displacement sensor 1 is arranged between the workpiece 6 and the milling power head 13, fixed on the lifting column 12, and monitors the distance between the workpiece 6 and the milling power head 13 in real time. The PLC controller 2 and the servo motor driver 4 are arranged on the inner side of the base of the traveling trolley 11. The servo motor 5 controls the Y-direction displacement of the traveling trolley 11 by driving the Y-direction lead screw 10.

[0051] The top motor 17, the motor of the trolley, and the cutter head motor of the milling power head 13 are all ordinary motors, and their start and stop, forward and reverse rotation, etc. are controlled by their respective inverters through the touch screen 3, thereby realizing the Z-direction displacement of the milling power head, the X-direction movement of the trolley 11, and the control of the milling power head cutter head self-rotation milling processing.

[0052] Embodiment 2:

[0053] The online profiling and edge milling method for long straight structural parts of the present application has two control modes:

[0054] The first is the touch screen control mode. At the beginning of processing, the power head cutter motor is started on the touch screen 3, and the preset Y and Z displacement values ​​are input. The PLC control system receives the Y-direction parameter of the touch screen to control the servo motor control system to realize the control and adjustment of the Y-direction displacement of the milling power head, and the Z-direction displacement of the milling power head is adjusted and controlled by the top motor 17. Under the joint action of the servo motor 5 and the top motor 17, the milling power head starts the initial milling process until the groove size of the workpiece meets the requirements of the drawing. The indication of the displacement sensor 1 at this time is recorded as the median displacement and input into the touch screen 3;

[0055] The other is the displacement sensor profiling control mode, which is enabled after the median value of the processing displacement is determined. During processing, the sensor monitors and transmits the distance signal to the PLC control system, and compares the real-time displacement value with the median displacement through program control, and then outputs forward and reverse instructions to the servo motor control system to control the real-time profiling changes of the Y-axis displacement of the milling power head 13.

[0056] The process of profiling edge milling based on displacement sensor is as follows Figure 4 As shown, fix the workpiece 6 on the workbench 16, start the power supply of the milling power head cutter motor, use the touch screen control mode, input the Y and Z displacements, adjust the position of the milling power head 13, start feeding processing, until the groove meets the requirements of the drawing, lock the displacement sensor 1 at this time as the displacement median A0, and set the tolerance A0±d, and lock the displacement median at this time through the touch screen.

[0057] Switch the displacement sensor control mode; start the X-direction feed motor power supply of the trolley on the touch screen, and the trolley 11 drives the milling power head 13 to start the X-direction feed processing; in the displacement sensor control mode, the displacement sensor 1 monitors the distance between the workpiece 6 and the milling power head 13 in real time, and transmits it to the PLC controller 2 and the touch screen 3 for display. The PLC controller 2 compares and judges the real-time displacement with the displacement median data through the internal program, and outputs the forward and reverse rotation instructions to the servo motor control system; the servo motor system receives the forward and reverse rotation instructions of the PLC controller 2, and adjusts the Y-direction displacement of the milling power head by rotating the Y-direction lead screw 10 until the Y-direction displacement returns to the displacement median range again, the servo motor 5 stops, the displacement is locked, and this step is repeated until the processing is completed.

[0058] The above description is only an example of the implementation of the present invention and does not limit the present invention in any form. The protection scope of the present invention shall be based on the claims and is not limited by the above specific embodiments. Any simple modification or equivalent changes and modifications made to the above implementation according to the technical essence of the present invention shall fall within the protection scope of the present invention.

Claims

1. An online profiling and edge milling equipment for long straight structural parts, characterized in that: It includes a milling power head (13), a workpiece distance measuring device, a PLC control system, and a servo motor control system; The milling power head (13) is connected to the lifting column (12), and the Z-direction movement of the milling power head (13) is realized by a top motor (17) and a Z-direction lead screw (15) arranged in the lifting column (12); the bottom of the lifting column (12) is connected to the traveling trolley (11), and the Y-direction movement of the milling power head (13) and the lifting column (12) as a whole is realized by a Y-direction lead screw (10) arranged in the traveling trolley (11); the traveling trolley (11) is arranged on the workbench guide rail (14), and the X-direction movement is realized by the traveling trolley's own motor moving along the workbench guide rail (14); The servo motor control system comprises a servo motor driver (4), a servo motor (5), and a Y-direction lead screw (10) connected to the servo motor (5); the servo motor driver (4) drives the Y-direction lead screw (10) through the servo motor (5) to control the Y-direction displacement of the lifting column (12) and the milling power head (13); The PLC control system comprises a PLC controller (2), wherein the PLC controller (2) is connected to a touch screen (3) via a touch screen transmission harness (7), and is connected to a displacement sensor (1) via a sensor transmission harness (8) to receive signals; the PLC controller (2) is connected to a servo motor driver (4) to transmit signals to control a servo motor (5), thereby controlling the Y-direction displacement of the power head; The top motor (17), the motor of the trolley, and the cutter head motor of the milling power head (13) are all common motors, and their respective frequency converters are controlled by the touch screen (3) to realize the start and stop, forward and reverse rotation of the motors, thereby realizing the Z-direction displacement of the power head, the X-direction movement of the trolley (11), and the control of the self-rotation milling process of the cutter head of the milling power head; The workpiece distance measuring device comprises a displacement sensor (1) arranged between the workpiece (6) and the milling power head (13); the displacement sensor (1) is fixed on the lifting column (12) and monitors the distance between the workpiece (6) and the milling power head (13) in real time.

2. The online profiling and edge milling processing equipment for long straight structural parts according to claim 1 is characterized in that: The workpiece distance measuring device realizes real-time monitoring of the distance between the milling power head (13) and the workpiece (6) through a displacement sensor (1), and transmits the distance parameter by outputting analog quantity to a PLC controller (2); The PLC controller (2) receives data from the touch screen (3) and the displacement sensor (1), and sends forward and reverse rotation instructions to the servo motor driver (4) of the servo motor system through program control; The servo motor control system receives forward and reverse rotation instructions from a PLC controller (2) through a servo motor driver (4), controls a servo motor (5), and controls and adjusts the Y-direction displacement of a milling power head (13) in real time, thereby realizing profiling of a workpiece.

3. The online profiling and edge milling equipment for long straight structural parts according to claim 1 is characterized in that: The workbench (16) has a convex cross-section, and the workpiece (6) is fixed on the top of the workbench (16); workbench guide rails (14) are provided at both side ends of the workbench (16).

4. The online profiling and edge milling processing equipment for long straight structural parts according to claim 1 is characterized in that: The PLC controller (2) and the servo motor driver (4) are arranged on the inner side of the base of the traveling trolley (11).

5. A method for online profiling and edge milling of a long straight structural part, characterized in that: The processing equipment described in any one of claims 1 to 4 is used for processing; the displacement sensor (1) is used to monitor the displacement between the workpiece (6) and the milling power head (13) in real time, and inputs it into the PLC control system in the form of analog quantity; the displacement median is calculated according to the dimensional requirements of the product drawing and a control program is compiled, the real-time Y-direction displacement of the workpiece (6) is judged by the PLC controller (2), and forward and reverse rotation instructions are sent to the servo motor control system to control the Y-direction position of the milling power head (13), adjust the processing amount to the dimensional requirements, and realize contour processing.

6. The processing method according to claim 1, characterized in that: The method has two control modes. The first is a touch screen control mode. At the initial stage of processing, the motor of the milling power head (13) is started on the touch screen (3) and preset Y and Z displacement values ​​are input. The PLC control system receives the Y-direction parameter of the touch screen to control the servo motor control system to realize the control and adjustment of the Y-direction displacement, and the Z-direction displacement is adjusted and controlled by the top motor (17). Under the joint action of the servo motor and the top motor, the milling power head (13) starts the initial milling process until the groove size of the workpiece meets the requirements of the drawing. The reading of the displacement sensor (1) at this time is recorded as the displacement median value and input into the touch screen; the other is a displacement sensor profiling control mode. After determining the processing displacement median value, the sensor monitors and transmits the distance signal to the PLC control system during processing. Through program control, the real-time displacement value and the displacement median value are compared, and then the forward and reverse instructions are output to the servo motor control system to control the real-time profiling change of the Y-direction displacement of the milling power head (13).

7. The processing method according to claim 1, characterized in that: Here are the steps: S1: fix the workpiece (6) on the workbench (16), start the power supply of the motor of the milling power head (13), use the touch screen control mode, input the Y and Z displacements, adjust the position of the milling power head (13), start feeding processing, until the groove meets the requirements of the drawing, lock the displacement sensor (1) at this time to the displacement median value, and record it on the touch screen; S2: Switch the displacement sensor control mode; start the X-direction feed motor power supply of the traveling carriage (11) on the touch screen, and the traveling carriage drives the milling power head (13) to start the X-direction feed processing; S3: In the displacement sensor control mode, the displacement sensor (1) monitors the distance between the workpiece (6) and the milling power head (13) in real time, and transmits it to the PLC controller (2) and the touch screen (3) for display. The PLC controller (2) compares and judges the real-time displacement with the displacement median data through the internal program, and outputs the forward and reverse rotation instructions to the servo motor control system; the servo motor system receives the forward and reverse rotation instructions from the PLC controller (2), and adjusts the Y-direction displacement of the power head (13) by rotating the Y-direction lead screw (10) until the Y-direction displacement returns to the displacement median range, and the servo motor (5) stops rotating and the displacement is locked; S4: Execute step S3 repeatedly until the edge milling of the workpiece is completed, and then turn off the X-axis feed power supply.

8. The processing method according to claim 1, characterized in that: In step S1, The touch screen control mode is adopted, and the position of the milling power head (13) is adjusted to the position under the blunt edge size of the groove required by the drawing by inputting the Y-axis and Z-axis displacements. The measurement data of the sensor at this time is defined as the displacement median A0, and the tolerance A0±d is set. The displacement median at this time is locked through the touch screen.

9. The processing method according to claim 1, characterized in that: In step S3, The sensor measures the distance A between the milling power head (13) and the workpiece (6) in real time and transmits it to the PLC control system in analog form. A is judged by the program. When A is within the tolerance range A0±d of the displacement median, the servo motor does not work and the Y-direction displacement does not change. When the A value exceeds the range of the median displacement, the PLC control system sends forward and reverse commands to the servo motor control system to control the Y-axis displacement of the milling power head and make real-time adjustments until A is within the range of the median displacement A0 again. The servo motor stops and the Y-axis displacement is locked. This step is repeated until the processing is completed.

10. The processing method according to claim 7, characterized in that: In step S3, the adjustment process is specifically as follows: When the sensor measures in real time that the distance A between the milling power head (13) and the workpiece (6) is greater than A0±d, the PLC control system sends a forward rotation instruction to the servo motor control system, and the servo motor (5) works to control the Y-direction displacement of the milling power head (13) to decrease until A enters the tolerance range A0±d of the median displacement again; When the sensor measures in real time that the distance A between the milling power head (13) and the workpiece (6) is less than A0±d, the PLC control system sends a reverse command to the servo motor control system, and the servo motor (5) starts to operate, controlling the Y-direction displacement of the power head (13) to increase until A enters the tolerance range A0±d of the median displacement again.

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