Turbine disc mortise automatic grinding machining system and machining process thereof

Abstract

The invention relates to an automatic grinding machining system for turbine disc mortises and a machining technology of the automatic grinding machining system. The system comprises a material carrying unit, a material changing unit, a grinding machining unit and a control system connected with the material carrying unit, the material changing unit and the grinding machining unit. The carrying robot grabs the turbine disc to be machined on the storage frame through a mechanical gripper and places the turbine disc to be machined on the conveying mechanism. The carrying robot conveys the turbine disc to the material changing unit through the magnetic attraction conveying technology, a rotating shaft conveying mechanism of the material changing unit is driven by a stepping motor to repeatedly obtain and deliver the turbine disc to one side of the grinding machining unit through rotation, and in the grinding machining unit, a control system drives a cup-shaped grinding wheel to conduct grinding machining on the turbine disc. And after grinding machining is completed, the turbine disc is recycled to a finished product storage shelf, and automatic machining of the turbine disc is completed. The problems that in the turbine disc mortise grinding machining process, the feeding and discharging procedures are complex, and the manual assembly operation efficiency is low are solved. The device has the characteristics of high automation degree, good processing quality and high processing efficiency.

Description

Technical Field

[0001] The invention relates to the field of turbine disc tenon and groove machining, and in particular to an automated grinding production line for turbine disc tenon and groove. Background Art

[0002] As one of the key components of the hot end of an aircraft engine, the turbine disk has extremely harsh working conditions and needs to withstand complex thermal loads during service. Therefore, it has special requirements for the mechanical properties and process performance of the manufacturing materials. Powder metallurgy high-temperature alloys have the advantages of good yield strength and excellent fatigue resistance. They can meet the requirements of high thrust-to-weight ratio, high power-to-weight ratio and long service life of aircraft engines, and can effectively ensure the service safety and reliability of aircraft engines and the whole machine. Therefore, it has become a key material for the turbine disk of new aircraft engines. The turbine disk is mainly composed of a disk body and a mortise and tenon distributed on the edge of the disk. The mortise and tenon space is narrow and the structure is complex, which has strict requirements on the surface quality and contour accuracy of the processing. Although certain progress has been made in the field of mechanical processing of turbine disk mortise and tenon, there are still many technical bottlenecks in the existing common processing methods such as broaching and milling. For example, these traditional methods generally face problems such as high tool manufacturing cost, severe tool wear, and unstable processing surface quality, which not only limits the improvement of processing efficiency, but also has an adverse effect on the service performance of the final product. Grinding is considered as the preferred technical means for the finishing of mortise and tenon due to its advantages of low processing cost, high precision and good quality. It can effectively ensure the shape accuracy and surface quality of the mortise and tenon processing surface. However, the grinding processing technology of turbine disc mortise and tenon is still in its early development stage, and there are mainly the following problems: First, the degree of automation of grinding processing is low, and the processing process still requires a lot of manual intervention; second, the workpiece loading and unloading and material replacement operations are inefficient, time-consuming and labor-intensive, which further limits the improvement of processing efficiency; third, the system integration of existing grinding equipment is low, making it difficult to achieve efficient and continuous automated production needs.

[0003] The invention patent of Qingdao University of Technology with publication number CN117564873A discloses a turbine disc tenon-groove forming grinding device and method. In order to solve the problems of low processing efficiency and poor processing accuracy in the current cup-type grinding wheel processing, an avoidance portion is reserved upstream and downstream of the grinding part of the grinding wheel. The avoidance portion can reduce the weight of the grinding wheel and reduce the difficulty of spindle driving and control, thereby improving the processing accuracy. The avoidance portion is used for the turbine disc to pass through to reduce the difficulty of feeding, facilitate switching of processing positions, and improve processing efficiency. However, the processing unit lacks an intelligent material transmission system, and the loading and unloading operations of the turbine disc workpiece need to be completed manually. In addition, the processing process does not integrate an online detection module, and real-time monitoring of phenomena such as tool collision and burns still requires manual monitoring.

[0004] Zhejiang Changer Intelligent Equipment Co., Ltd.'s invention patent with publication number CN108655494 A discloses an automated production line for turbine disc tenon broaching. This production line can completely get rid of manual labor and realize automated processing of turbine disc tenon broaching, greatly improving work efficiency, reducing labor intensity, and avoiding errors caused by manual operation, thereby improving processing accuracy and reducing defective and scrap rates. However, this technology still has the disadvantages of long broaching tool design and manufacturing cycle and high cost, and it is difficult to ensure processing accuracy and surface quality for difficult-to-process materials such as powder high-temperature alloys.

[0005] Xi'an Jingdiao Precision Machinery Engineering Co., Ltd. has publicly proposed an automated production line for tool grinding. The system uses a three-axis manipulator and a ground rail to work together to achieve efficient distribution of workpieces between the silo and the machine tool. It supports multiple machine tools and is equipped with multiple silos to ensure that the silo gives priority to the nearest machine tool. The three-axis manipulator adopts a pneumatic two-hand claw structure, which can quickly and accurately complete the workpiece pick-up and placement operations. The production line effectively reduces labor costs, significantly improves production efficiency, and reduces labor intensity. It has the advantages of high automation integration, controllable processing accuracy, low operating costs, high reliability, and low maintenance frequency. However, the production line is not suitable for large aerospace parts such as turbine discs. In addition, the force sensor and burn monitoring module are not integrated in the production line, and it is impossible to monitor abnormal phenomena occurring during the processing process in real time.

[0006] In view of the above problems, the present invention proposes an automated production line for turbine disc tenon-groove grinding. Through advanced automated control systems and efficient functional unit integration, it aims to significantly improve the automation level of grinding, reduce manual participation, save human resources, achieve high efficiency and continuity of the processing process, and meet the production needs of high-end manufacturing fields such as aerospace. Summary of the invention

[0007] The present invention aims to solve the problems of low automation, high manual operation intensity, unstable processing precision, etc. in the prior art of turbine disc tenon and groove grinding, and provides an automated processing system and processing technology for turbine disc tenon and groove grinding. The automated processing system can greatly improve the production efficiency and processing quality of turbine disc tenon and groove processing through efficient and accurate automated operation processes, reduce the labor intensity of manual operation, reduce human errors, and meet the high precision and high efficiency requirements of turbine disc tenon and groove processing in the field of aviation engine manufacturing.

[0008] The technical solution adopted by the present invention to solve the above problems is: A turbine disc tenon-groove automated grinding system includes a material handling unit, a material changing unit, a grinding processing unit, a grinding online detection system and a control system; the material handling unit includes a storage rack for placing a turbine disc to be processed, a movable handling robot I for clamping and carrying the turbine disc, and a conveying mechanism for conveying the turbine disc; the movable handling robot I transfers the turbine disc to be processed to a conveyor belt body through its manipulator, which is a first working state; the conveying mechanism conveys the turbine disc to the material changing unit through the conveyor belt body, which is a second working state; the handling robot II on the left side of the rotating shaft absorbs the conveyor belt body through the magnetic suction cup on its surface The turbine disc on the surface is transferred to the shaft transmission mechanism through the movable mechanical arm, which is the third working state; the control system controls the stepper motor to drive the shaft to rotate 180 degrees, and transfers the turbine disc to the handling robot II on the other side, which is the fourth working state; the handling robot II moves its mechanical arm to complete the alignment of the surface of the turbine disc tenon to be processed and the grinding surface of the cup grinding wheel in the grinding unit, which is the fifth working state; the control system drives the cup grinding wheel to start grinding and remove the excess, which is the sixth working state; the control system drives the AGV car under the handling robot I to move and retrieve the turbine disc that has completed the grinding process, which is the seventh working state. The grinding process monitoring system can identify and feedback the burns and other conditions in the grinding process in real time, thereby improving the stability of the grinding process.

[0009] The material handling unit includes a movable handling robot I with a gripper (placed on an AGV trolley), a storage rack for storing turbine discs, and a conveying mechanism for conveying turbine discs to be processed. The handling robot I grabs the turbine disc from the storage rack through a mechanical gripper and conveys it to the conveying mechanism, the material changing unit, and the grinding unit in sequence, completing the precise loading process of the turbine disc from the initial position to the grinding unit.

[0010] The material changing unit adopts a magnetic spindle mechanism, which is driven by a stepper motor to rotate the magnetic spindle to transfer the turbine disc to be processed. During this process, the transfer robots II on the left and right sides coordinate and cooperate through the automatic control system to accurately transfer the turbine disc to the vertical grinding device of the grinding unit. This design avoids the positioning error introduced by traditional manual material changing and improves the accuracy and efficiency of material changing.

[0011] The grinding unit is a vertical grinding unit, including a cup grinding wheel for mortise and tenon grinding, a standardized tool holder, a spindle, a ram and a vertical machine tool with a slide rail. The cup grinding wheel performs precision grinding on the turbine disc mortise and tenon under the drive of the control system, which can meet the strict requirements of aircraft engines on the shape accuracy and surface quality of the turbine disc mortise and tenon. The design of the ram and the slide rail further improves the processing stability and grinding efficiency.

[0012] The grinding process online monitoring system realizes multi-modal real-time monitoring of the processing process through the collaborative perception of force sensors and industrial cameras. The system uses dynamic grinding force signal analysis combined with high frame rate visual inspection to simultaneously track grinding force signal fluctuations, spark morphology evolution and surface burn characteristics, and can accurately identify process deviations such as tool collision and grinding burns. After the monitoring data is analyzed in real time by the control cabinet, the core parameters such as spindle speed and feed rate are dynamically optimized through a closed-loop feedback mechanism, effectively suppressing the risks of grinding tool collision and burns while ensuring processing accuracy.

[0013] The automated control system runs through the entire production line, and controls the operation of the material handling unit, material changing unit, and grinding unit through preset programs. The system can monitor the processing status in real time and coordinate the actions of each functional unit, thereby achieving continuous and efficient operation of the production line.

[0014] Based on the above turbine disc tenon and groove automated grinding process, the steps are as follows: (1) The turbine disks to be processed are uniformly stored in the storage rack. The handling robot I of the material handling unit is driven by the AGV car at the bottom. According to the instructions of the automatic control system, the mechanical gripper takes out the turbine disks to be processed from the storage rack one by one and transports them to the conveying mechanism. The conveying mechanism accurately transfers the turbine disks to the material changing unit to complete the loading process.

[0015] (2) The material changing unit transfers the turbine disc through a magnetic shaft mechanism and a stepper motor. After the turbine disc is received from the conveyor belt and arrives at the material changing unit, the transfer robots II on the left and right sides complete the grasping and positioning of the turbine disc under the command of the control system. Through high-precision material changing actions, the turbine disc is accurately transferred to the clamping position of the grinding processing unit.

[0016] (3) After the turbine disk enters the vertical grinding system, the system moves precisely to the processing position through the slide and the slide rail; the cup grinding wheel in the grinding unit is driven by the spindle to perform precision grinding on the turbine disk tenon according to the preset trajectory; the automated control system monitors the fluctuation of the grinding force signal in real time through the force sensor installed on the robot arm to ensure that the processing meets the precision requirements and achieves efficient and continuous grinding operations.

[0017] (4) The grinding process online monitoring system uses industrial cameras and force sensors, and adopts technologies such as machine vision to monitor the key parameters and phenomena in the grinding process in real time, determine whether burns, sparks, etc. occur in the grinding process, and optimize the process parameters through feedback from the control system to ensure the stability and reliability of the processing process.

[0018] (5) The finished turbine disc is transferred from the vertical grinding system to the material handling unit and transported to the finished product storage area after precise positioning. If subsequent processing or inspection is required, the handling robot I can transfer the turbine disc to other workstations according to the scheduling instructions of the control system.

[0019] (6) In the entire automated production line, the material handling unit, material changing unit, grinding processing unit and automated control system work together to realize the continuous cycle of processing steps in an assembly line mode. The processed turbine disk automatically exits the system and the new turbine disk to be processed enters immediately, ensuring the continuity and efficiency of production.

[0020] Beneficial effects: Compared with the prior art, the turbine disc tenon-groove automated grinding system of the present invention has the following significant advantages: (1) Fully automated control: Through the coordination of the control system, all units can run automatically according to the preset program, which greatly improves production efficiency, avoids manual intervention, reduces human errors in the production process, and ensures processing accuracy.

[0021] (2) Improve processing accuracy and quality stability: Automated operation effectively avoids fluctuations in processing accuracy caused by manual operation, ensures the stable processing quality of each turbine disk, improves the yield rate, and reduces the scrap rate.

[0022] (3) Real-time monitoring and feedback: During the grinding process, force sensors and machine vision recognition technology can be used to promptly detect unexpected situations such as tool collision and burns. The control system can then optimize and adjust the process parameters to ensure the reliability and stability of the machining process.

[0023] (4) Reduce labor intensity and labor costs: Through the fully automated production process, the number of manual operations is reduced, which significantly reduces the labor intensity of operators, reduces the dependence on highly skilled workers, and also reduces the additional costs caused by manual operation errors.

[0024] (5) Efficient production: By optimizing the workflow and rationally configuring each unit, the entire production line can quickly respond to market demand, ensure the efficient production of turbine disc tenons and grooves, and meet the high requirements for processing efficiency in the fields of aerospace engines and other fields.

[0025] (6) System adjustability and flexibility: The control system has strong adjustment capabilities. Operators can flexibly adjust the working parameters of each unit according to different production needs and adapt to the processing requirements of different workpieces. It has strong system flexibility and scalability. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 A schematic diagram of the connection relationship of the turbine disc tenon-and-groove automated grinding system of the present invention; Figure 2 Schematic diagram of the connection relationship between the turbine disk handling robot 1 and the turbine disk storage rack 2; Figure 3 A schematic diagram of a conveyor belt mechanism for conveying turbine disks to be processed; Figure 4 It is a schematic diagram of a rotating shaft mechanism used to transfer the turbine disc to the grinding processing unit in the material changing system; Figure 5 The figure is a composition diagram of the rotating shaft mechanism, including a stepping motor, a flange plate and fastening screws connecting the magnetic rotating shaft and the motor main shaft; Figure 6 The working principle diagram of the shaft transmission mechanism 6 is shown in FIG. 1 , in which the stepper motor drives the shaft to rotate, and the turbine disk fixed by the magnetic shaft on the left is transferred to the magnetic shaft on the right; Figure 7 The figure shows the structure diagram of the handling robot II 6; Figure 8 It is a schematic diagram of the structure of a vertical grinding device, including a cup grinding wheel for mortise and tenon grinding, a tool holder, a fixing base plate, a machine tool spindle, a ram and a machine tool bed; Fig. 9 It is a partial enlarged view of the vertical grinding device; Fig.10 This is an exploded view of the turbine disk to be processed, including the turbine disk body, fastening screws, base plate and magnetic chuck; Fig.11 Schematic diagram of turbine disc tenon and groove grinding using a cup grinding wheel; Fig.12 It is the structural diagram of the grinding process online monitoring system; Among them, 1-control cabinet; 2-storage rack; 2.1-storage rack body; 2.2-turbine disc to be processed; 3-handling robot I; 3.1-automatic guided vehicle (AGV) I; 3.2-handling robot I operating arm; 3.3-mechanical gripper; 3.4-industrial camera I; 4-transmission mechanism; 4.1-conveyor belt shaft; 4.2-industrial camera II; 4.3-conveyor belt body; 5-shaft transmission mechanism; 5.1-magnetic suction shaft; 5.2-stepping motor; 6-handling robot II; 6.1 -Automatic guided vehicle II; 6.2-base; 6.3-mechanical arm; 6.4-force sensor; 6.5-magnetic suction cup; 7-vertical grinding device; 7.1-cup grinding wheel; 7.2-tool handle; 7.3-spindle; 7.4-vertical grinding machine bed; 7.5-slide; 8.1-fastening screw; 8.2-turbine disc body; 8.3-bottom plate; 8.4-magnetic disc; 9-grinding monitoring system; 9.1-monitoring system body; 9.2-workbench; 9.3-industrial camera III. DETAILED DESCRIPTION

[0027] The present invention is further described in detail below with reference to the accompanying drawings. Example

[0028] Reference Figure 1 As shown, an automated grinding system for turbine disc tenon grooves includes a material handling unit, a material changing unit, a grinding unit, a grinding online detection system and a control system; each unit works in coordination to achieve efficient and high-quality automated processing of turbine disc tenon grooves.

[0029] The material handling unit includes a storage rack 2 for placing assembled turbine discs, a movable handling robot I3 with a mechanical gripper for clamping and handling turbine discs, and a conveying mechanism 4 for conveying turbine discs; the handling robot I3 transfers the turbine discs to be processed to the conveying mechanism through its operating arm and mechanical gripper; the conveying mechanism 4 conveys the turbine discs to the material changing unit through the conveyor belt body; The handling robot II6 on one side of the rotating shaft transmission mechanism 5 absorbs the turbine disc transported by the transmission mechanism through the magnetic suction cup on its surface, and transfers it to the fixed position of the rotating shaft through the movable operating arm, which is the third working state; the control system controls the stepper motor to drive the rotating shaft to transfer the turbine disc to the handling robot II on the other side, which is the fourth working state; the handling robot II moves its operating arm to complete the alignment of the surface of the turbine disc tenon groove to be processed with the grinding surface of the cup grinding wheel in the grinding system, which is the fifth working state; the control system drives the cup grinding wheel to start grinding and remove the excess, which is the sixth working state; the control system drives the AGV car under the handling robot I to move and retrieve the turbine disc that has completed the grinding process, which is the seventh working state. The grinding process monitoring system can identify and feedback the burns and other conditions in the grinding process in real time, thereby improving the stability of the grinding process.

[0030] like Figure 2As shown, the handling robot I (3.2) is installed on a mobile carrier, and the mobile carrier is an automatic guided vehicle (AGV) 3.1, which can move along a predetermined path to a material storage unit or other work area. The handling robot I (3.2) is equipped with a mechanical gripper (3.3) for clamping the turbine disc (2.2) to be processed. In order to further improve the grasping accuracy and efficiency, an industrial camera I (3.4) is installed above the mechanical gripper (3.3) for real-time recognition of the position and posture of the turbine disc (2.2). The industrial camera I (3.4) can photograph and analyze the turbine disc (2.2) on the storage rack body (2.1) through machine vision technology, and can accurately obtain the spatial position and direction data of the turbine disc, and feed back the information to the control system to guide the mechanical gripper (3.3) to adjust the grasping posture to achieve accurate grasping and handling. The storage rack body (2.1) is designed as a layered or grid structure for storing the turbine disc (2.2) to be processed. The turbine discs (2.2) to be processed are neatly placed on the storage rack at preset intervals, so as to facilitate the handling robot I (3.2) to perform the grasping operation. The storage rack (2.1) has a simple structure, is easy to maintain, and has sufficient load-bearing capacity to meet the storage requirements of the turbine discs in the production line. Through the coordinated work of the industrial camera I and the mechanical gripper, the automation level and grasping accuracy of the handling operation are further improved.

[0031] Figure 3 The conveying mechanism (4) is driven by a belt transmission, which is powered by a built-in three-phase asynchronous motor. When the handling robot I (3.2) places the turbine disc (2.2) on the conveyor belt body through the mechanical gripper (3.3), the conveyor belt body receives the start signal sent by the control cabinet (1) and starts to operate; the industrial camera II (4.2) above the conveyor belt recognizes the specific position and posture of the turbine disc (2.2) through real-time image acquisition and processing, and feeds the data back to the control system. When the turbine disc is about to reach the end of the conveyor belt, the industrial camera II (4.2) will trigger a reminder signal to notify the robot II (6) to go to the designated position for grabbing. At the same time, the inductive sensor at the tail works together to stop the conveyor belt in time when the turbine disc (2.2) arrives, ensuring the safety and accuracy of the grabbing operation.

[0032] Reference Figures 4 to 6The material changing unit in the present invention has the main function of accurately transferring the turbine disk from the transmission mechanism to the grinding processing unit to ensure the continuity and accuracy of the processing process. The material changing unit includes a magnetic rotation shaft (5.1), a stepper motor (5.2), a fixed flange and fastening screws, and a handling robot cooperating therewith. The stepper motor (5.2) drives the magnetic rotation shaft (5.1) as the core transmission unit to rotate in the vertical direction. The stepper motor realizes the precise angle rotation of the rotation shaft through its high-precision positioning function, drives the magnetic rotation shaft to rotate in the vertical direction, and ensures that the turbine disk can be accurately transferred to the handling robot II on the other side. A strong magnet is embedded on the surface of the magnetic rotation shaft, which is used to adsorb the bottom magnetic disc (8.4) of the turbine disk to be processed to achieve stable fixation and transmission. In order to ensure the reliable connection between the rotation shaft and the stepper motor, the two are fixed by a flange and screws. The flange is fastened to the motor shaft by screws, and the magnetic shaft is firmly combined with the flange. This structure can effectively prevent components from loosening due to vibration during high-frequency rotation, ensuring the stability and durability of the entire material changing unit.

[0033] Figure 6 The working principle diagram of the rotating shaft conveying mechanism 5 is shown in FIG. 1. There is a handling robot II (6) mounted on an AGV trolley on each side of the rotating shaft conveying mechanism 5. The two robots respectively perform the tasks of picking up and handing over the turbine disk. The material change process is as follows: the handling robot on the left side picks up the turbine disk sent by the conveying mechanism (4) and transfers it to the surface of the rotating shaft (5.1) through the magnetic suction function on the surface of its mechanical arm. The multi-degree-of-freedom design of the robot mechanical arm allows it to operate flexibly in three-dimensional space, ensuring that the turbine disk can be accurately docked with the rotating shaft. The control system issues a command, and the stepper motor (5.2) starts to drive the magnetic suction rotating shaft (5.1). The magnetic suction rotating shaft rotates the picked-up turbine disk 180 degrees along the preset trajectory, rotating the turbine disk from the left to the right. The handling robot on the other side takes over the turbine disk from the magnetic suction rotating shaft through the magnetic suction disk (6.5) on the surface of the mechanical arm, completing the handover of the turbine disk. During the handover process, the control system monitors the position and state of the turbine disk through sensors to ensure the stability and reliability of the handover action. Driven by the AGV, the right-side handling robot II accurately transfers the received turbine disc to the grinding processing unit to complete the material replacement operation.

[0034] Figure 7The diagram shows the structure of the mobile handling robot II (6). The handling robot II is installed on an automatic guided vehicle (AGV) with the help of a base (6.2). The AGV (6.1) has an automatic navigation function and can travel along a predetermined path to flexibly move the robot to a designated work area. The bottom of the robot is equipped with multiple sets of driving wheels to ensure smooth movement in a factory environment. The base (6.2) connects the AGV and the robotic arm to ensure the stability of the robot operation. The base integrates a communication module with the control system to receive instructions and provide real-time data feedback. The robotic arm (6.3) has multiple degrees of freedom and can rotate flexibly in three-dimensional space to achieve precise grasping, handling and auxiliary operations. The high degree of freedom design of the robotic arm enables it to adapt to complex working environments and different process requirements. A force sensor (6.4) is installed at the end of the robotic arm. The sensor adopts the piezoelectric multi-dimensional force measurement principle and collects the dynamic coupling signals of the normal force, tangential force and axial force in the grinding process in real time through a three-dimensional force sensitive element. The sensor measurement unit performs temperature compensation and noise filtering on the original signal through the embedded signal conditioning circuit, and transmits the standardized grinding force data to the CNC system in real time through the industrial Ethernet bus. The process parameter optimization module built into the control system is based on the fuzzy PID control algorithm. By comparing the real-time grinding force with the preset threshold range (F min ,F max ), dynamically adjusts the coordinated parameter combination of grinding wheel speed, feed speed and grinding depth. When it is detected that the instantaneous fluctuation of grinding force exceeds the safety threshold (such as collision with the tool, overcutting, etc.), the control system will issue a warning to remind the operator to check and adjust the process parameters. The end of the robot arm is also equipped with a magnetic suction cup (6.5) for firmly fixing with the magnetic component (8.4) on the turbine disk to ensure safety and reliability during handling. The magnetic suction cup is compact in design and can adapt to different postures and position requirements of the turbine disk.

[0035] Figure 8 It is a structural diagram of the vertical grinding device. Fig. 9The vertical grinding device includes: a cup-shaped grinding wheel (7.1), a tool holder (7.2), a grinding spindle (7.3), a vertical grinding machine (7.4), and a ram (7.5). The cup-shaped grinding wheel (7.1) is a grinding tool for mortise and tenon processing. Its shape design is adapted to the geometric shape of the turbine disc mortise and tenon, and can maintain efficient material removal during the grinding process while ensuring the shape accuracy and surface quality of the mortise and tenon grinding. The grinding wheel base material is 45 steel, and its grinding surface is electroplated with high-hardness CBN abrasive grains with a particle size of 80 / 100# to ensure its wear resistance when processing high-strength alloy materials. The tool holder (7.2) is a connecting device between the grinding wheel and the spindle. It adopts a standardized tool holder interface to ensure the rapid installation and replacement of the grinding wheel. At the same time, the high-rigidity connection reduces the vibration during grinding and improves the processing accuracy. The spindle (7.3) is the core component of power transmission. It is driven by a high-precision servo motor and can run stably at high speed. The high speed and low radial runout characteristics of the spindle ensure that the grinding wheel always maintains stable cutting performance during the processing. The machine tool body (7.4) adopts a vertical structure and is provided with a slide rail. The slide rail has high linearity, ensuring the position accuracy of the grinding wheel in the feeding direction and meeting the requirements of the turbine disc tenon groove for shape accuracy and size consistency. The spindle is set on the ram, and the ram (7.5) is installed on the slide rail. The ram is the bearing part of the grinding wheel spindle and is controlled by the control cabinet (1) to realize the up and down feeding and positioning of the grinding wheel along the slide rail. The servo control system of the ram realizes precise displacement control through a high-resolution encoder, providing reliable support for the precise processing of the tenon groove. In the actual processing process, the turbine disc to be processed is fixed on the magnetic suction cup. The ram (7.5) moves vertically along the slide rail (7.4) under the command of the control system, driving the grinding wheel (7.1) to gradually approach the turbine disc tenon groove area, completing the precise tool setting of the grinding position. The main shaft (7.3) drives the grinding wheel to rotate at high speed. The grinding wheel grinds the mortise and tenon layer by layer under the control of appropriate grinding depth and feed speed to ensure that the shape accuracy and surface quality of the machined surface meet the requirements. The control system monitors the machining process in real time through built-in sensors and detection devices, and automatically adjusts the feed rate according to the wear of the grinding wheel to ensure the stability of continuous machining.

[0036] Fig.10The exploded view of the turbine disk to be processed is shown in FIG. The turbine disk body (8.2) is in the shape of a disk and is made of metals such as high-temperature alloys, titanium alloys, stainless steel, or various composite materials, which can meet the needs of various types of aircraft engines under different usage requirements. There are multiple tongue and groove structures distributed around the outer periphery of the disk body for installing blades, and the ideal shape accuracy and surface quality must be achieved through precision grinding. The fastening screws are used to reliably connect the turbine disk body (8.2) with the base plate (8.3) and the magnetic disk (8.4) to ensure stability during the processing. The screws are made of high-strength alloy steel and have high fatigue resistance and shear resistance. The base plate (8.3) is used as the installation support component of the turbine disk and is fastened to the disk body by screws to ensure the stable positioning of the disk body during the processing. The base plate is made of high-strength steel and is precisely designed to ensure the installation accuracy of the turbine disk. The magnetic disc (8.4) is strongly adsorbed to the magnetic suction cup (6.5) on the surface of the handling robot II (6) and to the magnetic shaft 5.1 through electromagnetic control. The adsorption force is evenly distributed, which can effectively avoid errors caused by vibration or displacement during the processing of the turbine disc. Referring to the flange design, the turbine disc body is firmly connected to the base plate (8.3) and the magnetic disc (8.4) through six fastening screws (8.1) to form an overall stable structural unit, which effectively avoids deformation or offset caused by uneven force during processing. During the overall assembly process, the positioning and connection accuracy of each component is extremely high to ensure the clamping rigidity during processing and the positioning consistency of the turbine disc.

[0037] Fig.11The working principle diagram of the cup grinding wheel for grinding the tenon groove of the turbine disk. The turbine disk is firmly fixed on the magnetic suction cup (6.5) of the handling robot II (6) through the magnetic disk (8.4) fixed to it. The magnetic suction cup provides high stability to avoid processing errors caused by vibration or offset during the grinding process. Before processing, the tenon groove of the turbine disk is aligned with the motion trajectory of the grinding spindle to ensure the dimensional accuracy and shape accuracy of the tenon groove processing. During the grinding process, the cup grinding wheel (7.1) is driven by the spindle (7.3) to grind the workpiece material in the form of high-speed rotation. Because the grinding surface shape of the cup grinding wheel matches the shape of the tenon groove to be processed, it can effectively cut the two sides of the turbine disk tenon groove while maintaining the dimensional accuracy of the tenon groove. During the processing, the grinding spindle provides axial feed along the ram (7.5) to gradually complete the grinding of the depth of the tenon groove. In the initial stage of the grinding process, the cup grinding wheel performs rough processing on the tenon groove to quickly remove excess material. In this stage, the control system controls the cutting depth and feed speed of the grinding wheel to ensure processing efficiency. When the rough grinding is close to the target size, the grinding parameters of the grinding wheel are adjusted to perform fine processing to achieve the surface quality and shape accuracy requirements of the mortise and tenon. During the grinding process, the grinding depth can be dynamically adjusted by the control system to ensure that each grinding amount of the mortise and tenon reaches the target size. During the processing, the grinding area is lubricated and cooled by spraying coolant to prevent thermal damage to the workpiece caused by heat accumulation, while extending the service life of the grinding wheel. According to the characteristics of the turbine disc material and the mortise and tenon size requirements, the rotation speed and feed speed of the grinding wheel are set by the control system to obtain the best processing quality and efficiency. After grinding, the surface quality (surface roughness, grinding burns, surface morphology, etc.) and shape and size accuracy of the turbine disc mortise and tenon are tested, and feedback is given based on the test results to adjust the processing parameters.

[0038] Fig.12The schematic diagram of the structure of the online monitoring system for grinding processing is shown in Figure 9.1. The system can monitor the key parameters and phenomena in the grinding process in real time through machine vision technology to ensure the stability and accuracy of the processing process. The main part (9.1) of the detection system has a stable structure and a high-precision slide rail is installed on the surface. The workbench 9.2 can move up and down on the slide rail. The moving range and accuracy can be set by the control system. By adjusting the position of the workbench, the industrial camera III (9.3) can be located at the best observation point to efficiently monitor the target area during the grinding process. The industrial camera III (9.3) is equipped with a high dynamic range (HDR) imaging module and a near-infrared spectral sensor to capture the color changes and sparks of the material surface on the surface of the grinding workpiece. In response to the needs of grinding burn detection, the time difference method is used to compare the abnormal color spot diffusion pattern in the continuous frame image, and then the convolutional neural network (CNN) is used to analyze the surface feature distortion caused by the oxide layer. When high-temperature oxidation color or sparks that meet the characteristics of burns are detected in a local area, the system will trigger a three-level response mechanism: first, adjust the macro zoom lens of the industrial camera III to perform multi-focal plane scanning verification of the grinding area, then record the spatial coordinates through the camera's built-in grating encoder, and feed it back to the grinding process monitoring system 9 through the industrial bus protocol. At the same time, the machine tool emergency stop program is started, and the sound and light alarm device is synchronously triggered to prompt the operator to check the surface condition of the mortise and tenon grinding.

[0039] In an embodiment of the present invention, by using a cup-type grinding wheel in a vertical grinding system to perform high-precision grinding on the turbine disc tenon, it can be ensured that its shape accuracy and surface quality meet the high standards required for aircraft engine service. At the same time, with the coordinated operation of the automated material handling unit, the material change system and the control system, not only the precision machining of the turbine disc tenon is achieved, but also the errors that may be introduced by manual operation are effectively avoided. In addition, the present invention introduces a grinding monitoring system, which combines a force sensor with an industrial camera III to monitor in real time whether there is a collision with the tool, overcutting, spark status, signs of burns, etc. during the grinding process, thereby achieving quality control and abnormal warning of the machining process.

[0040] The present invention combines a variety of efficient functional units, such as a magnetic shaft material replacement mechanism, a mechanical gripper handling robot, an AGV transportation system, and an online monitoring system, which greatly improves the intelligence and automation level of the production line. The mechanical arm equipped with a force sensor can provide real-time feedback on the grinding force during the grinding process, optimize the processing parameters, and thus improve the processing stability and product consistency. The automated production line reduces manual intervention, improves processing efficiency and continuity, reduces manufacturing costs, and meets the high-precision and high-quality requirements of aircraft engine turbine disc manufacturing.

Claims

1. A turbine disc tenon-groove automated grinding system, characterized in that: include: The material handling unit, material changing unit, grinding processing unit and the control system connecting the above units work in coordination to achieve efficient and high-quality automated processing of turbine disc tenon and groove; The material handling unit comprises: a storage rack (2) for placing turbine discs to be processed; a movable handling robot I (3), the robot being equipped with a mechanical gripper (3.3) with a clamping function for accurately handling the turbine discs; and a conveyor belt (4) for connecting materials between different units; the handling robot I (3) grasps the turbine discs to be processed on the storage rack with the help of the mechanical gripper and places them on the conveying mechanism; The material changing unit comprises: a rotating shaft conveying mechanism driven by a motor, the rotating shaft conveying mechanism being a centrally symmetrical structure, and transferring a turbine disc fixed at one end to a grinding processing unit by vertically rotating 180 degrees; a movable handling robot II (6) is distributed on both sides of the rotating shaft conveying mechanism, respectively, to complete the conveying action of the turbine disc from the conveying mechanism to the rotating shaft conveying mechanism; The grinding processing unit comprises: a vertical grinding machine tool (7.4) provided with a slide rail, a ram (7.5) mounted on the slide rail, a handle of a cup-shaped grinding wheel (7.1) fixed on the ram via a spindle, the cup-shaped grinding wheel can reciprocate up and down along the slide rail to adjust the height, the spindle is connected to a servo motor, and the ram is connected to a control system; The control system comprises: a manually operable control cabinet (1), in which a control module, a signal processing unit and a human-machine interaction interface are integrated; the control system is connected with a material handling unit, a material changing unit and a grinding processing unit through signals, so as to realize real-time monitoring and coordinated control of the operating status of each unit, and can improve production efficiency and processing quality through parameter optimization and adjustment.

2. The processing technology of the turbine disc tenon-groove automatic grinding system according to claim 1 is characterized in that: Here are the steps: (1) The handling robot I (3) uses a mechanical gripper to grab the turbine disc to be processed on the storage rack and places it on the conveying mechanism; the conveying mechanism conveys the turbine disc to the material changing unit; (2) The handling robot II (6) obtains the turbine disk delivered by the conveying mechanism, transfers it to one end of the rotating shaft conveying mechanism through the robot arm, and under the drive of the stepper motor, the rotating shaft rotates 180 degrees to deliver the turbine disk to one side of the grinding processing unit. The handling robot II (6) on this side takes the turbine disk and transfers it to the grinding processing unit; at the same time, the other end of the rotating shaft conveying mechanism rotates to the same side of the conveying mechanism to obtain a new turbine disk to be processed, and repeats this process, and continuously transfers the turbine disk to be processed to the grinding processing unit through the rotation transmission of the rotating shaft conveying mechanism; (3) In the grinding unit, the control system drives the cup grinding wheel to grind the turbine disc; (4) After the grinding process, the finished turbine disc is recovered by the handling robot I (3) to the finished product storage shelf, completing the automatic processing of the turbine disc.

3. The processing technology of the turbine disc tenon-groove automatic grinding system according to claim 2 is characterized by: In step (2), the handling robot II (6) transfers the turbine disc to be processed from the conveying mechanism to the rotating shaft conveying mechanism through magnetic suction conveying technology; The turbine disk is reliably connected to the turbine disk body (8.2), the base plate (8.3) and the magnetic disk (8.4) by means of fastening screws. The magnetic disk (8.4) is electromagnetically controlled to achieve strong adsorption with the magnetic suction cup (6.5) on the surface of the handling robot II (6) and the magnetic rotation shaft 5.

1.

4. The processing technology of the turbine disc tenon-groove automatic grinding system according to claim 2 is characterized by: The handling robot II (6) in step (2) and the handling robot I (3) in step (1) are both installed on an AGV vehicle. The AGV vehicle is controlled by a control system and autonomously drives along a predetermined path to achieve flexible movement and precise positioning of the robots between various working units.

5. The processing technology of the turbine disc tenon-groove automatic grinding system according to claim 2 is characterized by: The automatic identification of the handling robot I (3) and the handling robot II (6) as well as the material handling, material changing and grinding processing are all controlled by the control system; at the same time, the control system automatically adjusts the operating parameters according to the feedback signal to ensure the stability of the production process.

6. The processing technology of the turbine disc tenon-groove automatic grinding system according to claim 2 is characterized by: In step (3), the grinding process online monitoring system realizes multi-modal real-time monitoring of the processing process through the collaborative perception of the force sensor and the industrial camera; in view of the grinding burn detection needs, the time difference method is used to compare the abnormal color spot diffusion pattern in the continuous frame image, and then the surface feature distortion caused by the oxide layer is analyzed by the convolutional neural network; when high-temperature oxidation color or sparks that meet the burn characteristics are detected in the local area, the system will trigger a three-level response mechanism: first, the macro zoom lens of the industrial camera III is adjusted to perform multi-focal plane scanning verification of the grinding area, and then the spatial coordinates are recorded through the built-in grating encoder of the camera, and fed back to the grinding process monitoring system (9) through the industrial bus protocol, and at the same time, the machine tool emergency stop program is started, and the sound and light alarm device is synchronously triggered to prompt the operator to check the surface condition of the mortise and tenon grinding.

7. The processing technology of the turbine disc tenon-groove automated grinding system according to claim 6 is characterized by: The force sensor (6.4) is installed at the end of the mechanical arm of the handling robot II (6). The force sensor adopts the piezoelectric multi-dimensional force measurement principle and collects the dynamic coupling signals of the normal force, tangential force and axial force in the grinding operation in real time through the three-axis force sensitive element; the original signal is firstly subjected to temperature compensation and noise filtering, and the standardized grinding force data is transmitted to the numerical control system in real time through the industrial Ethernet bus; the control system is based on the fuzzy PID control algorithm, and dynamically adjusts the coordinated parameter combination of the grinding wheel speed, feed speed and grinding depth by comparing the real-time grinding force with the preset threshold range (Fmin, Fmax): When collision with the tool or overcutting occurs, the control system detects that the instantaneous fluctuation of the grinding force exceeds the safety threshold, and the control system will issue a warning to remind the operator to check and adjust the process parameters.

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