Machining Control System Based on Drilling of Castings

Abstract

The present invention relates to the technical field of drilling processing control, and discloses a processing control system for drilling on castings, including a chip removal monitoring module, a channel monitoring module, and a chip removal control module. The present invention realizes the real-time monitoring and automatic control of chip accumulation and chip removal channel blockage during the drilling process; the chip removal monitoring module uses a reflective optical sensor to accurately detect the chip accumulation amount, and ensures the accuracy of the monitoring data by establishing a relationship model between the light intensity and the chip accumulation amount; the channel monitoring module uses a flow sensor to judge the unobstructed situation of the chip removal channel in real time and accurately locate the blockage position; the chip removal control module automatically adjusts the wind force of the dust suction fan or triggers the vibrator for dredging treatment according to the monitoring results, ensuring that the chips are discharged in time and avoiding the decline of processing quality and equipment failures; the system significantly improves the processing efficiency and quality, and reduces the manual intervention and equipment maintenance costs.

Description

Technical Field

[0001] The present invention relates to the technical field of drilling processing control, and specifically relates to a processing control system based on drilling of castings. Background Art

[0002] In the field of modern machining, drilling is a common and important machining method, which is widely used in the machining process of workpieces such as metals, plastics, and composite materials. However, a large amount of chips will be generated during the drilling process. If the chips cannot be discharged in time, chip accumulation will occur, which will affect the machining quality, tool life, and even the operation safety of the equipment. Especially in high-precision and high-efficiency machining scenarios, the problems of chip accumulation and chip discharge channel blockage are particularly prominent, which may lead to problems such as a decrease in machining accuracy, an increase in tool wear, and an increase in equipment failure rate.

[0003] Traditional chip discharge methods mainly rely on manual cleaning or simple mechanical chip discharge devices, and have the following deficiencies:

[0004] Poor real-time performance: Manual cleaning cannot monitor the chip accumulation situation in real time, and intervention can only be carried out after the problem occurs, resulting in a decrease in machining efficiency.

[0005] Low automation level: Traditional mechanical chip discharge devices lack intelligent monitoring and control functions, and cannot dynamically adjust the chip discharge strategy according to the chip accumulation amount or the blockage situation of the chip discharge channel.

[0006] Low blockage handling efficiency: When the chip discharge channel is blocked, traditional methods usually require shutting down the machine and manual cleaning, which not only affects production efficiency but also increases labor costs.

[0007] Therefore, there is an urgent need for an intelligent machining control system that can monitor the chip accumulation amount and the state of the chip discharge channel in real time and achieve precise control, so as to improve machining efficiency, ensure machining quality, reduce equipment failure rate, and reduce manual intervention. Summary of the Invention

[0008] The purpose of the present invention is to provide a processing control system based on drilling of castings, which solves the technical problems proposed in the background art.

[0009] The purpose of the present invention can be achieved through the following technical solutions:

[0010] A processing control system based on drilling of castings includes:

[0011] A chip discharge monitoring module, which is used to detect the chip accumulation amount by setting a plurality of reflective optical sensors around the drill hole during the drilling process;

[0012] A channel monitoring module, which is used to set a flow sensor in the chip discharge channel and judge whether the chip discharge channel is unobstructed by detecting the air flow rate in the channel through the flow sensor;

[0013] The chip removal control module is used to control the chip removal process according to the information obtained by the chip removal monitoring module and the channel monitoring module.

[0014] As a further solution of the present invention: before working, the chip removal monitoring module measures the light intensity under different chip accumulation amounts through experiments in advance, and then establishes a relationship model between the light intensity and the chip accumulation amount through the experimental measurement results, and calculates the chip accumulation coefficient. The chip accumulation coefficient represents the change rate of the light intensity caused by the unit chip accumulation amount.

[0015] As a further solution of the present invention: the calculation method of the chip accumulation coefficient is as follows:

[0016] Formulate a linear equation: Q = Q0 - K×M;

[0017] In the formula, Q0 is the reference light intensity without chip accumulation, K is the slope, representing the change rate of the light intensity with the chip accumulation amount, that is, the chip accumulation coefficient, M is the chip accumulation amount, and Q is the light intensity when the chip accumulation amount is M;

[0018] Calculate the chip accumulation coefficient K through the least squares method. Among them, the goal of the least squares method is to minimize the sum of squared errors, and then the following formula is obtained:

[0019] ;

[0020] In the formula, E is the sum of squared errors, Q i is the different light intensities measured during the experiment, M i is the different chip accumulation amounts measured during the experiment, i = 1, 2,... n, and n represents the number of measurements of different chip accumulation amounts;

[0021] Then make the value of E equal to 0, and then take the partial derivative of K to obtain the value of K.

[0022] As a further solution of the present invention: the method for the reflective optical sensor to detect the chip accumulation amount is as follows:

[0023] Obtain the current light intensity through the reflective optical sensor, and then combine it with Q = Q0 - K×M to calculate the current chip accumulation amount.

[0024] As a further solution of the present invention: among them, when measuring the chip accumulation amount, the light intensity is measured simultaneously, that is, the chip accumulation amount and the light intensity are measured synchronously.

[0025] As a further solution of the present invention: the method for judging whether the chip removal channel is unobstructed is as follows:

[0026] Obtain the air flow rate of the chip removal channel when no chips are flowing through, and mark it as K0;

[0027] At the same time, real-time monitor the air flow rate of the chip removal channel when chips are flowing through, that is, the air flow rate when the chip removal channel discharges chips, and mark it as K;

[0028] Then, through: D = K / K0, calculate the blockage coefficient D of the chip removal channel;

[0029] Then compare the blockage coefficient D of the chip removal channel with the preset blockage threshold DY. When D≥DY, it is determined that the chip removal channel is unobstructed; otherwise, it is determined that the chip removal channel is unobstructed;

[0030] As a further solution of the present invention: when judging whether the chip removal channel is unobstructed, it is determined by setting a flow sensor at the tail of the chip removal channel; the tail of the chip removal channel refers to the end far from the drilling part.

[0031] As a further solution of the present invention: the chip removal control method is as follows:

[0032] Accumulation treatment:

[0033] Compare the chip accumulation amount M obtained by the chip removal monitoring module with the preset accumulation threshold M0:

[0034] When M>M0, there is more chip accumulation at the current drilling part, which may affect the processing, and then a chip cleaning signal is generated;

[0035] The chip cleaning signal is used to increase the wind force of the dust suction fan set at the entrance of the chip removal channel, so that the chips at the current drilling part are quickly sucked into the chip removal channel;

[0036] When M≤M0, the chip accumulation amount at the current drilling part is normal, does not affect the processing, and no chip cleaning signal is generated. At this time, the dust suction fan set at the entrance of the chip removal channel operates normally according to the preset wind force, so that the chips at the current drilling part are normally sucked into the chip removal channel;

[0037] Blockage treatment:

[0038] When the chip removal channel is unobstructed, extract the air flow rates of each part in the chip removal channel detected by the flow sensors evenly distributed in the chip removal channel, and mark them as K j , j = 1, 2,... m, where m represents the number of flow sensors in the chip removal channel;

[0039] The specific method is as follows:

[0040] Calculate the absolute value of the difference between the air flow rates obtained by the flow sensors at two adjacent parts in the chip removal channel;

[0041] Its calculation formula is: ;

[0042] In the formula, the value of j is not 1, and KC （j，j-1） is the absolute value of the difference between adjacent air flow rates;

[0043] Then, the absolute value of the difference is compared with a pre-set flow difference threshold:

[0044] When the absolute value of the difference between two adjacent air flow rates is greater than or equal to the flow difference threshold, it is determined that there is a blockage between the corresponding parts of the adjacent flow sensors in the chip removal channel, and then a single-body dredging signal is generated;

[0045] When the absolute value of the difference between two adjacent air flow rates is less than the flow difference threshold, the absolute value of the difference between the air flow rates obtained by setting flow sensors at the head and tail in the chip removal channel is calculated;

[0046] Its calculation formula is: ;

[0047] In the formula, KC （1，m） is the absolute value of the difference between the air flow rates at the head and tail in the chip removal channel;

[0048] Then, the absolute value of the difference is compared with a pre-set flow difference threshold:

[0049] If the absolute value of the difference between the air flow rates at the head and tail is greater than or equal to the flow difference threshold, and at the same time, the absolute values of the differences between all adjacent two air flow rates are less than the flow difference threshold, it is determined that there is a long-distance blockage in the chip removal channel, and then an overall dredging signal is generated;

[0050] If the absolute value of the difference between the air flow rates at the head and tail is less than the flow difference threshold, and at the same time, the absolute values of the differences between all adjacent two air flow rates are less than the flow difference threshold, it is determined that there is no blockage between the corresponding parts of the adjacent flow sensors in the chip removal channel.

[0051] As a further solution of the present invention: Among them, the vibrator is arranged in the middle of the corresponding parts of the adjacent flow sensors.

[0052] As a further solution of the present invention: The single-body dredging signal is used to trigger the start of the vibrator arranged at the corresponding position of the chip removal channel, and at the same time, increase the wind force of the dust suction fan arranged at the entrance of the chip removal channel. The vibrator vibrates and knocks at the blockage position of the chip removal channel, so that the blocked chips are dispersed, and the chips flow and are discharged through the dust suction fan;

[0053] The overall unblocking signal is used to trigger the start-up of the vibrators set at all positions of the chip removal channel, and at the same time increase the wind force of the dust suction fan set at the entrance of the chip removal channel. The vibrator vibrates and knocks the entire part of the chip removal channel to evacuate the blocked chips, and the chips are flowed and discharged through the dust suction fan.

[0054] As a further solution of the present invention: after the vibrator is started at time S0, S0 is a preset time period value;

[0055] The channel monitoring module continues to detect the air flow by setting a flow sensor at the tail of the chip removal channel to determine whether the chip removal channel is unobstructed;

[0056] At this time, if D≥DY, the drilling operation is stopped and a fault alarm is issued to remind the operator that the chip removal channel is seriously blocked and then manually clean it;

[0057] On the contrary, it means that the blockage is cleared successfully and the chip removal channel returns to normal.

[0058] Beneficial effects of the present invention:

[0059] In the present invention, the chip removal monitoring module detects the chip accumulation in real time through a reflective optical sensor, and accurately determines the chip accumulation situation in combination with a chip accumulation coefficient model. The chip removal control module automatically adjusts the wind force of the dust suction fan according to the chip accumulation amount to ensure that the chips are discharged in time, avoiding the influence of processing accuracy and efficiency due to excessive chip accumulation, thereby significantly improving processing quality and production efficiency.

[0060] In the present invention, the channel monitoring module detects the air flow of the chip removal channel in real time through the flow sensor, calculates the blockage coefficient, and can quickly determine whether the chip removal channel is unobstructed. When blockage is detected, the system automatically triggers the vibrator and the dust suction fan to perform local or overall dredging, effectively preventing the chip removal channel from being blocked and ensuring the continuity and stability of the processing process.

[0061] In the present invention, through the coordinated operation of multiple flow sensors in the chip removal channel, the system can accurately locate the blockage position and generate a single clearing signal or a whole clearing signal according to the blockage type (local blockage or long-distance blockage). The linkage operation of the vibrator and the dust suction fan can quickly evacuate the blocked chips, restore the normal operation of the chip removal channel, and reduce downtime.

[0062] The present invention sets a time period detection mechanism after the vibrator is started to continuously monitor the air flow of the chip removal channel to determine the dredging effect. If the blockage problem is not solved, the system will automatically stop the drilling operation and issue a fault alarm to prompt the operator to perform manual cleaning. This intelligent design reduces the frequency of manual intervention and improves the automation level of the system.

[0063] In the present invention, a relationship model between chip accumulation amount and light intensity is established through experiments, and the chip accumulation coefficient is calculated by combining the least squares method, ensuring the accuracy and reliability of monitoring data. At the same time, the logic design of chip removal channel blockage judgment and dredging treatment is scientific and reasonable, which can meet the requirements of different processing scenarios and has high practicability and reliability.

[0064] In the present invention, through real-time monitoring and automatic control, the system can effectively prevent equipment failures caused by chip accumulation or chip removal channel blockage, extend the service life of the equipment, and reduce the maintenance cost. At the same time, the automatic dredging treatment reduces the frequency of manual cleaning, further reducing the labor cost.

[0065] In summary, through the intelligent and automatic design, the present invention significantly improves the efficiency, quality and reliability of drilling processing, while reducing the equipment failure rate and maintenance cost, and is applicable to high-precision and high-efficiency industrial production scenarios. Brief Description of the Drawings

[0066] The present invention will be further described below with reference to the accompanying drawings.

[0067] Figure 1 It is a system block diagram of the processing control system for drilling on castings according to the present invention.

[0068] Figure 2 It is a schematic flow diagram of the chip removal control module in the processing control system for drilling on castings according to the present invention. Detailed Embodiments

[0069] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0070] Embodiment 1

[0071] Please refer to Figure 1 and Figure 2 As shown, the present invention is a processing control system for drilling on castings, including:

[0072] A chip removal monitoring module, which is used to detect the chip accumulation amount during the drilling process by setting a plurality of reflective optical sensors around the drill hole;

[0073] Among them, under normal circumstances, that is, when there is no chip accumulation and there is air near the drill hole area, the light reflection of the reflective optical sensor is normal; when there is chip accumulation, the light is scattered and blocked, and the light intensity received by the reflective optical sensor changes:

[0074] Before working, the chip removal monitoring module measures the light intensity under different chip accumulation amounts through experiments in advance. Then, based on the experimental measurement results, it establishes a relationship model between the light intensity and the chip accumulation amount, and calculates the chip accumulation coefficient. The chip accumulation coefficient represents the change in light intensity caused by a unit chip accumulation amount.

[0075] The calculation method of the chip accumulation coefficient is as follows:

[0076] Formulate a linear equation: Q = Q0 - K×M;

[0077] In the formula, Q0 is the reference light intensity without chip accumulation, K is the slope, representing the change rate of the light intensity with the chip accumulation amount, that is, the chip accumulation coefficient, M is the chip accumulation amount, and Q is the light intensity when the chip accumulation amount is M.

[0078] Calculate the chip accumulation coefficient K through the least squares method. Among them, the goal of the least squares method is to minimize the sum of squared errors, and then the following formula is obtained:

[0079] ;

[0080] In the formula, E is the sum of squared errors, Q i is the different light intensities measured during the experiment, M i is the different chip accumulation amounts measured during the experiment, i = 1, 2,... n, n represents the number of measurements of different chip accumulation amounts. Among them, when measuring the chip accumulation amount, the light intensity is measured simultaneously, that is, the chip accumulation amount and the light intensity are measured synchronously.

[0081] Then make the value of E equal to 0, and then take the partial derivative of K to obtain the value of K;

[0082] The method for the reflective optical sensor to detect the chip accumulation amount is as follows:

[0083] Obtain the current light intensity through the reflective optical sensor, and then combine it with Q = Q0 - K×M to calculate the current chip accumulation amount;

[0084] The chip removal control module is used to perform accumulation processing on the chips around the drill hole according to the information obtained by the chip removal monitoring module;

[0085] The chip removal control module is used to ensure that the chips can be discharged in a timely and effective manner during the drilling process, maintaining a good processing environment;

[0086] The accumulation processing method is as follows:

[0087] Compare the chip accumulation amount M obtained by the chip removal monitoring module with the preset accumulation threshold M0:

[0088] When M > M0, there is a relatively large accumulation of chips at the current drilling site, which may affect the machining. Subsequently, a chip cleaning signal is generated.

[0089] The chip cleaning signal is used to increase the wind force of the dust suction fan set at the entrance of the chip discharge channel, so that the chips at the current drilling site are quickly sucked into the chip discharge channel, thereby reducing the chip accumulation amount and ensuring the normal progress of machining.

[0090] The dust suction fan is a prior art. Its working principle is that the motor drives the fan impeller to rotate at high speed, so that the air is discharged at high speed. And the air at the dust suction part in front of the fan continuously replenishes the air in the fan, resulting in an instantaneous vacuum inside the dust suction fan and a negative pressure difference with the external atmospheric pressure. Under the action of this pressure difference, the chips at the current drilling site are sucked in.

[0091] When M ≤ M0, the chip accumulation amount at the current drilling site is normal, which does not affect the machining, and no chip cleaning signal is generated. At this time, the dust suction fan set at the entrance of the chip discharge channel operates normally according to the pre-set wind force, so that the chips at the current drilling site are normally sucked into the chip discharge channel.

[0092] In the first embodiment, by setting up a chip discharge monitoring module and using a reflective optical sensor to continuously monitor the chip accumulation amount during the drilling process, it can effectively avoid affecting the machining quality due to excessive chip accumulation. By establishing a relationship model between the light intensity and the chip accumulation amount and combining the least square method to calculate the chip accumulation coefficient, the system can accurately judge the chip accumulation situation. The chip discharge control module automatically adjusts the wind force of the dust suction fan according to the chip accumulation amount to ensure that the chips are discharged in time, maintain a good machining environment, and thus improve the machining efficiency and product quality.

[0093] Embodiment Two

[0094] Please refer to Figure 1 and Figure 2 As shown, as the second embodiment of the present invention, when the present application is specifically implemented, compared with the first embodiment, the technical solution of this embodiment is only different from that of the first embodiment in that this embodiment further includes:

[0095] A channel monitoring module, which is used to set a flow sensor in the chip discharge channel and judge whether the chip discharge channel is unobstructed by detecting the air flow rate in the channel through the flow sensor.

[0096] The specific method is as follows:

[0097] Obtain the air flow rate of the chip discharge channel when no chips flow through it and mark it as K0.

[0098] At the same time, continuously monitor the air flow rate of the chip discharge channel when chips flow through it, that is, the air flow rate when the chip discharge channel discharges chips, and mark it as K.

[0099] Then, the blockage coefficient D of the chip removal channel is calculated through: D = K / K0;

[0100] Then, the blockage coefficient D of the chip removal channel is compared with a preset blockage threshold DY. When D≥DY, it is determined that the chip removal channel is unobstructed; otherwise, it is determined that the chip removal channel is unobstructed;

[0101] When judging whether the chip removal channel is unobstructed, it is determined by setting a flow sensor at the tail of the chip removal channel;

[0102] The tail of the chip removal channel refers to the end far from the drilling part;

[0103] The chip removal control module is also used to perform blockage processing on the chip removal channel according to the information obtained by the channel monitoring module;

[0104] The blockage processing method is as follows:

[0105] When the chip removal channel is unobstructed, the air flow at each part in the chip removal channel detected by the uniformly arranged flow sensors in the chip removal channel is extracted and marked as K j , j = 1, 2,... m, where m represents the number of flow sensors in the chip removal channel;

[0106] The specific method is as follows:

[0107] The absolute value of the difference between the air flows obtained by the flow sensors at two adjacent parts in the chip removal channel is calculated, and then the absolute value of the difference is compared with a preset flow difference threshold:

[0108] When the absolute value of the difference between two adjacent air flows is greater than or equal to the flow difference threshold, it is determined that there is a blockage between the corresponding parts of the adjacent flow sensors in the chip removal channel, and then a single-body dredging signal is generated;

[0109] The single-body dredging signal is used to trigger the vibration motor set at the corresponding position of the chip removal channel to start, and at the same time increase the wind force of the dust suction fan set at the entrance of the chip removal channel. The vibration motor vibrates and knocks at the blockage position of the chip removal channel, so that the blocked chips are dispersed, and the chips flow and are discharged through the dust suction fan to ensure the normal use of the chip removal channel;

[0110] Among them, the vibration motor is set in the middle of the corresponding parts of the adjacent flow sensors;

[0111] In this embodiment, an electromagnetic vibrator is adopted for the vibrator. It is a prior art. The electromagnetic vibrator is composed of components such as a vibrating body, a resonance spring, an electromagnet, and a machine base. According to the resonance principle of mechanical vibration, when the circuit is connected, a positive half-cycle pulsating DC voltage is applied to the electromagnetic coil. Due to the action of the electromagnet, a pulsed electromagnetic force is generated between the vibrating body and the machine base, and the vibrating body is attracted. At this time, the elastic system stores potential energy. In the negative half-cycle, the diode is not conducting, the electromagnetic force disappears, and with the potential energy stored in the elastic system, the vibrating body vibrates in the opposite direction.

[0112] When the absolute value of the difference between two adjacent airflows is less than the flow difference threshold, the absolute value of the difference between the airflows obtained by the flow sensors arranged at the head and tail in the chip removal channel is calculated, and then the absolute value of the difference is compared with the pre-set flow difference threshold:

[0113] If the absolute value of the difference between the airflows at the head and tail is greater than or equal to the flow difference threshold, and at the same time, the absolute value of the difference between all adjacent two airflows is less than the flow difference threshold, it is determined that there is a long-distance blockage in the chip removal channel, and then an all-round dredging signal is generated;

[0114] The all-round dredging signal is used to trigger the start of the vibrators arranged at all positions of the chip removal channel, and at the same time increase the wind force of the dust suction fan arranged at the inlet of the chip removal channel. The vibrators vibrate and strike the overall part of the chip removal channel, so that the blocked chips are dispersed, and the chips flow and are discharged through the dust suction fan to ensure the normal use of the chip removal channel;

[0115] If the absolute value of the difference between the airflows at the head and tail is less than the flow difference threshold, and at the same time, the absolute value of the difference between all adjacent two airflows is less than the flow difference threshold, it is determined that there is no blockage between the corresponding parts of the adjacent flow sensors in the chip removal channel;

[0116] In Embodiment 2, a channel monitoring module is added on the basis of Embodiment 1. By using the flow sensors to detect the airflows in the chip removal channel in real time, it can be judged whether the chip removal channel is unblocked. By calculating the blockage coefficient, the system can timely detect the blockage situation of the chip removal channel and trigger the vibrators and the dust suction fan for dredging treatment. This solution can not only effectively prevent the chip removal channel from being blocked, but also quickly restore the normal operation of the chip removal channel through local or overall dredging measures, further improving the reliability and processing efficiency of the system.

[0117] Embodiment 3

[0118] Please refer to Figure 1 and Figure 2As shown in the figure, as the third embodiment of the present invention, in the specific implementation of this application, compared with the first and second embodiments, the technical solution of this embodiment is to combine the solutions of the above-mentioned first and second embodiments. The difference between the technical solution of this embodiment and the first and second embodiments is only that in this embodiment: after the S0 time when the vibrator starts, S0 is a preset time period value;

[0119] The channel monitoring module continues to detect the air flow through the flow sensor set at the tail of the chip removal channel to judge whether the chip removal channel is unobstructed;

[0120] At this time, if D≥DY, the drilling operation is stopped, and a fault alarm is issued at the same time, prompting the operator that the chip removal channel is seriously blocked, and then manual cleaning is carried out;

[0121] On the contrary, it means that the blockage removal is successful and the chip removal channel returns to normal;

[0122] Embodiment 3 combines the technical solutions of Embodiment 1 and Embodiment 2, and sets a time period detection mechanism after the vibrator starts. By continuously monitoring the air flow of the chip removal channel, the system can judge whether the chip removal channel returns to normal after the dredging operation. If the blockage problem is not solved, the system will automatically stop the drilling operation and issue a fault alarm, prompting the operator to carry out manual cleaning. This solution further improves the intelligent level of the system, ensuring that manual intervention can be taken in time when the automatic processing is ineffective, and avoiding equipment damage or processing accidents.

[0123] Embodiment 4

[0124] Please refer to Figure 1 and Figure 2 As shown in the figure, as the fourth embodiment of the present invention, in the specific implementation of this application, compared with the first, second, and third embodiments, the technical solution of this embodiment is to combine the solutions of the above-mentioned first, second, and third embodiments.

[0125] Embodiment 4 synthesizes the technical solutions of Embodiment 1, Embodiment 2, and Embodiment 3 to form a complete processing control system. By integrating chip removal monitoring, channel monitoring, and dredging processing functions, the system can realize the full-process automatic management from chip accumulation detection to chip removal channel dredging. This solution not only significantly improves the stability and efficiency of the processing process, but also reduces the frequency of manual intervention, reduces the occurrence of equipment failures and processing accidents, and is applicable to high-precision and high-efficiency industrial production scenarios.

[0126] The above formulas are all dimensionless and take their numerical values for calculation. The formula is obtained by collecting a large amount of data and performing software simulation to obtain a formula closest to the actual situation. The preset parameters and threshold values in the formula are set by those skilled in the art according to the actual situation.

[0127] As described above, it is only the specific implementation manner of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present application can easily think of changes or substitutions, which should all be covered within the protection scope of the present application. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims described.

Claims

1. A machining control system based on casting drilling, characterized in that, Including: A chip removal monitoring module, which is used to detect the chip accumulation amount during the drilling process by setting multiple reflective optical sensors around the drill hole; A channel monitoring module, which is used to set a flow sensor in the chip removal channel and judge whether the chip removal channel is unobstructed by detecting the air flow rate in the channel through the flow sensor; A chip removal control module, which is used to control the chip removal process according to the information obtained by the chip removal monitoring module and the channel monitoring module; When the chip removal channel is unobstructed, calculate the absolute value of the difference between the air flow rates obtained by the flow sensors at two adjacent parts in the chip removal channel; When the absolute value of the difference between two adjacent air flow rates is greater than or equal to the flow difference threshold, it is determined that there is a blockage between the corresponding parts of the adjacent flow sensors in the chip removal channel, and then a single body dredging signal is generated; When the absolute value of the difference between two adjacent air flow rates is less than the flow difference threshold, calculate the absolute value of the difference between the air flow rates obtained by the flow sensors arranged at the head and tail of the chip removal channel; If the absolute value of the difference between the head and tail air flow rates is greater than or equal to the flow difference threshold, and at the same time, the absolute value of the difference between all adjacent two air flow rates is less than the flow difference threshold, it is determined that there is a long-distance blockage in the chip removal channel, and then an overall dredging signal is generated; If the absolute value of the difference between the head and tail air flow rates is less than the flow difference threshold, and at the same time, the absolute value of the difference between all adjacent two air flow rates is less than the flow difference threshold, it is determined that there is no blockage between the corresponding parts of the adjacent flow sensors in the chip removal channel; The single body dredging signal is used to trigger the vibrator set at the corresponding position of the chip removal channel to start, and at the same time increase the wind force of the dust suction fan set at the entrance of the chip removal channel. The vibrator vibrates and knocks at the blocked position of the chip removal channel to disperse the blocked chips, and the chips flow and are discharged through the dust suction fan; The overall dredging signal is used to trigger the vibrators set at all positions of the chip removal channel to start, and at the same time increase the wind force of the dust suction fan set at the entrance of the chip removal channel. The vibrators vibrate and knock on the overall part of the chip removal channel to disperse the blocked chips, and the chips flow and are discharged through the dust suction fan.

2. The machining control system based on casting drilling according to claim 1, wherein The judgment method of whether the chip removal channel is unobstructed is as follows: Obtain the air flow rate of the chip removal channel when no chips flow through, and mark it as K0; At the same time, real-time monitor the air flow rate of the chip removal channel when chips flow through, that is, the air flow rate when the chip removal channel discharges chips, and mark it as K; Then calculate the blockage coefficient D of the chip removal channel through: D = K / K0; Then compare the blockage coefficient D of the chip removal channel with the preset blockage threshold DY. When D≥DY, it is determined that the chip removal channel is unobstructed; otherwise, it is determined that the chip removal channel is unobstructed.

3. The machining control system based on casting drilling according to claim 2, characterized in that, When judging whether the chip removal channel is unobstructed, it is judged by setting a flow sensor at the tail of the chip removal channel; the tail of the chip removal channel refers to the end far from the drill hole part.

4. The machining control system based on casting drilling according to claim 2, wherein, The chip removal control method is as follows: Accumulation treatment: Compare the chip accumulation amount M obtained by the chip removal monitoring module with the preset accumulation threshold M0: When M>M0, the chips at the current drill hole part accumulate more, which may affect the processing, and then a chip cleaning signal is generated; The chip cleaning signal is used to increase the wind force of the dust suction fan set at the entrance of the chip removal channel, so that the chips at the current drilling position are quickly sucked into the chip removal channel; When M ≤ M0, the chip accumulation amount at the current drilling position is normal, does not affect the processing, and no chip cleaning signal is generated. At this time, the dust suction fan set at the entrance of the chip removal channel operates normally according to the preset wind force, so that the chips at the current drilling position are normally sucked into the chip removal channel.

5. The machining control system based on casting drilling according to claim 2, characterized in that, After the vibrator starts for S0 time, S0 is a preset time period value; The channel monitoring module continues to detect the air flow through the flow sensor set at the tail of the chip removal channel to judge whether the chip removal channel is unobstructed; At this time, if D ≥ DY, the drilling operation is stopped, and at the same time a fault alarm is issued to prompt the operator that the chip removal channel is seriously blocked, and then manual cleaning is carried out; On the contrary, it means that the blockage removal is successful and the chip removal channel returns to normal.

6. The machining control system based on casting drilling according to claim 1, wherein Among them, The vibrator is arranged in the middle of the corresponding part of the adjacent flow sensor.

7. The machining control system based on casting drilling according to claim 1, wherein Before the chip removal monitoring module works, it measures the light intensity under different chip accumulation amounts through experiments in advance, and then establishes a relationship model between the light intensity and the chip accumulation amount through the experimental measurement results, and calculates the chip accumulation coefficient. The chip accumulation coefficient represents the change in light intensity caused by a unit chip accumulation amount.

8. The machining control system based on casting drilling according to claim 7, characterized in that, The calculation method of the chip accumulation coefficient is as follows: Formulate a linear equation: Q = Q0 - K × M; In the formula, Q0 is the reference light intensity without chip accumulation, K is the slope, representing the change rate of the light intensity with the chip accumulation amount, that is, the chip accumulation coefficient, M is the chip accumulation amount, and Q is the light intensity when the chip accumulation amount is M; The chip accumulation coefficient K is calculated by the least squares method. Among them, the goal of the least squares method is to minimize the sum of squared errors, and the following formula is obtained: ; where E is the sum of squared errors, and Q i is the different light intensities measured during the experiment, and M i is the different chip accumulation amounts measured during the experiment, i = 1, 2, …… n, and n represents the number of measurements of different chip accumulation amounts; Then let the value of E be 0, and then take the partial derivative of K to obtain the value of K.

9. The machining control system based on casting drilling according to claim 8, wherein, The method for the reflective optical sensor to detect the chip accumulation amount is as follows: Obtain the current light intensity through the reflective optical sensor, and then combine it with Q = Q0 - K × M to calculate the current chip accumulation amount.

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