An intelligent control system and its fully automatic edge milling machine

Abstract

The present invention discloses an intelligent control system and its full-automatic edge milling machine. An intelligent control system includes: a workpiece parameter detection unit; a parameter calculation unit; an adaptive adjustment unit; an optimization objective function unit; a main circuit, including: a working circuit provided with relays KM2-KM9 for controlling the operation of motors M1-M7; a driving circuit provided with fuses FU1-FU2 and a TC circuit; a control circuit provided with a main circuit breaker QF and control chips UF1-UF3 connected in parallel. The control chips UF1-UF3 send control signals to the driving circuit through the TC circuit according to the calculation results of the parameter calculation unit to achieve automatic adjustment of machining parameters. A full-automatic edge milling machine applies the above intelligent control system. The present invention has the following beneficial effects: This intelligent control system and its full-automatic edge milling machine can identify the workpiece size and can adjust the milling speed and feed speed in real time according to the detection results, thereby improving the machining accuracy and efficiency.

Description

Technical Field

[0001] The present invention relates to a control system for a milling machine and a milling machine, and particularly to an intelligent control system and a fully automatic milling machine thereof. Background Art

[0002] Edge milling of workpieces is an important process in machining, and its processing quality directly affects the appearance and service performance of products. Existing milling machines mainly perform cutting processing on the edges of workpieces through the high-speed rotation of milling cutters, and this processing method is widely used in the machinery manufacturing industry.

[0003] The existing process of workpiece edge milling is usually as follows: First, the operator manually sets the rotation speed and feed speed of the milling cutter according to the material and size parameters of the workpiece, especially the thickness of the workpiece; then the workpiece is fixed on the workbench and the milling cutter motor is started; finally, the feeding mechanism drives the workpiece for edge milling processing. During the processing, the relative movement between the milling cutter and the workpiece completes the cutting forming of the edge.

[0004] However, the main problem of existing milling machines is that the setting of processing parameters relies too much on manual experience. The operator needs to manually calculate and set appropriate milling speeds and feed speeds according to the thickness of the workpiece. This method has great subjectivity and uncertainty. Especially when processing workpieces of different specifications, it is necessary to frequently adjust the processing parameters, which not only increases the operation difficulty but also easily causes improper parameter setting.

[0005] Due to the lack of an accurate parameter control system, it is difficult to guarantee the processing accuracy of existing milling machines. Minor changes in the thickness of the workpiece may affect the final processing effect, and the parameters set manually cannot respond in a timely manner.

[0006] Frequent manual parameter adjustment also causes a large waste of time. For each change of the workpiece specification, the operator needs to recalculate and set the processing parameters, which not only reduces the utilization rate of the equipment but also increases the production cost. At the same time, the method of manual calculation and parameter setting is also prone to errors, resulting in unstable processing quality.

[0007] Therefore, it is of great significance to develop a milling machine that can automatically identify the thickness of workpieces and intelligently adjust processing parameters. This intelligent control system and its milling machine have the function of automatically detecting the size of workpieces and can adjust the milling speed and feed speed in real time according to the detection results, thereby improving the processing accuracy and efficiency and realizing the intelligence and standardization of the processing process. Summary of the Invention

[0008] The object of the present invention is to provide an intelligent control system and a fully automatic milling machine thereof. This intelligent control system and its fully automatic milling machine can identify the size of workpieces and can adjust the milling speed and feed speed in real time according to the detection results, thereby improving the processing accuracy and efficiency.

[0009] The above technical objectives of the present invention are achieved through the following technical solutions:

[0010] An intelligent control system, comprising:

[0011] A workpiece parameter detection unit for real-time detecting the thickness parameter of the workpiece;

[0012] A parameter calculation unit for calculating the milling speed, feed speed, and cutting depth required during the machining process according to the detected workpiece parameters;

[0013] An adaptive adjustment unit for dynamically adjusting the machining parameters according to the calculation results;

[0014] An optimization objective function unit for determining the optimal parameter configuration based on the dynamically adjusted machining parameters;

[0015] The main circuit includes: a working circuit provided with relays KM2-KM9 for controlling the operation of motors M1-M7; a driving circuit provided with fuses FU1-FU2 and a TC circuit; a control circuit provided with a main circuit breaker QF and parallel control chips UF1-UF3, wherein: the control chip UF1 is used to control the movement of the milling cutter; the control chip UF2 is used to control the workpiece feed; the control chip UF3 is used to control the position of the carriage; the control chips UF1-UF3 send control signals to the driving circuit through the TC circuit according to the calculation results of the parameter calculation unit to achieve automatic adjustment of the machining parameters.

[0016] The present invention is further configured as: the calculation of the parameter calculation unit includes:

[0017] Thickness deviation rate calculation: , for calculating the deviation between the actual thickness and the target thickness of the workpiece;

[0018] Feed speed calculation: , for determining the feed speed of the workpiece according to the deviation rate;

[0019] Spindle speed calculation: , for determining the rotational speed of the milling cutter according to the deviation rate;

[0020] Cutting depth calculation: , for determining the cutting depth according to the workpiece thickness and the tool wear state;

[0021] Cutting speed calculation: , for determining the cutting speed according to the tool diameter and the spindle speed;

[0022] Power estimation: , for calculating the power required during the machining process.

[0023] The present invention is further configured such that: the adaptive adjustment unit includes:

[0024] A dynamic update adjustment coefficient calculation module:

[0025] , which is used to update the feed speed coefficient and the spindle speed coefficient according to the actual machining effect;

[0026] A parameter dynamic change calculation module:

[0027] ;

[0028] , which is used to adjust the feed speed and the spindle speed in real time according to the updated coefficients.

[0029] The present invention is further configured such that:

[0030] The parameter dynamic change calculation module is further provided with constraint conditions, including:

[0031] Cutting force constraint: ;

[0032] Power constraint: ;

[0033] Surface quality constraint: .

[0034] The present invention is further configured such that: the optimization objective function:

[0035] , which is used to configure the optimal parameters.

[0036] The present invention is further configured such that: in the working circuit:

[0037] Relays KM2 and KM3 are used to control the forward and reverse rotations of motors M1 and M2;

[0038] Relays KM4 and KM5 are used to control the forward and reverse rotations of motors M3 and M4;

[0039] Relays KM6 and KM7 are used to control the forward and reverse rotations of motor M5;

[0040] Relays KM8 and KM9 are used to control the forward and reverse rotations of motor M7.

[0041] A full-automatic edge milling machine, which applies the above intelligent control system, includes a bracket, and a tool control device and a feeding control device are arranged on the bracket;

[0042] The tool control device includes:

[0043] A milling cutter, the milling cutter is connected with a drive shaft, and the drive shaft is connected to the bracket by a bearing;

[0044] A tool holder is arranged outside the drive shaft, and a support plate is fixedly connected to the end of the tool holder;

[0045] Two first motors are connected to the drive shaft through belts;

[0046] A fourth servo motor is arranged on both sides of the support plate, and its output shaft is fixedly connected to the bracket;

[0047] The feeding control device includes:

[0048] A plurality of roller shafts are arranged on the bracket in sequence and are connected to the bracket by bearings;

[0049] A sliding seat is arranged above the roller shaft and can move up and down;

[0050] A roller is arranged in the middle of the sliding seat and corresponds to the roller shaft.

[0051] The present invention is further configured as: including a bracket, and a tool control device and a feeding control device are arranged on the bracket;

[0052] The tool control device includes:

[0053] A milling cutter, the milling cutter is connected with a drive shaft, and the drive shaft is connected to the bracket by a bearing;

[0054] A tool holder is arranged outside the drive shaft, and a support plate is fixedly connected to the end of the tool holder;

[0055] Two first motors are connected to the drive shaft through belts;

[0056] A fourth servo motor is arranged on both sides of the support plate, and its output shaft is fixedly connected to the bracket;

[0057] The feeding control device includes:

[0058] A plurality of roller shafts are arranged on the bracket in sequence and are connected to the bracket by bearings;

[0059] A sliding seat is arranged above the roller shaft and can move up and down;

[0060] A roller is arranged in the middle of the sliding seat and corresponds to the roller shaft;

[0061] The present invention is further configured as: two pull rods are connected to the top of the sliding seat, and a third motor is connected to the top of the pull rod, and the third motor is a servo motor.

[0062] In summary, the present invention has the following beneficial effects:

[0063] The present invention can detect parameters such as the thickness and size of a workpiece in real time by combining control chips (UF1, UF2, UF3) with sensors, automatically identify the specifications of the workpiece, and dynamically adjust machining parameters such as milling speed, feed rate, cutting depth, and milling angle according to the detection results. Compared with the traditional method of setting machining parameters relying on manual experience, the present invention significantly reduces the possibility of manual intervention, reduces subjectivity and uncertainty, and improves machining accuracy and production stability.

[0064] The present invention adopts a dynamic parameter adjustment algorithm based on the thickness deviation rate to automatically optimize the machining process through a non-linear calculation formula. The system can intelligently adjust the feed rate and spindle speed according to real-time data, enabling the machining process to quickly respond to changes in workpiece thickness while ensuring the running stability of the tool and cutting efficiency. This design solves the problems of time waste and operation complexity caused by frequent parameter adjustment when traditional edge milling machines process workpieces of different specifications, thus significantly improving equipment utilization and production efficiency.

[0065] The present invention ensures the safety and stability of the machining process by setting cutting force constraints, power constraints, and surface quality constraints, avoiding problems such as milling cutter overload and equipment overheating, while extending the service life of the tool and equipment and reducing maintenance costs. The dynamic adjustment algorithm also adopts an exponential decay term and smoothing processing technology to avoid over-adjustment or parameter oscillation phenomena, further enhancing the stability and accuracy of the machining process.

[0066] Through the collaborative work of the tool control device, feed control device, and carriage control device, the present invention realizes a fully automated process from workpiece feeding, milling machining to completion. The organic combination of the main circuit and the control circuit enables the equipment to monitor the workpiece status in real time during the machining process, dynamically adjust machining parameters, and ensure the efficiency, precision, and stability of the machining process. BRIEF DESCRIPTION OF THE DRAWINGS

[0067] Figure 1 It is a schematic structural diagram of a fully automatic edge milling machine;

[0068] Figure 2 It is a schematic rear view structural diagram of a fully automatic edge milling machine;

[0069] Figure 3 It is a schematic bottom view structural diagram of a fully automatic edge milling machine;

[0070] Figure 4 It is a main circuit and drive circuit diagram of the intelligent control system of a fully automatic edge milling machine;

[0071] Figure 5 It is a control circuit diagram of the intelligent control system of a fully automatic edge milling machine;

[0072] Figure 6It is a flowchart of the control chips UF1 - UF3 in the intelligent control system.

[0073] Reference numerals: 1, bracket; 2, tool control device; 3, feeding control device; 4, milling cutter; 5, drive shaft; 6, tool rest; 7, support plate; 8, motor 1; 9, motor 4; 10, roller; 11, slide; 12, roller barrel; 13, gear; 14, motor 2; 15, pull rod; 16, motor 3; 17, motor 5; 18, lead screw. Detailed implementation manners

[0074] In the description of the present invention, it should be understood that the orientation or positional relationship indicated by the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "page", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc. is based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as a limitation of the present invention.

[0075] In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be construed as indicating or implying relative importance or implicitly specifying the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include one or more of such features.

[0076] In the description of the present invention, the meaning of "a plurality" is two or more unless otherwise specifically defined. In the present invention, unless otherwise clearly specified and limited, the terms "mounted", "connected", "connected to", "fixed" and other terms should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0077] The present invention will be further described in detail below with reference to the accompanying drawings.

[0078] As Figures 1 - 3 shown, a fully automatic edge milling machine includes a bracket 1. A tool control device 2 and a feeding control device 3 for inputting workpieces are provided on the bracket 1.

[0079] 1. Tool control device 2

[0080] Two sets of the described tool control devices 2 are provided, including a milling cutter 4. The milling cutter 4 is connected to a drive shaft 5. The milling cutter 4 is arranged on a bracket 1 such that the drive shaft 5 is connected to the bracket 1 through bearings. A tool holder 6 is arranged outside the drive shaft 5 to isolate the drive shaft 5 from the external environment. A support plate 7 is fixedly connected to the end of the tool holder 6. One end of the drive shaft 5 passing through the support plate 7 is connected to two first motors 8 through a belt. By the rotation of the first motors 8, the drive shaft 5 rotates, thereby ensuring the high-speed operation of the milling cutter 4.

[0081] Correspondingly, the tool control device 2 further includes fourth servo motors 9 arranged on both sides of the support plate 7. The output shafts at the ends of the fourth motors 9 are fixedly connected to the bracket 1. When the fourth motors 9 work, they can drive the support plate 7 of the tool adjustment device to swing, thereby adjusting the angle of the milling cutter 4 and milling the workpiece according to different angle setting requirements.

[0082] 2. Feeding control device 3

[0083] The described feeding control device 3 includes a plurality of roller shafts 10 arranged in sequence on the bracket 1. The roller shafts 10 are connected to the bracket 1 through bearings. A slidable seat 11 that can move up and down is arranged above the roller shafts 10. A roller 12 corresponding to the roller shafts 10 is arranged in the middle of the slidable seat 11. The roller 12 is connected to the slidable seat 11 through bearings. Among them, the roller 12s are meshed and connected to each other through an odd number of gears 13. One end of one of the roller 12s is connected to a second motor 14. When the second motor 14 works, it can drive the roller 12 to rotate, thereby making each roller 12 rotate in the same direction. The frictional force between the roller 12s rotating in the same direction and the roller shafts 10 can push the workpiece to move.

[0084] Correspondingly, two pull rods 15 are connected to the top of the slidable seat 11. A third motor 16 is connected to the top of the pull rods 15. The third motor 16 is a servo motor. By the work of the third motor 16, the pull rods 15 drive the entire slidable seat 11 to move up and down. The slidable seat 11 can contact the workpiece, thereby driving the workpiece to feed.

[0085] Optimally, a fifth motor 17 is connected to the tops of the tool control device 2 and the feeding control device 3 of the present application. The fifth motor 17 drives the whole to slide back and forth on the horizontal plane through the movement of a lead screw 18, thereby adjusting the positions of the tool control device 2 and the feeding control device 3.

[0086] For the above-mentioned edge milling machine, the present application also provides an intelligent control system for a full-automatic edge milling machine. This intelligent control system can automatically identify the size of the workpiece and can adjust the milling speed and the feeding speed according to the detection results, improving the machining accuracy and production efficiency. Specifically as follows:

[0087] An intelligent control system for a full-automatic edge milling machine includes a main power and control circuit.

[0088] As Figure 4 shown, the main circuit includes a working circuit and a driving circuit. The working circuit includes relays KM2 - KM9, a total of 8 relay modules.

[0089] Relay KM1 is used to control the control circuit.

[0090] In order to achieve the purpose of controlling the rotation of the tool in the tool control device, relay KM2 is connected to motor M1, and relay KM3 is connected to motor M2. Relay KM3 is in parallel with relay KM2. When relay KM2 is closed, motors M1 and M2 rotate forward. When relay KM3 is closed, motors M1 and M2 rotate in reverse.

[0091] Relay KM4 is connected to motor M3, and relay KM5 is connected to motor M4. Relay KM4 is in parallel with relay KM5. When relay KM4 is closed, motors M3 and M4 rotate forward. When relay KM5 is closed, motors M3 and M4 rotate in reverse.

[0092] Through the above settings, the rotation speed and rotation direction of the tools in the two groups of tool control devices are controlled, thus ensuring better stability during the operation of the milling cutter. Among them, motors M1 - M4 are the four motors in the two groups of tool control devices.

[0093] In order to achieve the technical purpose of controlling the feeding speed and feeding direction in the feeding control device, relay KM6 is connected to motor M5, and relay KM7 is in parallel with relay KM6. When relay KM6 is closed, motor M5 rotates forward. When relay KM7 is closed, motor M5 rotates in reverse. Through the above settings, by switching between relay KM6 and relay KM7, the feeding direction can be adjusted. The feeding speed is controlled by the output power of motor M5. The above motor M5 is motor two.

[0094] In order to achieve the technical purpose of controlling the position of the sliding seat in the feeding control device, so that the roller and the roller shaft squeeze the workpiece and drive the workpiece to move through friction, relay KM8 is connected to motor M7. Relay KM9 is in parallel with relay KM8. When relay KM8 is closed, motor M7 rotates forward and the sliding seat moves down. When relay KM9 is closed, motor M7 rotates in reverse and the sliding seat moves up.

[0095] Through the above settings, relays KM8 and KM9 change the moving direction of the sliding seat, so that the sliding seat can contact or disengage from the workpiece. The above motor M7 is motor three.

[0096] Furthermore, the driving circuit includes fuses FU1 - FU2. A TC circuit is arranged between fuse FU1 and fuse FU2. The TC circuit is connected to the control circuit signal to perform corresponding action control on the driving circuit.

[0097] The drive circuit includes a main switch SB1, switches SB2 - SB5, contactors KM1 - KM9, and normally - closed switches KM2 - KM9. Among them, the drive circuit is divided into branch one - branch five. Branch one includes contactor KM1. When contactor KM1 closes, the control circuit starts to be powered on and work. Branch two is controlled by switch SB2 for on - off, and is divided into two circuits, namely circuit A and circuit B. Circuit A includes contactor KM2, and contactor KM2 is connected to switch KM3. Circuit B includes contactor KM3, and contactor KM3 is connected to switch KM2. When switch SB2 switches to circuit A, contactor KM2 works. At this time, switch KM2 in circuit B disconnects, and contactor KM3 disconnects. At this time, motors M1 and M2 rotate forward. When switch SB2 switches to make circuit B closed, contactor KM3 closes, making the normally - closed switch KM3 in circuit A disconnect. At this time, motors M1 and M2 rotate in reverse.

[0098] Similarly, when contactor KM4 in branch three closes, contactor KM5 is open - circuited, and motors M3 and M4 rotate forward; when contactor KM4 disconnects and contactor KM5 closes, motors M3 and M4 rotate in reverse.

[0099] When contactor KM6 in branch four closes, contactor KM7 is open - circuited, and motor M5 rotates forward; when contactor KM6 disconnects and contactor KM7 closes, motor M5 rotates in reverse.

[0100] When contactor KM8 in branch five closes, contactor KM9 is open - circuited, and motor M6 rotates forward; when contactor KM8 disconnects and contactor KM9 closes, motor M5 rotates in reverse.

[0101] The above - mentioned drive circuit provides an isolation function to prevent the equipment from being overloaded and burned due to a short - circuit in the circuit.

[0102] As Figure 5 shown, the control circuit includes a main circuit breaker QF. The main circuit breaker QF is connected to a normally - open switch KM1. When the drive circuit is powered on, contactor KM1 works, making the normally - open switch KM1 close, and the control circuit is powered on.

[0103] The normally - open switch KM1 is provided with control chips UF1 - UF3 in parallel. Control chip UF1 is used to control the tool control device. Control chip UF2 is used to control the operation of the roller in the feeding control device. Control chip UF3 is used to control the up - and - down movement of the slide.

[0104] Control chip UF1 is connected to motors D1 - D4. Motors D1 and D2 are used to control the circuit switching of switch SB2. Motors D3 and D4 are used to control the circuit switching of switch SB3.

[0105] The control chip UF2 is connected to motors D5 - D8. Motors D5 and D6 are used to control the milling angles of two groups of cutters, and motors D7 and D8 are used to control switch SB4, that is, to control the forward and reverse rotation of the roller.

[0106] The control chip UF3 is connected to motors D9 and D10. Motors D9 and D10 are used to control switch SB5, which is used to control the up and down movement of the carriage.

[0107] As described above, the control chips UF1 - UF3 transmit signals to the drive motor through the TC circuit to control the working process of each contactor. The control chips UF1 - UF3 are connected to the working circuit in the main circuit through pins R1, S1, T1 to form a closed loop.

[0108] Overall working process:

[0109] 1. Power - on preparation stage:

[0110] The three - phase AC power supply is connected to the system through the main circuit breaker QF to supply power to the overall circuit.

[0111] The control chips UF1, UF2, UF3 enter the standby state, ready to receive the start signal.

[0112] 2. Start - up stage:

[0113] The operator presses switch SB1, and the start signal is transmitted to the control chips UF1, UF2, UF3 through the control circuit. The control chips UF1 - UF3 convert the start signal into a drive signal to start the operation of each circuit. Specifically:

[0114] The cutter control device starts (controlled by UF1), and the cutter motor starts to rotate, ready for milling.

[0115] The carriage in the feeding control device moves down (controlled by UF3) and contacts the workpiece entering the bracket.

[0116] Input the milling edge angle, adjust the milling cutter angle through the control chip UF2, and make the roller in the feeding control device rotate (controlled by UF3). The sensor detects the input state of the workpiece, determines the thickness of the workpiece, and changes the parameters according to the thickness of the workpiece through an algorithm and feeds back to the control chips UF1 - UF3.

[0117] 3. Milling edge processing stage:

[0118] After the adjustment parameters are completed, the workpiece is fed into the milling position. The milling cutter rotates at high speed to mill the edges of the workpiece. At the same time, the sensor detects the edge state of the workpiece to ensure that the machining process meets the preset requirements. If an abnormality is detected (such as workpiece offset or irregular edges), the sensor will feedback the signal to the control chips UF1-UF3 to trigger a stop or adjustment action.

[0119] 4. Stop stage:

[0120] The operator presses the stop button (SB1), the overall circuit is disconnected, and waits for the next machining.

[0121] Through the cooperation of the main circuit and the control circuit, an automated process for the workpiece from feeding to machining to completion is achieved. The main circuit provides power for the motor, and the control modules (UF1, UF2, UF3) are responsible for the operation of the tool motor, the control of the feeding conveyor, and the monitoring of the workpiece state. The whole process takes the sensor feedback as a closed loop, dynamically adjusts the parameters in real time to ensure the efficiency and accuracy of machining. At the same time, it has overcurrent protection and fault shutdown functions to ensure the safe operation of the equipment.

[0122] As Figure 6 shown, in order to show the amplitude and effect of parameter changes, this application also provides an overall parameter adjustment algorithm for the control chips UF1-UF3. It includes the following steps:

[0123] 1. Parameter detection and calculation:

[0124] (1) Calculate the thickness deviation rate:

[0125] The deviation rate is the main basis for the overall parameter adjustment, used to measure the deviation degree between the workpiece thickness and the target thickness. To avoid excessive adjustment caused by too large a deviation rate, the following non-linear calculation formula is used for calculation:

[0126]

[0127] Where: T: The thickness of the workpiece detected in real time. T0 = 10mm: The target thickness. k: The adjustment coefficient (k = 0.5 can be taken), used to control the growth rate of the deviation rate.

[0128] When T is close to T0, the above formula shows linear growth. When T deviates from T0, the deviation rate tends to be stable to prevent excessive adjustment.

[0129] (2) Calculate the workpiece feed speed:

[0130]

[0131] Where, F0 = 100mm / min: The reference feed speed; K F=0.8: negative correlation adjustment coefficient, dynamically updated. δT: thickness deviation rate; F limit : Feed speed limit value (such as 0.4F0 or 1.5F0); exponential decay term When the feed speed approaches the limit, reduce the adjustment range to avoid oscillation.

[0132] (3) Calculation of spindle speed:

[0133]

[0134] Where, S0=3000rpm: reference spindle speed. K S =1.2: positive correlation adjustment coefficient, dynamically updated; δT: thickness deviation rate. S limit : The limit value of the spindle speed (can be 0.7S0 or 1.8S0).

[0135] (4) Calculation of cutting depth:

[0136] Cutting depth a p Dynamic adjustment based on workpiece thickness and tool wear status:

[0137]

[0138] Where, T: the workpiece thickness detected in real time. η∈[0.5,1.0]: tool wear compensation factor, dynamically adjusted (tool status is monitored through vibration signals).

[0139] (5) Calculation of cutting speed

[0140]

[0141] Where, D is tool diameter, in mm; S is spindle speed, in rpm.

[0142] (6) Power estimation:

[0143]

[0144] Among them, C m ≥1, is the material hardness coefficient, used to correct the power output. S: spindle speed, a p : Cutting depth. F: Feed speed.

[0145] Through the above-mentioned parameter detection and calculation process, the workpiece size, material hardness and other conditions are fully detected, and the corresponding milling cutter parameters and roller feed parameters are adjusted according to the situation of the workpiece.

[0146] 2. Adaptive adjustment

[0147] (1) Dynamic update of adjustment coefficient calculation:

[0148] Adjustment coefficient K F and K S indicate the feedback dynamic coefficient during the processing, reducing noise interference through smoothing, specifically:

[0149]

[0150] where λ = 0.95: smoothing coefficient, controlling the amplitude of adjustment update; ΔF=(F actual -F expected ) / F0: feed speed deviation; ΔS=(S actual -S expected ) / S0: spindle speed deviation; , : update threshold, used to avoid unnecessary parameter updates caused by small-amplitude noise.

[0151] (2)Parameter dynamic change calculation:

[0152] Respond and adjust parameter changes in real time, specifically as follows:

[0153] ;

[0154]

[0155] Among them, in the feed speed adjustment formula,

[0156] F(t): feed speed at the current moment t.

[0157] F(t - 1): feed speed at the previous moment t - 1.

[0158] △F(t): change in feed speed at the current moment t.

[0159] K F : feed speed adjustment coefficient (negative correlation adjustment coefficient), indicating the influence degree of thickness deviation change on the feed speed.

[0160] δT(t): thickness deviation rate at the current moment t, that is:

[0161]

[0162] δT(t - 1): thickness deviation rate at the previous moment t - 1.

[0163] F0: reference feed speed.

[0164] Among them, in the spindle speed adjustment formula:

[0165] S(t): spindle speed at the current moment t.

[0166] S(t - 1): Spindle speed at the previous moment t - 1.

[0167] ΔS(t): Change in spindle speed at the current moment t.

[0168] K S : Spindle speed adjustment coefficient (positive correlation adjustment coefficient), indicating the influence degree of thickness deviation change on spindle speed.

[0169] δT(t): Thickness deviation rate at the current moment t.

[0170] δT(t - 1): Thickness deviation rate at the previous moment t - 1.

[0171] S0: Reference spindle speed.

[0172] Through the above formula, the change in spindle speed parameter is proportional to the change in deviation rate, while the change in feed speed parameter is inversely proportional to the change in deviation rate, so as to adjust and respond to parameter changes in real time. Under the above settings, when the thickness deviation rate of the workpiece increases, the feed speed decreases and the spindle speed increases for sufficient milling. When the thickness deviation rate of the workpiece decreases, the feed speed increases and the spindle speed decreases, reducing the damage to the tool on the basis of ensuring sufficient milling.

[0173] 3. Constraint conditions:

[0174] Through cutting force constraint, specifically:

[0175]

[0176] Through power constraint, specifically:

[0177]

[0178] Through surface quality constraint, specifically:

[0179]

[0180] Through the above constraint conditions, the cutting load can be controlled to prevent the milling cutter from being overloaded, and the power can be limited to prevent the motor from being overloaded and burned out, and the ratio of cutting speed to feed speed can be ensured to meet the requirements of surface quality.

[0181] 4. Optimization objective function

[0182] Considering thickness deviation, corresponding parameter changes, energy consumption, etc. comprehensively, through the optimization objective function:

[0183]

[0184] Among them, w1, w2, w3, w4 are weight coefficients, satisfying w1 + w2 + w3 + w4 = 1. Minimize the objective function J to achieve the optimal configuration of the machining process, achieve higher machining accuracy, machining stability, and prevent component overload.

[0185] The following is an example calculation to illustrate the algorithm process described in the present invention:

[0186] Select specific workpiece parameters for calculation to show how the algorithm dynamically adjusts machining parameters.

[0187] 1. Workpiece thickness:

[0188] The actually detected workpiece thickness T = 12 mm.

[0189] The target thickness T0 = 10 mm.

[0190] 2. Reference parameters:

[0191] The reference feed rate F0 = 100 mm / min.

[0192] The reference spindle speed S0 = 3000 rpm.

[0193] The reference value of the cutting depth a p = 1.5 mm.

[0194] The tool diameter D = 50 mm.

[0195] The material hardness coefficient C m = 1.2.

[0196] 3. Adjustment coefficients:

[0197] The thickness deviation adjustment coefficient k = 0.5.

[0198] The feed rate adjustment coefficient K F = 0.8.

[0199] The spindle speed adjustment coefficient K S = 1.2.

[0200] 4. Constraint conditions:

[0201] The feed rate limit F limit = [40 mm / min, 150 mm / min].

[0202] The spindle speed limit S limit = [2100 rpm, 5400 rpm].

[0203] 1. Thickness deviation rate calculation

[0204] Calculate the thickness deviation rate according to the formula δT = k × (T - T0) / T0:

[0205] δT = 0.5 ×(12 - 10) / 10 = 0.5 × 0.2 = 0.1

[0206] 2. Calculation of workpiece feed speed

[0207] Calculate the feed speed according to the formula F = F0 × (1 - K F × δT):

[0208] F = 100 × (1 - 0.8 × 0.1) = 100 × (1 - 0.08) = 100 × 0.92 =92mm / min

[0209] At the same time, check the constraint condition, F limit = [40, 150], and the feed speed of 92mm / min is within the limit range and is valid.

[0210] 3. Calculation of spindle speed

[0211] Calculate the spindle speed according to the formula S = S0 × (1 + K S × δT):

[0212] S = 3000 × (1 + 1.2 × 0.1) = 3000 × (1 + 0.12) = 3000 × 1.12 =3360rpm

[0213] Check the constraint condition, S limit = [2100, 5400], and the spindle speed of 3360rpm is within the limit range and is valid.

[0214] 4. Calculation of cutting depth

[0215] According to the formula a p = η × T / 10 (assuming the tool wear compensation factor η = 0.8), calculate the cutting depth.

[0216] a p = 0.8 ×12 / 10 = 0.8 × 1.2 = 0.96mm

[0217] 5. Calculation of cutting speed

[0218] According to the formula V c = π × D × S / 1000, calculate the cutting speed:

[0219] V c = π× 50 × 3360 / 1000 = 3.1416 × 50 × 3360 / 1000 = 527.79m / min

[0220] 6. Power Estimation

[0221] According to the formula P = C m × a p × F × V c / 60, calculate the power:

[0222] P = 1.2 × 0.96 × 92 × 527.79 / 60 = 1.2 × 0.96 × 92 × 8.7965 =929.4W

[0223] Calculation Results:

[0224] 1. Thickness Deviation Rate: 0.1

[0225] 2. Feed Rate: 92 mm / min

[0226] 3. Spindle Speed: 3360 rpm

[0227] 4. Cutting Depth: 0.96 mm

[0228] 5. Cutting Speed: 527.79 m / min

[0229] 6. Power Estimation: 929.4 W

[0230] In the above calculation process, the system dynamically adjusted the feed rate to 92 mm / min, the spindle speed to 3360 rpm, and the cutting depth to 0.96 mm according to the deviation of the actual thickness of the workpiece (12 mm) compared with the target thickness (10 mm). The above parameter adjustments enable the milling cutter to fully mill during the machining process and avoid overload or deterioration of machining quality caused by the increase in workpiece thickness.

[0231] The intelligent control system of the present invention can respond to the workpiece state in real time and adjust the machining parameters to ensure machining accuracy and efficiency, while meeting the requirements of safety and energy consumption optimization.

[0232] Through the above algorithm settings, it is possible to detect the corresponding workpiece parameters in real time through sensors, and then adjust the milling cutter speed and feed rate. On the basis of sufficient milling, the adaptability and automation of the overall intelligent control system are improved, and different milling measures are taken for different workpieces. Compared with the method of manually adjusting parameters, the milling edge machine described in the present invention has a high degree of full automation and accuracy, thereby improving the machining accuracy and ensuring the production efficiency.

[0233] In summary, through the intelligent control system and its fully automatic milling edge machine, the present invention has achieved a comprehensive intelligent upgrade of the milling process, with remarkable technical effects. Specifically: by introducing sensors to detect key parameters such as workpiece size and thickness in real time, the system can automatically optimize machining parameters based on a dynamic adjustment algorithm, including milling speed, feed rate, and cutting depth. This intelligent feedback mechanism effectively solves the subjectivity and uncertainty problems brought about by the traditional milling edge machine relying on manual experience to set parameters, improving the machining accuracy and stability. At the same time, the realization of dynamically updating the adjustment coefficient enables the system to quickly respond to changes in the workpiece state, adapt to workpieces of different specifications and materials, and improve the adaptability and automation of the equipment.

[0234] The present invention optimizes the objective function, balances the machining efficiency and energy consumption on the basis of ensuring the machining accuracy, and further improves the overall performance. The constraint setting ensures the safe operation of the equipment, prevents overload and burnout, extends the service life of the tool and the equipment, and reduces the maintenance cost. By combining the parameter adjustment formula with nonlinear calculation and exponential decay terms, the problems of over-adjustment or response lag are avoided, ensuring the stability and efficiency of the machining process.

[0235] Through the coordinated work of the tool control device and the feeding control device, full-automatic control from workpiece feeding to the machining process is realized, significantly reducing the intervention of manual operations and improving the production efficiency.

[0236] This specific embodiment is only an explanation of the present invention, and it is not a limitation of the present invention. Those skilled in the art can make modifications without creative contributions to this embodiment according to needs after reading this specification, but as long as they are within the scope of the claims of the present invention, they are protected by the patent law.

Claims

1. An intelligent control system, characterized in that: include: Workpiece parameter detection unit, used to detect the thickness parameters of the workpiece in real time; A parameter calculation unit, used for calculating the milling speed, feed speed and cutting depth required for the machining process according to the detected workpiece parameters; The parameter calculation unit comprises: Thickness deviation rate calculation: , used to calculate the deviation between the actual thickness of the workpiece and the target thickness; where: T: the workpiece thickness detected in real time; T0: the target thickness; k: the adjustment coefficient, used to control the growth rate of the deviation rate; Feed speed calculation: , used to determine the feed speed of the workpiece according to the deviation rate; where F0: reference feed speed; K F : negative correlation adjustment coefficient; δT: thickness deviation rate; F limit : Feed speed limit value; is the exponential decay term; Spindle speed calculation: , used to determine the speed of the milling cutter according to the deviation rate; where S0: reference spindle speed; K S : positive correlation adjustment coefficient, dynamically updated; δT: thickness deviation rate; S limit : Spindle speed limit value; Cutting depth calculation: , used to determine the cutting depth according to the workpiece thickness and tool wear status; where T: the workpiece thickness detected in real time; η: tool wear compensation factor; Cutting speed calculation: , used to determine the cutting speed based on the tool diameter and spindle speed; where D is the tool diameter in mm; S is the spindle speed in rpm; Power estimation: , used to calculate the power required for the machining process; where C m , is the material hardness coefficient, used to correct the power output; S: spindle speed, a p : cutting depth; F: feed speed; An adaptive adjustment unit, used to dynamically adjust processing parameters according to calculation results; Optimize the objective function unit and determine the optimal parameter configuration based on the dynamic adjustment of processing parameters; The main circuit includes: a working circuit, which is provided with relays KM2-KM9 for controlling the operation of motors M1-M7; a driving circuit, which is provided with fuses FU1-FU2 and a TC circuit; The control circuit is provided with a main circuit breaker QF and parallel control chips UF1-UF3, wherein: The control chip UF1 is used to control the movement of the milling cutter; The control chip UF2 is used to control the workpiece feeding; The control chip UF3 is used to control the position of the slide; The control chip UF1-UF3 sends a control signal to the drive circuit through the TC circuit according to the calculation result of the parameter calculation unit, so as to realize automatic adjustment of the processing parameters.

2. The intelligent control system according to claim 1, characterized in that: The adaptive adjustment unit comprises: Dynamic update adjustment coefficient calculation module: , used to update the feed speed coefficient and spindle speed coefficient according to the actual processing effect; where λ is the smoothing coefficient, which controls the amplitude of the adjustment update; ΔF is the feed speed deviation; ΔS is the spindle speed deviation; , : Update threshold; Parameter dynamic change calculation module: ; Among them, F(t): feed speed at the current time t; F(t-1): feed speed at the previous time t-1; △F(t): change in feed speed at the current time t; K F : Negative correlation adjustment coefficient, indicating the influence of thickness deviation change on feed speed; δT(t): thickness deviation rate at current time t; δT(t-1): thickness deviation rate at previous time t-1; F0: reference feed speed; ; Used to adjust the feed speed and spindle speed in real time according to the updated coefficient; S(t): spindle speed at the current time t; S(t-1): spindle speed at the previous time t-1; ΔS(t): change in spindle speed at the current time t; K S : Positive correlation adjustment coefficient, indicating the influence of thickness deviation change on spindle speed; δT(t): thickness deviation rate at current time t; δT(t-1): thickness deviation rate at previous time t-1; S0: reference spindle speed.

3. The intelligent control system according to claim 2, characterized in that: The parameter dynamic change calculation module is also provided with constraint conditions, including: Cutting force constraints: ; Where F is the feed rate, a p is the cutting depth; Power Constraints: ; P is power; Surface quality constraints: ; V c is the cutting speed.

4. The intelligent control system according to claim 3, characterized in that: The optimization objective function is: ; Among them, w1, w2, w3, w4 are weight coefficients, satisfying w1+w2+w3+w4=1.

5. The intelligent control system according to claim 1, characterized in that: In the working circuit: Relays KM2 and KM3 are used to control the forward and reverse rotation of motors M1 and M2; Relays KM4 and KM5 are used to control the forward and reverse rotation of motors M3 and M4; Relays KM6 and KM7 are used to control the forward and reverse rotation of motor M5; Relays KM8 and KM9 are used to control the forward and reverse rotation of motor M7.

6. A fully automatic edge milling machine, characterized in that: It comprises a bracket, on which a tool control device and a feed control device are arranged; The tool control device comprises: A milling cutter, wherein the milling cutter is connected to a driving shaft, and the driving shaft is connected to the bracket by a bearing; A tool holder is arranged outside the driving shaft, and a support plate is fixedly connected to the end of the tool holder; Two motors one, connected to the drive shaft via a belt; The servo motor four is arranged on both sides of the support plate, and its output shaft is fixedly connected to the bracket; The feed control device comprises: A plurality of rollers are arranged in sequence on the bracket and connected with bearings between the brackets; A slide seat, which is arranged above the roller shaft and can move up and down; The roller is arranged in the middle of the slide and corresponds to the roller shaft; The edge milling machine is controlled by the intelligent control system described in any one of claims 1-5.

7. The fully automatic edge milling machine according to claim 6, characterized in that: The rollers are meshed and connected with each other through an odd number of gears, and one end of one of the rollers is connected to motor 2.

8. The fully automatic edge milling machine according to claim 6, characterized in that: Two pull rods are connected to the top of the slide seat, and a motor three is connected to the top of the pull rods. The motor three is a servo motor.

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