A turbine disc mortise automatic grinding processing system and a processing technology thereof

Abstract

The present application relates to a kind of turbine disc mortise automated grinding processing system and its processing technology, the system includes material handling unit, material changing unit, grinding processing unit and the control system connected with above-mentioned unit.Machine people are placed on conveying mechanism by mechanical gripper of handling robot and grab the turbine disc to be processed on storage rack;Turbine disc is conveyed to material changing unit by magnetic attraction conveying technology, the rotating shaft conveying mechanism of material changing unit is driven under stepping motor, and turbine disc is repeatedly obtained and delivered to the side of grinding processing unit by rotation, and cup-shaped grinding wheel is driven by control system in grinding processing unit to turbine disc and carries out grinding processing;After completing grinding processing, it is recycled to finished product storage rack, and the automatic processing of turbine disc is completed.The problems such as complex loading and unloading process, low manual assembly operation efficiency in turbine disc mortise grinding processing process are solved.It has the characteristics of high degree of automation, good processing quality and high processing efficiency.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of turbine disc mortise and tenon machining, in particular to a turbine disc mortise and tenon automatic grinding machining production line. BACKGROUND

[0002] As one of the key components of the hot end of an aero-engine, the turbine disc has extremely harsh working conditions and needs to withstand complex thermal and mechanical loads during service, thus having special requirements for the mechanical properties and process properties of the manufacturing material. Powder metallurgy high-temperature alloy has good yield strength and excellent fatigue strength, and can meet the needs of high thrust-to-weight ratio, high power-to-weight ratio and long service life of the aero-engine, effectively ensuring the service safety and reliability of the aero-engine and the whole machine, so it has become the key material for new aero-engine turbine discs. The turbine disc is mainly composed of a disc body and mortises and tenons distributed on the disc edge. The mortises and tenons have narrow space and complex structure, and strict requirements on the surface quality and contour accuracy of machining. Although certain progress has been made in the field of turbine disc mortise and tenon machining, there are still many technical bottlenecks in the existing common machining methods such as broaching and milling. For example, these traditional methods generally face problems such as high cost of tool manufacturing, serious tool wear, and unstable machining surface quality, which not only limits the improvement of machining 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 stage of mortises and tenons due to its low processing cost, high precision and good quality, which can effectively ensure the shape accuracy and surface quality of the mortise and tenon machining surface. However, the grinding machining technology of turbine disc mortises and tenons is still in the initial development stage, and mainly has the following problems: first, the automation degree of grinding machining is low, and a large amount of manual intervention is still required in the machining process; second, the workpiece loading and unloading and material changing operation is inefficient, time-consuming and labor-intensive, which further limits the improvement of machining efficiency; third, the system integration degree of the existing grinding equipment is low, and it is difficult to realize efficient and continuous automatic production demand.

[0003] The invention patent with publication number CN117564873A of Qingdao University of Technology discloses a turbine disc mortise and tenon forming grinding device and method. In view of the problems of low machining efficiency and poor machining precision during cup-shaped grinding wheel machining, an avoidance part is left upstream and downstream of the grinding part of the grinding wheel. The avoidance part can reduce the weight of the grinding wheel, reduce the difficulty of spindle driving and control, thereby improving the machining precision. The avoidance part is used for the turbine disc to pass through to reduce the difficulty of feeding, facilitate the switching of machining positions, and improve the machining efficiency. However, the processing unit lacks an intelligent material conveying system, and the loading and unloading operation of the turbine disc workpiece needs to be completed by manual operation. Moreover, the processing process is not integrated with an online detection module, and real-time monitoring of phenomena such as tool collision and burning still needs manual monitoring.

[0004] In the invention patent CN108655494 A of Zhejiang Chang'er Intelligent Equipment Co., Ltd., an automatic production line for turbine disc mortise broaching is disclosed. The production line can completely separate from manual operation, realize automatic processing of turbine disc mortise broaching, greatly improve work efficiency, reduce labor intensity, avoid errors caused by manual operation, thereby improve processing precision, reduce the rate of defective products and waste products. However, the technology still has the disadvantages of long design and manufacturing period and high cost of broaching tool, and it is difficult to ensure the processing precision and surface quality for difficult-to-machine materials such as powder high-temperature alloy.

[0005] Xi'an Jingdiao Precision Machinery Engineering Co., Ltd. discloses a tool grinding automatic production line. The system cooperates with the ground rail through a three-axis manipulator to realize efficient distribution of workpieces between the stock bin and the machine tool, supports multiple machine tools and is equipped with multiple stock bins to ensure that the stock bin serves the nearest machine tool first. The three-axis manipulator adopts a pneumatic double-claw structure and can quickly and accurately complete the workpiece picking and placing operation. The production line effectively reduces labor cost, significantly improves production efficiency, reduces labor intensity, has high automation integration, controllable processing precision, low running cost, high reliability and low maintenance frequency. However, the production line is not suitable for large aerospace parts such as turbine discs. Moreover, the production line does not integrate force sensors and burn monitoring modules, and cannot monitor abnormal phenomena in the processing process in real time.

[0006] To solve the above problems, the present application provides a turbine disc mortise grinding automatic production line. Through advanced automatic control system and efficient function unit integration, the purpose is to significantly improve the automation degree of grinding, reduce manual operation, save human resources, realize the efficiency and continuity of the processing process, and meet the production needs of high-end manufacturing fields such as aerospace. SUMMARY

[0007] The present application provides a turbine disc mortise grinding automatic processing system and its processing technology to solve the problems of low automation degree, high labor intensity, unstable processing precision and other problems in the turbine disc mortise grinding process of the prior art. The automatic processing system can greatly improve the production efficiency and processing quality of turbine disc mortise processing through efficient and accurate automatic operation process, reduce the labor intensity of manual operation, reduce human error, and meet the high precision and high efficiency requirements of turbine disc mortise processing in the field of aircraft engine manufacturing.

[0008] The technical scheme adopted by the present application to solve the above problems is as follows:

[0009] A turbine disc mortise and tenon groove automatic grinding processing system, comprising a material handling unit, a material changing unit, a grinding processing unit, a grinding processing online monitoring system and a control system; the material handling unit comprises a storage rack for placing turbine discs to be processed, a movable handling robot I for clamping and handling the turbine discs, and a conveying mechanism for conveying the turbine discs; the movable handling robot I transfers the turbine discs to be processed to the conveying belt body through its mechanical hand, which is the first working state; the conveying mechanism conveys the turbine discs to the material changing unit by the conveying belt body, which is the second working state; the handling robot II on the left side of the rotating shaft sucks the turbine discs on the surface of the conveying belt body through the magnetic suction disc on its surface, and transfers them to the rotating shaft conveying mechanism through the movable mechanical arm, which is the third working state; the control system controls the step motor to drive the rotating shaft to rotate 180 degrees, and transfers the turbine discs 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 tool setting of the surface of the turbine disc mortise and tenon groove to be processed and the grinding surface of the cup-shaped grinding wheel in the grinding processing unit, which is the fifth working state; the control system drives the cup-shaped 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 take back the turbine discs that have completed the grinding processing, which is the seventh working state. The grinding processing monitoring system can identify and feedback the burning and other conditions in the grinding process in real time, thereby improving the stability of the grinding processing.

[0010] The material handling unit comprises a movable handling robot I with a gripper (placed on an AGV car), a storage rack for storing turbine discs, and a conveying mechanism for conveying turbine discs to be processed. The handling robot I grasps the turbine discs from the storage rack through the mechanical gripper, and conveys them to the conveying mechanism, the material changing unit and the grinding processing unit in turn, to complete the accurate feeding process of the turbine discs from the initial position to the grinding processing unit.

[0011] The material changing unit adopts a magnetic rotating shaft mechanism, which rotates the magnetic rotating shaft through a step motor to realize the transfer of the turbine discs to be processed. In this process, the handling robots II on the left and right sides are coordinated by the automatic control system to accurately transfer the turbine discs to the vertical grinding processing device of the grinding processing unit. This design avoids the positioning errors introduced by traditional manual material changing, and improves the accuracy and efficiency of material changing.

[0012] The grinding processing unit is a vertical grinding unit, which comprises a cup-shaped grinding wheel for mortise and tenon groove grinding, a standardized tool shank, a main shaft, a ram and a vertical machine tool with a slide rail. The cup-shaped grinding wheel precisely grinds the turbine disc mortise and tenon groove under the drive of the control system, which can meet the strict requirements of the aero-engine on the shape precision and surface quality of the turbine disc mortise and tenon groove. The design of the ram and the slide rail further improves the processing stability and grinding efficiency.

[0013] The grinding processing online monitoring system realizes multi-modal real-time monitoring of the processing process through force sensor and industrial camera cooperative perception. The system uses dynamic grinding force signal analysis combined with high frame rate visual detection to synchronously track grinding force signal fluctuations, spark shape evolution and surface burn characteristics, which can accurately identify process deviations such as tool collision and grinding burn. After real-time analysis of the monitoring data by the control cabinet, the closed-loop feedback mechanism dynamically optimizes the core parameters such as spindle speed and feed rate, effectively suppressing the risk of grinding tool collision and burn while ensuring processing accuracy.

[0014] The automatic control system runs through the entire production line and controls the operation of the material handling unit, the material changing unit and the grinding processing unit through a preset program. The system can monitor the processing state in real time and coordinate the actions of each functional unit, thereby realizing continuous and efficient operation of the production line.

[0015] Based on the above-mentioned automatic grinding processing technology of turbine disc mortise and tenon, the steps are as follows:

[0016] (1) The turbine discs to be processed are uniformly stored in the storage rack. The handling robot I of the material handling unit is driven to travel by the AGV trolley at the bottom. According to the instructions of the automatic control system, the turbine discs to be processed are taken out one by one from the storage rack by the mechanical gripper and transported to the conveying mechanism. The conveying mechanism accurately delivers the turbine discs to the material changing unit, completing the feeding process.

[0017] (2) The material changing unit delivers the turbine discs through a magnetic shaft mechanism and a stepper motor. After the turbine discs are received from the conveying belt and arrive at the material changing unit, the handling robots II on the left and right sides complete the grabbing and positioning of the turbine discs under the instructions of the control system. Through high-precision material changing actions, the turbine discs are accurately transferred to the clamping position of the grinding processing unit.

[0018] (3) After the turbine disc enters the vertical grinding processing system, the system accurately moves to the processing position through the ram and slide rail. The cup-shaped grinding wheel in the grinding unit is driven by the spindle and precisely grinds the turbine disc mortise according to the preset trajectory. The automatic control system monitors the grinding force signal fluctuations in real time through the force sensor installed on the machine arm, ensures that the processing process meets the accuracy requirements, and realizes efficient and continuous grinding operation.

[0019] (4) The grinding processing online monitoring system uses industrial cameras and force sensors to monitor key parameters and phenomena in the grinding process in real time through machine vision technology, judges whether the grinding process has burn, spark and other conditions, and optimizes the process parameters through the feedback of the control system to ensure the stability and reliability of the processing process.

[0020] (5) The finished turbine disc is transferred to the material handling unit by the vertical grinding processing system, and after accurate positioning, it is transported to the finished product storage area. If subsequent processing or inspection is required, the handling robot I can transmit the turbine disc to other workstations according to the scheduling instructions of the control system.

[0021] (6) In the entire automatic production line, the material handling unit, the material replacement unit, the grinding processing unit and the automatic control system work together to realize the continuous circulation of the processing steps in a pipeline mode. The finished turbine disc automatically exits the system, and a new turbine disc to be processed enters immediately, ensuring the continuity and efficiency of production.

[0022] Advantages: Compared with the prior art, the turbine disc mortise automatic grinding processing system has the following advantages:

[0023] (1) Full automation control: Through the coordination of the control system, all units can automatically operate according to the preset program, greatly improving the production efficiency, avoiding manual intervention, reducing human error in the production process, and ensuring the processing accuracy.

[0024] (2) Improve processing accuracy and quality stability: Automatic operation effectively avoids the fluctuation of processing accuracy caused by manual operation, ensures the stable processing quality of each turbine disc, improves the yield rate and reduces the scrap rate.

[0025] (3) Real-time monitoring and feedback: During the grinding process, force sensors and machine vision recognition technology can timely detect sudden conditions such as tool collision and burn, and the control system can optimize and control the process parameters to ensure the reliable and stable processing process.

[0026] (4) Reduce labor intensity and labor cost: Through the full-automatic production process, the manual operation link is reduced, the labor intensity of the operator is significantly reduced, the dependence on high-skilled workers is reduced, and the additional cost caused by manual operation errors is also reduced.

[0027] (5) High efficiency: Through the optimization of the work flow and the reasonable allocation of each unit, the entire production line can quickly respond to market demand, ensure the efficient production of turbine disc mortises, and meet the high requirements of aviation engines and other fields on processing efficiency.

[0028] (6) System adjustability and flexibility: The control system has strong adjustment ability, and the operator can flexibly adjust the working parameters of each unit according to different production needs, adapt to the processing requirements of different workpieces, and has strong system flexibility and expandability. BRIEF DESCRIPTION OF DRAWINGS

[0029] Figure 1 is a schematic diagram of the connection relationship of the turbine disc mortise automatic grinding processing system of the present application;

[0030] Figure 2 The schematic diagram of the connection between the turbine disk carrying robot I and the turbine disk storage rack 2;

[0031] Figure 3 The schematic diagram of the conveying belt mechanism for conveying the turbine disk to be processed;

[0032] Figure 4 The schematic diagram of the rotating shaft mechanism for transferring the turbine disk to the grinding processing unit in the refueling system;

[0033] Figure 5 The composition diagram of the rotating shaft mechanism, including the step motor, the flange plate and the fastening screw for connecting the magnetic rotating shaft and the motor spindle;

[0034] Figure 6 The working principle diagram of the rotating shaft conveying mechanism 6, the step motor drives the rotating shaft to rotate, and the turbine disk fixed on the left magnetic rotating shaft is transferred to the right magnetic rotating shaft;

[0035] Figure 7 The schematic diagram of the structure of the carrying robot II 6 is shown;

[0036] Figure 8 The schematic diagram of the structure of the vertical grinding processing device, including the cup-shaped grinding wheel for tenon and slot grinding, the tool handle, the fixing bottom plate, the machine tool spindle, the ram and the machine tool bed;

[0037] Figure 9 The enlarged view of the local part of the vertical grinding processing device;

[0038] Figure 10 The exploded view of the turbine disk to be processed, including the turbine disk body, the fastening screw, the bottom plate and the magnetic suction disc;

[0039] Figure 11 The schematic diagram of using the cup-shaped grinding wheel for turbine disk tenon and slot grinding;

[0040] Figure 12 The schematic diagram of the structure of the grinding processing online monitoring system;

[0041] Wherein, 1 - control cabinet; 2 - storage rack; 2.1 - storage rack body; 2.2 - to be processed turbine disc; 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 - conveying mechanism; 4.1 - conveying belt shaft; 4.2 - industrial camera II; 4.3 - conveying belt body; 5 - rotating shaft conveying mechanism; 5.1 - magnetic rotating shaft; 5.2 - stepper 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 processing device; 7.1 - cup-shaped grinding wheel; 7.2 - tool holder; 7.3 - main shaft; 7.4 - vertical grinding machine bed; 7.5 - ram; 8.1 - fastening screw; 8.2 - turbine disc body; 8.3 - bottom plate; 8.4 - magnetic disc; 9 - grinding processing monitoring system; 9.1 - monitoring system main body; 9.2 - workbench; 9.3 - industrial camera III. DETAILED DESCRIPTION

[0042] The application will be further described in detail below with reference to the drawings. EMBODIMENT

[0043] REFERENCE Figure 1 As shown in the drawings, a turbine disc mortise automatic grinding processing system includes a material handling unit, a material changing unit, a grinding processing unit, a grinding processing online monitoring system and a control system; each unit works in coordination to realize efficient and high-quality automatic processing of turbine disc mortise.

[0044] The material handling unit includes a storage rack 2 for placing assembled turbine discs, a movable handling robot I 3 with a mechanical gripper for clamping and handling turbine discs, and a conveying mechanism 4 for conveying turbine discs; the handling robot I 3 passes the turbine disc to be processed to the conveying mechanism through its operating arm and mechanical gripper; the conveying mechanism 4 conveys the turbine disc to the material changing unit by the conveying belt body;

[0045] The transfer mechanism 5 on one side of the transfer robot II 6 is attracted by the magnetic suction disc on the surface to transfer the turbine disc conveyed by the transfer mechanism, and the turbine disc is transferred to the shaft fixing place through the movable operating arm, which is the third working state; the control system controls the step motor to drive the shaft to transfer the turbine disc to the transfer robot II on the other side, which is the fourth working state; the transfer robot II moves the operating arm to complete the tool setting of the surface to be machined of the tenon groove of the turbine disc with the grinding surface of the cup-shaped grinding wheel in the grinding processing system, which is the fifth working state; the control system drives the cup-shaped grinding wheel to start grinding to remove the excess amount, which is the sixth working state; the control system drives the AGV car under the transfer robot I to move to take back the turbine disc after completing the grinding processing, which is the seventh working state. The grinding processing monitoring system can identify and feedback the burning and other conditions in the grinding process in real time, thereby improving the stability of the grinding processing.

[0046] As shown in Figure 2 The transfer robot I 3.2 is installed on the mobile carrier, which is an automatic guided vehicle (AGV) 3.1, which can move along the predetermined path to the material storage unit or other working area. The transfer robot I 3.2 is equipped with a mechanical gripper 3.3 for clamping the turbine disc 2.2 to be machined. In order to further improve the grasping precision and efficiency, an industrial camera I 3.4 is installed above the mechanical gripper 3.3 for real-time identification of the position and attitude of the turbine disc 2.2. The industrial camera I 3.4 can take pictures and analyze the turbine disc 2.2 on the storage rack body 2.1 through machine vision technology, 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 attitude, realize precise grasping and transfer. The storage rack body 2.1 is designed as a layered or net format structure for storing the turbine disc 2.2 to be machined. The turbine disc 2.2 to be machined is placed neatly on the storage rack at a predetermined interval, which is convenient for the transfer robot I 3.2 to grasp and operate. The storage rack 2.1 has simple structure, easy maintenance and sufficient bearing capacity to meet the storage requirements of turbine discs in the production line. Through the cooperative work of the industrial camera I and the mechanical gripper, the automation level and grasping precision of the transfer operation are further improved.

[0047] Figure 3The conveying mechanism 4 in the middle is transmitted by a belt, which is powered by an internal three-phase asynchronous motor. After the handling robot I3.2 places the turbine disc 2.2 on the conveyor belt body through the mechanical gripper 3.3, the conveyor belt body is connected to the start signal sent by the control cabinet 1 to run; the industrial camera II4.2 above the conveyor belt identifies the specific position and attitude 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 II4.2 will trigger a reminder signal to inform the robot II6 to go to the designated position for grabbing. At the same time, the inductive sensor at the tail works cooperatively to stop the conveyor belt running in time when the turbine disc 2.2 is detected to arrive, ensuring the safety and accuracy of the grabbing operation.

[0048] Referring to Figures 4 to 6 The main function of the refueling unit in the present application is to accurately transfer the turbine disc from the conveying mechanism to the grinding processing unit, ensuring the continuity and accuracy of the processing process. The refueling unit includes a magnetic rotating shaft 5.1, a stepping motor 5.2, a fixed flange plate and fastening screws, and a handling robot cooperating therewith. The stepping motor 5.2 drives the magnetic rotating shaft 5.1 as the core transmission unit to rotate in the vertical direction. The stepping motor realizes accurate angle rotation of the rotating shaft through its high-precision positioning function, drives the magnetic rotating shaft to rotate in the vertical direction, and ensures that the turbine disc can be accurately transferred to the handling robot II on the other side. Strong magnets are embedded on the surface of the magnetic rotating shaft for adsorbing the bottom magnetic disc 8.4 of the turbine disc to be processed, realizing stable fixation and transmission. In order to ensure the reliable connection of the rotating shaft and the stepping motor, the flange plate and the screws are used to fix them. The flange plate is fastened on the motor spindle by screws, and the magnetic rotating shaft is stably combined with the flange plate. This structure can effectively prevent the parts from loosening due to vibration in high-frequency rotation, ensuring the stability and durability of the entire refueling unit.

[0049] Figure 6There are two handling robots II 6 on both sides of the rotating shaft conveying mechanism 5, each installed on an AGV trolley. They perform the tasks of picking up and transferring the turbine disk respectively. During the material changing process, the handling robot on the left side uses the magnetic attraction function on the surface of its mechanical arm to pick up the turbine disk sent by the conveying mechanism 4 and transfer it to the surface of the rotating shaft 5.1. The multi-degree-of-freedom design of the robot arm allows it to operate flexibly in three-dimensional space, ensuring that the turbine disk can be accurately interfaced with the rotating shaft. The control system issues instructions, and the stepper motor 5.2 starts to drive the magnetic rotating shaft 5.1. The magnetic rotating shaft rotates the picked-up turbine disk along the preset trajectory by 180 degrees, rotating the turbine disk from the left side to the right side. The handling robot on the other side picks up the turbine disk from the magnetic rotating shaft through the magnetic disc 6.5 on the surface of the mechanical arm, completing the transfer of the turbine disk. During the transfer process, the control system monitors the position and state of the turbine disk through sensors to ensure the stability and reliability of the transfer action. The right handling robot II accurately transfers the received turbine disk to the grinding processing unit under the drive of the AGV, completing the material changing operation.

[0050] Figure 7 The structure of the movable handling robot II 6 is shown. The handling robot II is installed on an automatic guided vehicle (AGV) through the base 6.2, and the AGV 6.1 has automatic navigation function and can travel along the predetermined path to move the robot flexibly to the designated work area. Its bottom is equipped with multiple groups of drive wheels, which can ensure smooth movement in the factory environment. The base 6.2 connects the AGV and the mechanical arm part, ensuring the stability of the robot operation. The base integrates a communication module with the control system inside, which can receive instructions and feedback data in real time. The mechanical arm 6.3 has multiple degrees of freedom and can rotate flexibly in three-dimensional space to achieve precise grabbing, handling and auxiliary operation. The high degree of freedom design of the mechanical arm makes it adapt to complex working environment and different process requirements. A force sensor 6.4 is installed at the end of the mechanical arm, which uses piezoelectric multi-dimensional force measurement principle to collect dynamic coupling signals of normal force, tangential force and axial force in real time through three-way force sensitive elements during grinding operation. The sensor measurement unit performs temperature compensation and noise filtering processing on the original signal through the embedded signal conditioning circuit, and transmits the standardized grinding force data to the numerical control system in real time through the industrial Ethernet bus. The process parameter optimization module built in the control system compares the real-time grinding force with the preset threshold range (F min , F max), dynamically adjusts the cooperative parameter combination of the grinding wheel speed, feed speed, and grinding depth. When the instantaneous fluctuation of the grinding force exceeds the safety threshold (such as tool collision, overcut, etc.), the control system will issue a warning to remind the operator to check and adjust the process parameters. The end of the mechanical arm is also equipped with a magnetic suction chuck 6.5, which is used to firmly fix with the magnetic component 8.4 on the turbine disc, ensuring safety and reliability during handling. The compact design of the magnetic suction chuck can adapt to different attitudes and position requirements of the turbine disc.

[0051] Figure 8 is a structural schematic diagram of a vertical grinding machining device, Figure 9 is a local enlarged view. The vertical grinding machining device includes a cup-shaped grinding wheel 7.1, a tool holder 7.2, a grinding machining spindle 7.3, a vertical grinding machine 7.4, and a ram 7.5. The cup-shaped grinding wheel 7.1 is a mortise processing grinding tool, and its shape is designed to adapt to the geometry of the mortise of the turbine disc, which can maintain high material removal capacity during grinding while ensuring the shape accuracy and surface quality of mortise grinding. The grinding wheel base material is 45 steel, and its grinding surface is electroplated with high-hardness CBN abrasive particles with a granularity 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, which adopts a standardized tool holder interface to ensure quick installation and replacement of the grinding wheel, and reduces vibration during grinding through high-rigidity connection to improve machining accuracy. The spindle 7.3 is the core component of power transmission, which is driven by a high-precision servo motor and can operate at high speed and stability. The high speed and low radial runout characteristics of the spindle ensure that the grinding wheel maintains stable cutting performance during processing. The machine tool body 7.4 adopts a vertical structure and is provided with a slide rail. The slide rail has high linearity to ensure the position accuracy of the grinding wheel in the feed direction, meeting the requirements of shape accuracy and size consistency of the mortise of the turbine disc. The spindle is arranged on the ram, and the ram 7.5 is installed on the slide rail. The ram is the load-bearing part of the grinding wheel spindle and is controlled by the control cabinet 1, which can realize the up-and-down feeding and positioning of the grinding wheel along the slide rail. The servo control system of the ram realizes accurate displacement control through a high-resolution encoder, providing reliable support for the precise machining of the mortise. In the actual machining process, the turbine disc to be processed is fixed on the magnetic suction chuck. The ram 7.5 moves vertically along the slide rail 7.4 under the instruction of the control system, driving the grinding wheel 7.1 to gradually approach the mortise area of the turbine disc, completing the accurate tool setting of the grinding position. The spindle 7.3 drives the grinding wheel to rotate at high speed, and the grinding wheel performs layer-by-layer grinding on the mortise under the control of appropriate grinding depth and feed speed, ensuring that the shape accuracy and surface quality of the processed surface meet the requirements. The control system monitors the processing process in real time through the built-in sensors and detection devices, automatically adjusts the feed amount according to the grinding wheel wear, and ensures the stability of continuous processing.

[0052] Figure 10For the explosion diagram of the turbine disc to be processed, the turbine disc body 8.2 is in the shape of a disc, and is made of high-temperature alloy, titanium alloy, stainless steel and other metals or various composite materials, which can meet the requirements of various aero-engines under different use requirements. The disc body is provided with a plurality of tenon and groove structures distributed on the outer periphery, which are used for installing blades and need to be precisely ground to achieve ideal shape accuracy and surface quality. The fastening screws are used to reliably connect the turbine disc body 8.2, the bottom plate 8.3 and the magnetic disc 8.4, and ensure the stability during the processing. The screw material is high-strength alloy steel, which has high fatigue resistance and shear resistance. The bottom plate 8.3 is used as the installation support component of the turbine disc, and is tightly connected with the disc body through the screws to ensure the stable positioning of the disc body during the processing. The bottom plate is made of high-strength steel material, and is designed accurately to ensure the installation accuracy of the turbine disc. The magnetic disc 8.4 is strongly adsorbed with the surface of the magnetic adsorption chuck 6.5 of the carrying robot II 6 and the magnetic adsorption rotating shaft 5.1 through electromagnetic control, and the adsorption force is uniformly distributed, which can effectively avoid the errors caused by vibration or displacement during the processing of the turbine disc. According to the design of the flange disc, the turbine disc body is firmly connected with the bottom plate 8.3 and the magnetic disc 8.4 through six fastening screws 8.1 to form a stable structure unit, which can effectively avoid the deformation or deviation caused by uneven stress during the processing. During the overall assembly process, the positioning and connection accuracy of each component is extremely high to ensure the clamping rigidity during the processing and the positioning consistency of the turbine disc.

[0053] Figure 11The working principle diagram for grinding the mortise of the turbine disc with a cup-shaped grinding wheel. The turbine disc is firmly fixed on the magnetic suction chuck 6.5 of the handling robot II 6 through the magnetic disc 8.4 fixed thereto. The magnetic suction chuck provides high stability, avoiding processing errors caused by vibration or deviation during grinding. Before processing, the mortise of the turbine disc is aligned with the motion trajectory of the grinding spindle to ensure the dimensional accuracy and shape accuracy of the mortise processing. During grinding, the cup-shaped grinding wheel 7.1 is driven by the spindle 7.3 to realize the grinding effect on the workpiece material in the form of high-speed rotation. The cup-shaped grinding wheel can effectively cut the two side surfaces of the turbine disc mortise due to the matching of the grinding surface shape and the shape of the mortise to be processed, while maintaining the dimensional accuracy of the mortise. During processing, the grinding spindle provides axial feed along the slide 7.5 to gradually complete the grinding of the mortise depth. In the initial stage of the grinding process, the cup-shaped grinding wheel performs rough machining on the mortise, quickly removing excess material. This stage controls the depth of cut and feed speed of the grinding wheel by the control system to ensure processing efficiency. When the rough grinding approaches the target size, fine grinding is performed by adjusting the grinding wheel grinding parameters to achieve the surface quality and shape accuracy requirements of the mortise. The grinding depth can be dynamically adjusted by the control system during the grinding process to ensure that each grinding amount of the mortise reaches the target size. During processing, the grinding area is lubricated and cooled by cooling liquid spraying to prevent thermal damage to the workpiece due to heat accumulation, while prolonging the service life of the grinding wheel. According to the material characteristics of the turbine disc and the size requirements of the mortise, the rotational speed and feed speed of the grinding wheel are set by the control system to obtain the best processing quality and efficiency. After grinding is completed, the surface quality (surface roughness, grinding burn condition, surface topography, etc.) and shape dimensional accuracy of the turbine disc mortise grinding surface are detected, and the processing process parameters are adjusted according to the detection results.

[0054] Figure 12The structure diagram of the grinding processing online monitoring system is shown in the figure. The system can monitor key parameters and phenomena in the grinding process in real time through machine vision technology, ensuring the stability and accuracy of the processing process. The main part 9.1 of the detection system is stable in structure, and high-precision sliding rails are installed on the surface. The workbench 9.2 can move up and down on the sliding rails, and 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 placed at the best observation point to monitor the target area in the grinding process efficiently. The industrial camera III 9.3 is equipped with a high dynamic range (HDR) imaging module and a near-infrared spectrum sensor, which can capture the color change and spark of the material surface on the grinding workpiece surface. For the grinding burn detection requirement, the time difference method is used to compare the abnormal stain 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 oxidation layer. When the local area appears high-temperature oxidation color or spark that meets the burn characteristics, the system will trigger a three-level response mechanism: first, adjust the macro zoom lens of the industrial camera III to perform multi-focal surface scanning verification on the grinding area, then record the spatial coordinates through the built-in grating encoder of the camera, and feedback to the grinding processing monitoring system 9 through the industrial bus protocol, at the same time, start the machine tool emergency stop program, and synchronously trigger the sound-light alarm device to prompt the operator to check the mortise grinding surface.

[0055] In the embodiment of the present application, by using the cup-shaped grinding wheel in the vertical grinding processing system to grind the mortise of the turbine disc, the shape accuracy and surface quality can meet the high standard requirements of the service of the aero-engine. At the same time, cooperating with the coordinated operation of the automatic material handling unit, the material changing system and the control system, not only the precision machining of the turbine disc mortise is realized, but also the errors introduced by manual operation are effectively avoided. In addition, the grinding processing monitoring system is introduced in the present application, which realizes real-time monitoring of whether the tool hits, overcuts, spark state, burn signs and other phenomena in the grinding process through the combination of force sensor and industrial camera III, and realizes quality control and abnormal warning of the processing process.

[0056] The present application combines a variety of high-efficiency functional units, such as magnetic attraction shaft material changing mechanism, mechanical gripper handling robot, AGV transportation system and online monitoring system, which greatly improves the intelligentization and automation level of the production line. The mechanical arm equipped with force sensor can feedback the grinding force in real time during grinding, optimize the processing parameters, and improve the processing stability and product consistency. The automatic production line reduces manual intervention, improves the processing efficiency and continuity, reduces the manufacturing cost, and meets the high precision and high quality requirements of the aero-engine turbine disc manufacturing.

Claims

1. A turbine disc mortise and tenon automated grinding system, characterized in that: The application relates to a material conveying unit, a material replacing unit, an online monitoring system for grinding processing, a grinding processing unit and a control system connecting the above units, and each unit works coordinately to realize efficient and high-quality automatic processing of a mortise and tenon joint of a turbine disc. The material conveying unit comprises a storage rack (2) for placing a turbine disc to be processed, a movable conveying robot I (3) which is provided with a mechanical gripper (3.3) with a clamping function and is used for accurate conveying of the turbine disc, and a conveying mechanism (4) for connecting materials between different units; the conveying robot I (3) grasps the turbine disc to be processed on the storage rack by means of the mechanical gripper and places the turbine disc on the conveying mechanism; The material replacing unit comprises a rotating shaft conveying mechanism driven by a motor, the rotating shaft conveying mechanism is a central symmetrical structure, one end of the turbine disc is fixed, and the turbine disc is transferred to the grinding processing unit through vertical rotation by 180 degrees; on both sides of the rotating shaft conveying mechanism, one movable conveying robot II (6) is distributed, one conveying robot II completes the conveying action of the turbine disc from the conveying mechanism to the rotating shaft conveying mechanism, and the other conveying robot II moves a mechanical arm to complete the tool setting of the surface of the mortise and tenon joint to be processed and a grinding surface of a cup-shaped grinding wheel in the grinding processing unit; The grinding processing unit comprises a vertical grinding machine tool (7.4) provided with a sliding rail, a ram (7.5) installed on the sliding rail, a tool handle of the cup-shaped grinding wheel (7.1) fixed on the ram through a main shaft, the cup-shaped grinding wheel can reciprocate up and down along the sliding rail to adjust the height, the main shaft is connected to a servo motor, and the ram is connected to a control system; The control system comprises a control cabinet (1) which can be manually operated, a control module, a signal processing unit and a man-machine interaction interface are integrated in the control cabinet; the control system is connected with the material conveying unit, the material replacing unit and the grinding processing unit through signals, realizes real-time monitoring and coordinated control on the running states of the units, and can improve the production efficiency and the processing quality through parameter optimization adjustment; The online monitoring system for grinding processing realizes multi-modal real-time monitoring in the processing process through force sensor and industrial camera cooperative sensing; the system utilizes dynamic grinding force signal analysis combined with high frame rate visual detection, synchronously tracks grinding force signal fluctuation, spark shape evolution and surface burn characteristics, can accurately identify tool collision, grinding burn process deviation; after real-time analysis of the monitoring data by the control cabinet, the core parameters of the main shaft rotating speed and the feed rate are dynamically optimized through a closed-loop feedback mechanism, the processing precision is ensured, and the grinding tool collision and burn risk is effectively inhibited. The steps are as follows:

2. The process of claim 1, wherein, (1) the conveying robot I (3) grasps the turbine disc to be processed on the storage rack by means of the mechanical gripper and places the turbine disc on the conveying mechanism; the conveying mechanism conveys the turbine disc to the material replacing unit; ​ (2) The transfer robot II (6) obtains the turbine disc conveyed by the conveying mechanism, transfers it to one end of the rotating shaft conveying mechanism through the mechanical arm, and under the driving of the stepping motor, the rotating shaft rotates 180 degrees to deliver the turbine disc to one side of the grinding processing unit. After the turbine disc is taken off by the transfer robot II (6) on this side, it is conveyed 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 disc to be processed. In this way, through the rotation transmission of the rotating shaft conveying mechanism, the turbine disc to be processed is continuously delivered to the grinding processing unit. (3) In the grinding processing unit, the control system drives the cup-shaped grinding wheel to grind the turbine disc. (4) The finished turbine disc after grinding is recycled to the finished product storage rack by the transfer robot I (3), and the automatic processing of the turbine disc is completed.

3. The process of claim 2, wherein: In step (2), the transfer robot II (6) transfers the turbine disc to be processed from the conveying mechanism to the rotating shaft conveying mechanism through magnetic conveying technology. The turbine disc is reliably connected by fastening screws, and the magnetic disc (8.4) is strongly adsorbed with the magnetic suction chuck (6.5) on the surface of the transfer robot II (6) and the magnetic suction rotating shaft (5.1) of the rotating shaft conveying mechanism through electromagnetic control.

4. The process of claim 2, wherein: The transfer robot II (6) in step (2) and the transfer robot I (3) in step (1) are both installed on the AGV trolley, which is controlled by the control system to drive along the predetermined path, realizing the flexible movement and accurate positioning of the robot between the working units.

5. The process of claim 2, wherein: The automatic identification of the transfer robot I (3) and the transfer robot II (6), as well as the material transfer, material replacement and grinding processing, are all controlled by the control system. At the same time, the control system automatically adjusts the operation parameters according to the feedback signals to ensure the stability of the production process.

6. The process of claim 2, wherein: In step (3), the grinding processing online monitoring system realizes multi-modal real-time monitoring of the processing process through force sensor and industrial camera cooperative sensing. For grinding burn detection requirements, the time difference method is used to compare the abnormal stain diffusion pattern in the continuous frame image, and then the convolutional neural network is used to analyze the surface feature distortion caused by the oxidation layer. When a high-temperature oxidation color or spark that meets the burn characteristics is 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 surface scanning verification of the grinding area, then record the spatial coordinates through the built-in grating encoder of the camera, and feed back to the grinding processing monitoring system (9) through the industrial bus protocol, and at the same time, start the machine tool emergency stop program, and synchronously trigger the sound and light alarm device to prompt the operator to check the mortise grinding surface.

7. The process of claim 6, wherein: The force sensor (6.4) is installed at the end of the mechanical arm of the handling robot II (6), which adopts a 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 through a three-way force sensitive element; the original signal is first temperature compensated and noise filtered, and the standardized grinding force data is transmitted to the numerical control system in real time through an industrial Ethernet bus; based on the fuzzy PID control algorithm, the control system dynamically adjusts the cooperative 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 the phenomenon of tool collision and overcutting occurs, the control system will issue a warning if the instantaneous fluctuation of the grinding force exceeds the safety threshold, reminding the operator to check and adjust the process parameters.

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