Control method and system of vertical multi-axis numerical control mortise broaching machine and storage medium

Abstract

The invention discloses a control method and system of a vertical multi-axis numerical control mortise broaching machine and a storage medium, and relates to the technical field of broaching machines. The control method comprises the following steps that S1, a three-dimensional model of a workpiece is imported, and a mortise machining area is recognized based on geometric features of the model; s2, according to the material attribute, the tool type and the machining precision requirement, the feeding speed, the cutting depth and the main shaft rotating speed parameter of a machining path are set; s3, generating a multi-axis linkage tool path plan, and decomposing a tool path into a control instruction of multi-axis cooperative motion through a numerical control system; s4, the deviation between the actual position and the theoretical position of each shaft is monitored in real time in the machining process, and the output torque and the rotating speed of the servo motor are dynamically adjusted; s5, collecting cutting force data in real time; s6, the distance between the cutter and the surface of the workpiece is measured in real time through a laser displacement sensor, and a displacement feedback signal is generated; and if the cutting force data and the displacement feedback signal exceed preset threshold values, a dynamic compensation mechanism is triggered. The broaching machine control method has the effect of improving broaching machine control accuracy.

Description

Technical Field

[0001] The present application relates to the technical field of broaching machines, and in particular to a control method, system and storage medium for a vertical multi-axis CNC mortise and tenon broaching machine. Background Art

[0002] Multi-axis CNC broaching machine is a high-precision equipment used to process complex workpieces. It is widely used in aerospace, automobile manufacturing, mold processing and other fields.

[0003] Traditional broaching machine control methods usually use single-axis or simple multi-axis control, which is difficult to meet the processing requirements of complex surfaces and high-precision workpieces, and there is room for improvement. Summary of the invention

[0004] In order to overcome the above-mentioned deficiencies of the prior art, the present application provides a control method, system and storage medium for a vertical multi-axis CNC mortise and tenon broaching machine.

[0005] In the first aspect, the present application provides a control method for a vertical multi-axis CNC mortise and tenon broaching machine, which adopts the following technical solution: A control method for a vertical multi-axis CNC mortise and tenon broaching machine comprises the following steps: S1. Import the 3D model of the workpiece and identify the mortise and tenon processing area based on the geometric features of the model; S2. Set the feed speed, cutting depth and spindle speed parameters of the machining path according to material properties, tool type and machining accuracy requirements; S3. Generate a tool path plan for multi-axis linkage, and decompose the tool path into control instructions for multi-axis coordinated motion through a numerical control system; S4. Monitor the deviation between the actual position and theoretical position of each axis in real time during the machining process, and dynamically adjust the output torque and speed of the servo motor; S5. Real-time collection of cutting force data, the cutting force includes radial force and axial force in the X / Y / Z direction; S6. The distance between the tool and the workpiece surface is measured in real time through a laser displacement sensor to generate a displacement feedback signal; if the cutting force data and the displacement feedback signal exceed the preset threshold, the dynamic compensation mechanism is triggered.

[0006] Preferably, step S2 also includes: Divide the machining path into rough machining section and finishing section; The cutting depth of each layer of the rough machining section is set based on the tool diameter, and the feed speed of the rough machining section is controlled to exceed the feed speed of the fine machining section; The finishing section is cut by adjusting the axial inclination angle of the tool.

[0007] Preferably, step S3 specifically includes: The multi-axis linkage path planning includes a spiral interpolation machining strategy, where the tool cuts in a spiral progressive manner along the mortise and tenon profile to reduce excessive single cutting load; The tool posture is deflected in real time through continuous angle adjustment of the rotation axis, ensuring that the cutting edge is always perpendicular to the side wall of the asymmetric mortise and tenon groove.

[0008] Preferably, it also includes: The cutting force, vibration and temperature data during the machining process are input into a machine learning model, which is trained based on historical machining data and is used to predict tool wear status and machined surface quality; Dynamically adjust the parameters of the next processing stage based on the prediction results: if the tool wear prediction value exceeds the threshold, prompt to replace the tool; if the surface roughness prediction value does not meet the standard, optimize the feed rate or spindle speed; After each processing is completed, a process optimization report is automatically generated and updated to the parameter database of the CAM system.

[0009] Preferably, it also includes: The processing area is monitored in real time by a binocular vision camera. If a person is detected entering the danger zone, an emergency stop is triggered immediately and the machine tool is locked. During the tool replacement stage, the RFID chip is used to verify the matching of the tool model and processing parameters. If they are inconsistent, the processing is prohibited from starting.

[0010] Preferably, the dynamic compensation mechanism further includes: Machining chatter is detected by a piezoelectric vibration sensor mounted on the workpiece fixture; When the vibration frequency exceeds the preset safety threshold, a reverse damping pulse is applied to the spindle to suppress the continued growth of vibration; The fault characteristic frequency of the spindle bearing is detected based on vibration spectrum analysis. When the continuous sampling of the characteristic frequency amplitude exceeds the set value, a maintenance work order is generated and pushed to the maintenance terminal.

[0011] Preferably, a graded response strategy is set in the dynamic compensation mechanism: first-level response: when the cutting force exceeds the limit instantaneously, the feed speed is reduced; second-level response: when the duration of the exceeding limit is greater than the set value, an emergency stop is triggered and the tool is retracted to a safe position.

[0012] Preferably, it also includes: Collect current and voltage data of spindle motor and servo drive in real time and calculate instantaneous power; Build an energy consumption prediction model based on historical processing data, and give priority to selecting the tool path with the lowest energy consumption during the path planning stage; Automatically switches to low power mode during non-cutting phases.

[0013] In the second aspect, the present application provides a vertical multi-axis CNC mortise and tenon broaching machine control system, which adopts the following technical solution: A vertical multi-axis CNC mortise and tenon broaching machine control system, applied to a control method of the vertical multi-axis CNC mortise and tenon broaching machine, comprising: a recognition module configured to import a three-dimensional model of a workpiece and identify a mortise and tenon machining area based on geometric features of the model; A multi-axis motion control module is configured to generate a tool path plan for multi-axis linkage and decompose the tool path into control instructions for multi-axis coordinated motion through a numerical control system; A monitoring and adjustment module is configured to monitor the deviation between the actual position and the theoretical position of each axis in real time during the machining process, and dynamically adjust the output torque and speed of the servo motor; A collection module is configured to collect cutting force data in real time, wherein the cutting force includes radial force and axial force in X / Y / Z directions; The adaptive compensation module is configured to measure the distance between the tool and the workpiece surface in real time through a laser displacement sensor to generate a displacement feedback signal; if the cutting force data and the displacement feedback signal exceed a preset threshold, a dynamic compensation mechanism is triggered.

[0014] In a third aspect, the present application provides a computer-readable storage medium having computer instructions stored thereon, which, when executed, execute the steps of the control method of the vertical multi-axis CNC mortise and tenon broaching machine.

[0015] Compared with the prior art, this application has the following characteristics and beneficial effects: By importing the 3D model of the workpiece and automatically identifying the mortise and tenon processing area, manual intervention is reduced and the automation of the processing process is improved. At the same time, the processing parameters are automatically set based on material properties, tool type and processing accuracy requirements, which improves the intelligent level of processing. By generating multi-axis linkage tool path planning and decomposing the path into control instructions for multi-axis collaborative motion, high-precision processing of complex mortise and tenon structures is achieved. Multi-axis linkage can handle complex geometric shapes and ensure processing accuracy and surface quality. Through automated parameter setting, multi-axis linkage control, and real-time monitoring and compensation, the entire processing process is more efficient, reducing human errors and processing time, while ensuring the consistency and repeatability of processing results and improving the accuracy of broaching machine control. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a step block diagram of a control method of a vertical multi-axis CNC mortise and tenon broaching machine mainly embodied in this embodiment; Figure 2 It is a block diagram of a control system of a vertical multi-axis CNC mortise and tenon broaching machine mainly embodied in this embodiment; Figure numerals: 1. Identification module; 2. Multi-axis motion control module; 3. Monitoring and adjustment module; 4. Acquisition module; 5. Adaptive compensation module. DETAILED DESCRIPTION

[0017] The present application is further described in detail below in conjunction with the following examples.

[0018] Reference Figure 1 A control method for a vertical multi-axis CNC mortise and tenon broaching machine includes S1. Importing a three-dimensional model of a workpiece and identifying a mortise and tenon processing area based on the geometric features of the model. By importing the three-dimensional model of the workpiece, the system can automatically identify the mortise and tenon processing area, reducing the complexity of manual measurement and programming. This automated feature recognition technology is particularly suitable for workpieces with complex geometric shapes, can significantly improve programming efficiency, and reduce the technical requirements for operators.

[0019] S2. According to the material properties, tool type and machining accuracy requirements, set the feed speed, cutting depth and spindle speed parameters of the machining path. The use of intelligent settings not only optimizes the machining efficiency, but also avoids machining quality problems caused by improper manual settings. Specifically, step S2 also includes: Divide the machining path into rough machining section and finishing section; The cutting depth of each layer of the rough machining section is set based on the tool diameter, and the feed speed of the rough machining section is controlled to exceed the feed speed of the fine machining section; The finishing section is cut by adjusting the axial inclination angle of the tool.

[0020] S3. Generate a multi-axis linkage tool path plan, and decompose the tool path into control instructions for multi-axis coordinated motion through the CNC system. Step S3 specifically includes: The multi-axis linkage path planning includes a spiral interpolation machining strategy, where the tool cuts in a spiral progressive manner along the mortise and tenon profile to reduce excessive single cutting load; The tool attitude is deflected in real time by continuous angle adjustment of the rotating axis, ensuring that the cutting edge is always perpendicular to the side wall of the asymmetric mortise. It should be noted that the spiral interpolation machining strategy allows the tool to cut into the workpiece in a spiral progressive manner along the mortise contour, effectively reducing the load of a single cut, avoiding tool wear, workpiece deformation or reduced surface quality caused by concentrated cutting force, and significantly improving the stability of the machining process and tool life.

[0021] Through the continuous angle adjustment of the rotating axis, the system can achieve real-time deflection of the tool posture, ensuring that the cutting edge is always perpendicular to the side wall of the asymmetric mortise, thereby improving cutting efficiency and quality. Especially when processing mortise with complex geometric shapes, it can effectively avoid processing errors or substandard surface roughness caused by improper tool posture. In addition, the combination of spiral interpolation processing strategy and real-time tool posture deflection technology optimizes the distribution of cutting force, reduces the risk of vibration and thermal deformation during processing, and further improves processing accuracy and surface quality.

[0022] S4. During the machining process, the deviation between the actual position and the theoretical position of each axis is monitored in real time, and the output torque and speed of the servo motor are adjusted dynamically. Specifically, it includes real-time acquisition of current and voltage data of the spindle motor and servo drive, calculation of instantaneous power; building an energy consumption prediction model based on historical machining data, giving priority to the tool path with the lowest energy consumption in the path planning stage; and automatically switching to low power consumption mode in the non-cutting stage.

[0023] S5. Collect cutting force data in real time, including radial force and axial force in the X / Y / Z directions. In actual use, by analyzing the cutting force data, the system can determine whether the processing status is normal (such as whether the tool is worn, whether the workpiece is deformed, etc.).

[0024] S6. The laser displacement sensor measures the distance between the tool and the workpiece surface in real time and generates a displacement feedback signal. If the cutting force data and displacement feedback signal exceed the preset threshold, the dynamic compensation mechanism is triggered. For example, if the cutting force is too large, the system can reduce the feed speed or adjust the tool path; if the displacement deviation is too large, the system can adjust the output of the servo motor to correct the position.

[0025] In the embodiment of the present application, the dynamic compensation mechanism also includes: Machining chatter is detected by a piezoelectric vibration sensor mounted on the workpiece fixture; When the vibration frequency exceeds the preset safety threshold, a reverse damping pulse is applied to the spindle to suppress the continued growth of vibration; The fault characteristic frequency of the spindle bearing is detected based on vibration spectrum analysis. When the continuous sampling of the characteristic frequency amplitude exceeds the set value, a maintenance work order is generated and pushed to the maintenance terminal.

[0026] By installing a piezoelectric vibration sensor on the workpiece fixture to detect chatter in the machining process in real time, the system can accurately capture the vibration signal and analyze its frequency characteristics. When the vibration frequency exceeds the preset safety threshold, the system applies a reverse damping pulse to the spindle to effectively suppress the continued growth of vibration, thereby avoiding the degradation of the machining surface quality, abnormal tool wear or equipment damage caused by chatter, and significantly improving the stability and quality of the machining process.

[0027] At the same time, based on vibration spectrum analysis technology, the system can detect the fault characteristic frequency of the spindle bearing. When the continuous sampling of the characteristic frequency amplitude exceeds the set value, a maintenance work order is automatically generated and pushed to the maintenance terminal, realizing real-time monitoring and predictive maintenance of the spindle bearing status, avoiding equipment shutdown or production interruption caused by bearing failure, extending equipment service life and reducing maintenance costs.

[0028] The cutting force, vibration, and temperature data during the machining process are input into the machine learning model, which is trained and generated based on historical machining data and is used to predict the tool wear status and machining surface quality. By collecting cutting force, vibration, and temperature data in real time and inputting them into the machine learning model trained based on historical data, the system can accurately predict the tool wear status. When the predicted value exceeds the preset threshold, the system automatically prompts to replace the tool, avoiding the decline in machining quality or equipment damage due to excessive tool wear, while realizing preventive maintenance of the tool, extending the tool life, and reducing production costs.

[0029] The machine learning model can predict the roughness of the machined surface based on multi-source data (cutting force, vibration, temperature) during the machining process. If the predicted value does not meet the standard, the system dynamically adjusts parameters such as feed speed or spindle speed to ensure that the machined surface quality meets the requirements. Dynamically adjust the parameters of the next processing stage based on the prediction results: if the tool wear prediction value exceeds the threshold, prompt to replace the tool; if the surface roughness prediction value does not meet the standard, optimize the feed rate or spindle speed; After each processing, a process optimization report is automatically generated and updated to the parameter database of the CAM system. The system automatically generates a process optimization report, recording key data in the processing process (such as cutting parameters, tool wear status, surface quality, etc.) and optimization suggestions. At the same time, the optimized parameters are updated to the parameter database of the CAM system, realizing the continuous accumulation of processing knowledge and iterative optimization of process parameters, providing data support and reference basis for subsequent processing.

[0030] A graded response strategy is set in the dynamic compensation mechanism: Level 1 response: when the cutting force exceeds the limit instantaneously, the feed speed is reduced; Level 2 response: when the duration of the limit exceeds the set value, an emergency stop is triggered and the tool is retracted to a safe position. Through the graded response strategy, the system can take differentiated response measures according to the severity of the cutting force exceeding the limit, which not only ensures the processing efficiency but also minimizes the processing risk.

[0031] Specifically, a control method for a vertical multi-axis CNC mortise and tenon broaching machine further includes the following steps: The processing area is monitored in real time by a binocular vision camera. If a person is detected entering the danger zone, an emergency stop is triggered immediately and the machine tool is locked. During the tool replacement stage, the RFID chip is used to verify the matching of the tool model and processing parameters. If they are inconsistent, the processing is prohibited from starting.

[0032] By using binocular vision cameras to monitor the processing area in real time, the system can accurately identify human entry into the dangerous area. Once a human is detected entering the dangerous area, the emergency stop is immediately triggered and the machine tool is locked, effectively avoiding personal injury accidents and significantly improving the safety and reliability of the processing process. The binocular vision camera has the characteristics of high precision and high response speed, and can capture the dynamic changes of the processing area in real time. Combined with the intelligent recognition algorithm, the system can quickly determine the dangerous state and trigger the emergency stop mechanism to ensure that the machine tool operation is quickly cut off in an emergency and minimize safety risks.

[0033] During the tool replacement stage, the system can automatically determine whether the tool is suitable for the current processing task by verifying the matching of the tool model and processing parameters through the RFID chip. If it is detected that the tool model is inconsistent with the processing parameters, the processing is prohibited from starting, avoiding processing quality problems or equipment damage caused by incorrect tool selection. The combination of binocular vision camera and RFID technology realizes real-time monitoring and automatic verification of the processing process, reduces dependence on manual inspection, improves production efficiency and intelligence level, and provides basic support for subsequent intelligent manufacturing system upgrades. By ensuring the matching of tools and processing parameters, the system can effectively avoid processing errors or equipment failures caused by tool mismatch, ensure processing quality and equipment operation stability, and extend equipment life.

[0034] The present application also provides a vertical multi-axis CNC mortise and tenon broaching machine control system, which is applied to a control method of the vertical multi-axis CNC mortise and tenon broaching machine, comprising: A recognition module 1 is configured to import a three-dimensional model of a workpiece and recognize a mortise and tenon processing area based on geometric features of the model; A multi-axis motion control module 2, configured to generate a tool path plan for multi-axis linkage, and decompose the tool path into control instructions for multi-axis coordinated motion through a numerical control system; A monitoring and adjustment module 3 is configured to monitor the deviation between the actual position and the theoretical position of each axis in real time during the machining process, and dynamically adjust the output torque and speed of the servo motor; A collection module 4 is configured to collect cutting force data in real time, wherein the cutting force includes radial force and axial force in X / Y / Z directions; The adaptive compensation module 5 is configured to measure the distance between the tool and the workpiece surface in real time through a laser displacement sensor to generate a displacement feedback signal; if the cutting force data and the displacement feedback signal exceed a preset threshold, a dynamic compensation mechanism is triggered.

[0035] The present application also provides a computer-readable storage medium on which computer instructions are stored. When the computer instructions are executed, the steps of the control method of the vertical multi-axis CNC mortise and tenon broaching machine are executed.

[0036] The above are all preferred embodiments of the present application, and the protection scope of the present application is not limited thereto. Therefore, any equivalent changes made according to the structure, shape, and principle of the present application should be included in the protection scope of the present application.

Claims

1. A control method for a vertical multi-axis CNC mortise and tenon broaching machine, characterized in that: The following steps are involved: S1. Import the 3D model of the workpiece and identify the mortise and tenon processing area based on the geometric features of the model; S2. Set the feed speed, cutting depth and spindle speed parameters of the machining path according to material properties, tool type and machining accuracy requirements; S3. Generate a multi-axis linkage tool path planning, and decompose the tool path into control instructions for multi-axis coordinated motion through a numerical control system; specifically, the multi-axis linkage path planning includes a spiral interpolation processing strategy, and the tool cuts in a spiral progressive manner along the mortise and tenon contour to reduce excessive single cutting load; The tool posture is deflected in real time through continuous angle adjustment of the rotation axis, ensuring that the cutting edge is always perpendicular to the side wall of the asymmetric mortise and tenon groove; S4. Monitor the deviation between the actual position and theoretical position of each axis in real time during the machining process, and dynamically adjust the output torque and speed of the servo motor; S5. Real-time collection of cutting force data, the cutting force includes radial force and axial force in the X / Y / Z direction; The cutting force, vibration and temperature data during the machining process are input into a machine learning model, which is trained based on historical machining data and is used to predict tool wear status and machined surface quality; Dynamically adjust the parameters of the next processing stage based on the prediction results: if the tool wear prediction value exceeds the threshold, prompt to replace the tool; if the surface roughness prediction value does not meet the standard, optimize the feed rate or spindle speed; After each processing, a process optimization report is automatically generated and updated to the parameter database of the CAM system; S6. Using a laser displacement sensor to measure the distance between the tool and the workpiece surface in real time, and generate a displacement feedback signal; if the cutting force data and the displacement feedback signal exceed a preset threshold, a dynamic compensation mechanism is triggered; wherein the dynamic compensation mechanism includes: Machining chatter is detected by a piezoelectric vibration sensor mounted on the workpiece fixture; When the vibration frequency exceeds the preset safety threshold, a reverse damping pulse is applied to the spindle to suppress the continued growth of vibration; The fault characteristic frequency of the spindle bearing is detected based on vibration spectrum analysis. When the characteristic frequency amplitude is continuously sampled and exceeds the set value, a maintenance work order is generated and pushed to the maintenance terminal. A graded response strategy is set in the dynamic compensation mechanism: first-level response: when the cutting force exceeds the limit instantaneously, the feed speed is reduced; second-level response: when the duration of the exceeding limit is greater than the set value, an emergency stop is triggered and the tool is retracted to a safe position.

2. The control method of the vertical multi-axis CNC mortise and tenon broaching machine according to claim 1, characterized in that: Step S2 also includes: Divide the machining path into rough machining section and finishing section; The cutting depth of each layer of the rough machining section is set based on the tool diameter, and the feed speed of the rough machining section is controlled to exceed the feed speed of the fine machining section; The finishing section is cut by adjusting the axial inclination angle of the tool.

3. The control method of the vertical multi-axis CNC mortise and tenon broaching machine according to claim 1, characterized in that: Also includes: The processing area is monitored in real time by a binocular vision camera. If a person is detected entering the danger zone, an emergency stop is triggered immediately and the machine tool is locked. During the tool replacement stage, the RFID chip is used to verify the matching of the tool model and processing parameters. If they are inconsistent, the processing is prohibited from starting.

4. The control method of a vertical multi-axis CNC mortise and tenon broaching machine according to claim 1, characterized in that: Also includes: Collect current and voltage data of spindle motor and servo drive in real time and calculate instantaneous power; Build an energy consumption prediction model based on historical processing data, and give priority to selecting the tool path with the lowest energy consumption during the path planning stage; Automatically switches to low power mode during non-cutting phases.

5. A vertical multi-axis CNC mortise and tenon broaching machine control system, applied to the control method of the vertical multi-axis CNC mortise and tenon broaching machine as claimed in any one of claims 1 to 4, characterized in that: include: A recognition module (1) is configured to import a three-dimensional model of a workpiece and identify a mortise and tenon processing area based on geometric features of the model; A multi-axis motion control module (2) is configured to generate a tool path plan for multi-axis linkage and decompose the tool path into control instructions for multi-axis coordinated motion through a numerical control system; A monitoring and adjustment module (3) is configured to monitor the deviation between the actual position and the theoretical position of each axis in real time during the processing, and dynamically adjust the output torque and speed of the servo motor; A collection module (4) is configured to collect cutting force data in real time, wherein the cutting force includes radial force and axial force in X / Y / Z directions; The adaptive compensation module (5) is configured to measure the distance between the tool and the workpiece surface in real time through a laser displacement sensor to generate a displacement feedback signal; if the cutting force data and the displacement feedback signal exceed a preset threshold, a dynamic compensation mechanism is triggered.

6. A computer-readable storage medium having computer instructions stored thereon, characterized in that: When the computer instructions are executed, the steps of the control method of the vertical multi-axis CNC mortise and tenon broaching machine described in any one of claims 1 to 4 are executed.

Images