A production system and method for high-energy efficiency components of a three-cylinder compressor

Abstract

The present invention discloses a production system and method for high - energy - efficiency three - cylinder compressor components, including: a disc magazine, a power turret CNC lathe, a truss robot, a turning and transfer device, a gripper, a workpiece positioning module, and a control system. The disc magazine is used to place and position the cylinders for the three - cylinder compressor to be machined, realizes composite positioning by inserting a mandrel into the inner hole, and supplies materials to the truss robot; the power turret CNC lathe integrates the processing functions of turning the plane, positioning holes, threaded holes, lateral suction holes, spring holes, and enthalpy - increasing holes; the truss robot cooperates with the disc magazine, the lathe, and the turning and transfer device for automatic workpiece transfer; the turning and transfer device is arranged between processes and adjusts the workpiece direction by driving a rotating platform with a servo motor; the gripper is installed at the end of the robot arm for grasping the workpiece; the workpiece positioning module is used for rapid workpiece positioning; the control system communicates with each module, monitors the tool state in real time, and triggers parameter adjustment.

Description

Technical Field

[0001] The present invention relates to the technical field of compressor component manufacturing, and specifically relates to a production system and method for high-efficiency three-cylinder compressor components. Background Art

[0002] As a core component of refrigeration and power equipment, the processing accuracy (such as flatness and hole position tolerance) and production efficiency of key components such as cylinders of a three-cylinder compressor directly affect the energy efficiency and reliability of the compressor. With the continuous growth of the market demand for high-efficiency compressors, the following limitations have gradually emerged in the traditional production technology of three-cylinder compressor components:

[0003] First of all, the coordination between loading positioning and feeding is insufficient. In the prior art, the loading of cylinder-type workpieces mostly relies on manual placement or simple bin positioning, which can only achieve single-dimensional positioning in the radial or circumferential direction, and often requires manual secondary adjustment of the direction, resulting in positioning deviation; at the same time, there is no dynamic matching mechanism between the feeding rhythm of the bin and the grasping cycle of the robotic arm, which is prone to feeding accumulation (leading to mis-grasping) or waiting (idle running of the equipment), reducing the production line efficiency.

[0004] Secondly, the integration degree of multi-process machining is low. Traditional numerical control lathes mostly adopt a single-process machining mode. Processes such as turning the plane, drilling, and tapping require multiple clamping switches. The connection between processes takes time, and the time coordination of multi-directional machining cannot be achieved, resulting in a long single-piece machining cycle and being difficult to meet the beat requirements of large-scale production of high-efficiency compressors.

[0005] Furthermore, the efficiency and accuracy of direction adjustment between processes are insufficient. Cylinder-type workpieces often need to be machined on multiple surfaces (such as the front and back end faces, and lateral hole positions). The prior art relies on manual flipping or a simple rotating table to adjust the direction, with a long adjustment time and low accuracy, which is prone to subsequent machining deviation and affects product consistency.

[0006] In addition, the management of cutting fluid and the protection of the gripper are lacking. The residual cutting fluid during the machining process is easy to corrode the gripper, and the cutting fluid drips onto the machine tool guide rail during transfer, shortening the service life of the equipment; at the same time, the grasping force control of the gripper is rough (too tight causes workpiece deformation, too loose causes falling off), further affecting the machining stability.

[0007] Finally, the monitoring of the tool state and the response to abnormalities are lagging. Traditional technologies mostly monitor tool wear through manual inspection or a single sensor (such as a current sensor), and cannot identify incipient wear in real time. Often, workpiece scrapping is caused by tool abnormalities (such as excessive wear); and when dealing with abnormalities, manual intervention is required to stop the machine and re-clamp, and it is difficult to continue machining after the interruption, resulting in a long production interruption time.

[0008] In summary, the existing production technologies for components of three-cylinder compressors have significant defects in aspects such as positioning accuracy, process integration, direction adjustment, cutting fluid protection, and tool monitoring. There is an urgent need for a production system and method with high energy efficiency, high precision, and intelligent collaboration capabilities to improve machining quality and production line efficiency and meet the large-scale production requirements of high-energy efficiency compressors. Summary of the Invention

[0009] In order to overcome the deficiencies of the prior art, the purpose of the present invention is to provide a production system and method for components of high-energy efficiency three-cylinder compressors, which are used to solve the technical problems existing in the production process of existing components of three-cylinder compressors (especially key components such as cylinders), including low positioning accuracy, poor process integration, insufficient direction adjustment efficiency and accuracy, lack of cutting fluid management, and lag in tool status monitoring.

[0010] To solve the above problems, the technical solutions adopted by the present invention are as follows:

[0011] A production system for components of high-energy efficiency three-cylinder compressors includes:

[0012] A disk magazine for placing and positioning cylinders for three-cylinder compressors to be machined and automatically feeding them to the truss robot arm.

[0013] A power turret CNC lathe configured to integrate multi-process machining functions.

[0014] A truss robot arm, which is cooperatively arranged with the disk magazine, the power turret CNC lathe, and the turning and transfer device, and is used for automatic transfer of workpieces.

[0015] A turning and transfer device, which is arranged between adjacent machining processes and is configured to adjust the direction of the workpiece within a preset time.

[0016] Jaws, which are installed at the end of the truss robot arm for gripping workpieces, and the structural design can reduce the damage of cutting fluid to the workpieces and the jaws themselves.

[0017] A workpiece positioning module, which integrates a laser displacement sensor, an industrial camera, and a vision processing unit, and is installed on the truss robot arm and the turning and transfer device. It is configured to perform multi-source data error characteristic modeling, dynamic adjustment of Kalman filter parameters, adaptive correction of reflectivity compensation parameters, and verification of positioning confidence, and output the final positioning coordinates and angle compensation values to identify the position of the workpiece.

[0018] A control system, which is communicatively connected to the disk magazine, the power turret CNC lathe, the truss robot arm, the turning and transfer device, the jaws, and the workpiece positioning module, and is configured to perform fusion analysis including multi-modal data time-frequency domain feature fusion and dynamic evolution of the random forest model to obtain the tool usage status and adjust the machining parameters.

[0019] A production method for components of a high - energy - efficiency three - cylinder compressor, comprising the following steps:

[0020] Manually place the cylinder of the three - cylinder compressor into the disc magazine in a preset direction, position the workpiece through the mandrel of the disc magazine, and automatically supply the workpiece to the truss robot arm;

[0021] After quickly determining the position of the workpiece by using the workpiece position - finding module, the truss robot arm grabs the workpiece with a gripper and transfers it to the power turret lathe;

[0022] The power turret lathe performs machining of plane turning, positioning holes, threaded holes, lateral suction holes, spring holes, and enthalpy - increasing holes;

[0023] Between adjacent processing operations, the turning and transfer device adjusts the direction of the workpiece within a preset time to provide a suitable orientation for subsequent processing;

[0024] The control system, based on multi - modal data, uses a machine - learning model to monitor the tool usage status in real time and dynamically adjusts the processing parameters to complete the automated processing of the cylinder for the three - cylinder compressor.

[0025] Preferably, when positioning the workpiece and automatically supplying it to the truss robot arm, it includes:

[0026] By inserting the mandrel into the inner hole of the workpiece, both radial and circumferential positioning of the workpiece are achieved simultaneously, and the workpiece is fixed on the surface of the disc magazine in a preset processing direction;

[0027] Through the rotary indexing device configured in the disc magazine, according to the grasping cycle of the truss robot arm, the positioned workpiece is conveyed to the grasping area of the truss robot arm at a preset beat;

[0028] During the feeding process, the contact sensor monitors the mating state between the workpiece and the mandrel. If it is detected that the workpiece is not fully sleeved on the mandrel, the disc magazine alarm is triggered and the feeding is paused;

[0029] Among them, the contact sensor is integrated at the key position where the side of the mandrel contacts the inner hole of the workpiece.

[0030] Preferably, when conveying to the grasping area of the truss robot arm, it includes:

[0031] Through the real - time interaction between the magazine controller and the control system, the actual grasping cycle T1 of the truss robot arm is obtained;

[0032] Compare the difference ΔT between the actual grasping cycle T1 and the theoretical grasping cycle T0 pre - stored in the magazine controller, and adopt a pre - compensation mechanism based on the cycle fluctuation trend to dynamically adjust the rotation speed of the rotary indexing device, so that the matching error between the actual feeding beat T2 and the actual grasping cycle T1 is lower than the set value;

[0033] Define the grasping area of the truss manipulator as the zero-position grasping point and pre-program it to be bound with the initial reset position of the truss manipulator and the starting coordinate of the motion trajectory;

[0034] Through the rotary indexing device, the positioned workpiece is pre-fed to the buffer position in the grasping area one beat cycle in advance. After the truss manipulator completes the grasping of the previous workpiece and returns to the initial position, the workpiece is pushed from the buffer position to the zero-position grasping point by the rotary indexing device.

[0035] Preferably, when monitoring the mating state of the workpiece and the mandrel, it includes:

[0036] Pre-store the standard pressure threshold P0 matching the cylinder for the three-cylinder compressor in the control system;

[0037] When the disk magazine starts, calibrate the zero point of the contact sensor through no-load testing;

[0038] When the workpiece is sleeved on the mandrel, the contact pressure value P is collected in real time through the contact sensor. If P≥P0, it is determined that it is fully sleeved. If P<P0, it is determined that it is not fully sleeved;

[0039] Among them, when it is detected that P<P0, the magazine controller triggers a three-level response mechanism.

[0040] Preferably, when using the workpiece positioning module to quickly determine the workpiece position, it includes:

[0041] Use a laser displacement sensor to scan the surface of the workpiece to obtain the initial spatial coordinates and contour features of the workpiece, providing a pre-positioning area for visual fine positioning;

[0042] Use an industrial camera to collect images of the workpiece in the pre-positioning area, and run a feature recognition algorithm through the visual processing unit to identify the key positioning features of the workpiece, and calculate the accurate coordinates and the inclination angle of the workpiece;

[0043] Input the initial spatial coordinates and the accurate coordinates into the data fusion algorithm, perform multi-source data error characteristic modeling, dynamic adjustment of Kalman filter parameters, adaptive correction of reflectivity compensation parameters, and verification of positioning confidence, and output the final positioning coordinates and angle compensation values;

[0044] Transmit the final positioning coordinates and angle compensation values to the control system through the workpiece positioning module to control the truss manipulator to dynamically adjust the grasping path.

[0045] Preferably, when transferring to a power turret numerical control lathe, it includes:

[0046] When the truss manipulator receives the final positioning coordinates and angle compensation values, dynamically adjust the jaw posture through the joint servo motor;

[0047] After the truss robot arm grasps the workpiece, it transfers along the preset lifting-translation-lowering path to the power turret CNC lathe. During the transfer process, the jaws maintain a preset inclination angle;

[0048] Before the truss robot arm reaches the lathe station, it communicates with the control system in real time to obtain the position coordinates of the current loading port of the lathe and the opening state of the fixture;

[0049] The truss robot arm fine-tunes the position of the jaws according to the obtained information and accurately places the workpiece into the lathe fixture.

[0050] Preferably, during multi-process integrated machining, it includes:

[0051] Based on the structural characteristics of the cylinder for a three-cylinder compressor, the control system pre-programs to generate a master-slave parallel machining path;

[0052] For the different process requirements of turning and drilling, the control system synchronously adjusts the parameters in real time;

[0053] After machining, the flatness of the turned plane and the position accuracy of each hole are on-line detected by the contact probe built in the lathe using a composite path of global grid scanning combined with local feature fine measurement. If the tolerance is exceeded, a multi-class compensation program based on the out-of-tolerance is triggered.

[0054] Preferably, when adjusting the workpiece direction, it includes:

[0055] After the previous process is completed, the workpiece is placed on the positioning platform of the turning transfer device by the truss robot arm;

[0056] Through the pre-programmed coordinate matching between the truss robot arm and the positioning platform, the initial position of the workpiece on the turning transfer device is fixed, providing a reference for direction adjustment;

[0057] Through the controller of the turning transfer device communicating with the lathes of the front and back processes in real time, the target angle θ1 required for the subsequent process is obtained, and the current rotation angle θ0 identified by the workpiece positioning module is synchronously received, and the required adjustment amount Δθ = θ1 - θ0 is calculated;

[0058] The workpiece is fixed by the pneumatic clamping component on the rotating platform equipped with the turning transfer device, and the servo motor drives the rotating platform according to Δθ to enable the workpiece to complete the direction adjustment within a preset time;

[0059] If tilt adjustment is required, the tilt axis built in the pneumatic clamping component acts synchronously;

[0060] After the adjustment is completed, an industrial camera equipped with the workpiece positioning module is used to collect images of the preset marks on the workpiece surface, and the actual angle θ2 of the marks is calculated through visual algorithms;

[0061] If the actual angle θ2 is lower than the target angle θ1 by less than the set value, it is determined that the adjustment is qualified. If there is an over-tolerance, the device will automatically trigger a secondary adjustment until the accuracy meets the standard.

[0062] Preferably, when the tool usage status is monitored in real time and the processing parameters are dynamically adjusted, it includes:

[0063] The control system collects tool status data in real time through various types of sensors integrated in the turret.

[0064] The control system performs fusion analysis on vibration, current, and temperature data through a machine learning model, including time-frequency domain feature fusion of multi-modal data and dynamic evolution of the random forest model, and outputs tool status labels.

[0065] Based on the tool status labels output by the machine learning model and combined with the sensor data features, the control system subdivides the abnormal types.

[0066] For the subdivided abnormal types, the control system dynamically adjusts the processing parameters according to the principle of minimum intervention - quality priority - efficiency balance to maintain the processing quality.

[0067] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0068] I. The coordination between positioning and feeding is improved, reducing the defective rate and production line waiting time.

[0069] The disk magazine adopts a core shaft radial - circumferential composite positioning (restricting horizontal offset and rotational angle deviation), combined with real-time monitoring by a contact sensor (sampling frequency ≥ 10Hz), to ensure that the workpiece is accurately fixed in the preset direction, avoiding manual secondary adjustment, eliminating the direction deviation caused by traditional single-dimensional positioning, and greatly reducing the defective rate.

[0070] The dynamic feeding beat adjustment mechanism (the matching error between the actual feeding beat and the robotic arm grasping cycle ≤ ±1 second) and the pre-feed buffer position design achieve zero-waiting synchronization of the truss robotic arm's "grasp immediately upon arrival", basically eliminating the problems of material accumulation or waiting in the production line feeding, and significantly improving the equipment utilization rate.

[0071] II. Multi-process integrated processing, greatly shortening the single-piece production cycle.

[0072] The power turret type CNC lathe integrates 6 types of processes such as turning the plane, drilling, and tapping (the 6 independent tool positions of the turret can be expanded). Through the master-slave parallel processing path planning (the time overlap between turning the plane and the positioning hole and thread hole processes ≥ 4 seconds), the traditional multi-process step-by-step processing is optimized into integrated processing, greatly shortening the single-piece processing cycle and significantly improving the production efficiency; at the same time, reducing the secondary clamping of the workpiece, effectively reducing the clamping error, and significantly improving the processing consistency.

[0073] III. The direction adjustment between processes is efficient and accurate, ensuring the quality of subsequent processing.

[0074] The turning and transfer device is driven by a servo motor to rotate the platform and implement closed-loop control through vision verification, replacing traditional manual flipping or simple turntables, ensuring that the processing orientation in subsequent processes is accurately adapted, avoiding hole position deviation caused by direction adjustment errors, and thus improving the product qualification rate.

[0075] IV. Enhancement of cutting fluid protection and gripper reliability, extending the equipment life

[0076] The gripper adopts a composite structure of corrosion-resistant alloy + elastic sealing layer, combined with the design of a diversion groove (groove depth 0.5 - 0.7 mm) and an oil-repellent coating (contact angle ≥ 110°), effectively guiding the diversion of cutting fluid and preventing adhesion, thereby extending the service life of the gripper; during the transfer process, the gripper maintains an inclination angle of 3° - 5°, basically eliminating the problem of cutting fluid dripping onto the guide rail and reducing the wear rate of the guide rail. At the same time, a pressure sensor is built into the gripper to dynamically control the grasping force (5 - 8 N), avoiding over-tight deformation or over-loose detachment, and significantly improving the grasping reliability.

[0077] V. Intelligent monitoring of tool status and rapid response to anomalies, reducing downtime losses

[0078] Multi-modal data fusion monitoring: The time-frequency domain features of vibration (band energy ratio), current (harmonic distortion rate), and temperature (change rate) are fused (generating a multi-dimensional feature vector), combined with a random forest classifier (initial training data n ≥ 2000 groups), and the accuracy of tool anomaly recognition is significantly improved compared with traditional single sensors; the dynamic evolution of the model (new anomaly type recognition) avoids missed detections and further reduces the defective product rate.

[0079] Precise adjustment of subdivided anomalies: According to the anomaly type (initial wear / medium wear / severe wear, etc.), adopt the strategy of "minimum intervention - quality first - efficiency balance". For example, in the case of initial wear, only adjust the feed rate and increase the cutting fluid flow rate (without affecting efficiency), and in the case of severe wear, only stop the abnormal tool (other tools continue to run). Compared with the traditional "speed reduction and shutdown" strategy, the effective operation time of the production line is increased and the tool replacement cost is reduced.

[0080] In summary, through multi-dimensional technological innovations, the present invention realizes high precision, high efficiency, and high reliability in the production of components of a three-cylinder compressor, providing key technical support for the large-scale manufacturing of high-efficiency compressors.

[0081] The following further elaborates on the present invention in detail in conjunction with the accompanying drawings and specific implementation manners. Brief Description of the Drawings

[0082] Figure 1 It is a process step diagram of the production method of components of a high-efficiency three-cylinder compressor according to an embodiment of the present invention;

[0083] Figure 2It is the flow chart of workpiece transportation facing the robotic arm in the embodiment of the present invention;

[0084] Figure 3 It is the flow chart of monitoring the cooperation state between the workpiece and the mandrel in the embodiment of the present invention;

[0085] Figure 4 It is the flow chart of workpiece transportation facing the lathe in the embodiment of the present invention. Detailed implementation manners

[0086] Hereinafter, exemplary embodiments of the present disclosure will be described in more detail with reference to the accompanying drawings. Although the exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided so that the present disclosure can be more thoroughly understood and the scope of the present disclosure can be fully conveyed to those skilled in the art.

[0087] Meanwhile, it should be understood that, for the sake of convenience of description, the dimensions of the various parts shown in the drawings are not drawn according to the actual proportional relationship.

[0088] The following description of at least one exemplary embodiment is merely illustrative and in no way limits the application or use of the present application.

[0089] Technologies, methods, and devices known to those of ordinary skill in the relevant art may not be discussed in detail, but where appropriate, the technologies, methods, and devices should be regarded as part of the specification.

[0090] Embodiment 1. The production system for high-energy-efficiency three-cylinder compressor parts provided by the present invention includes: a disk magazine, a power turret lathe, a truss robotic arm, a turning and transfer device, a gripper, a workpiece positioning module, and a control system.

[0091] The disk magazine is used to place and position the cylinders for the three-cylinder compressor to be machined and automatically supply materials to the truss robotic arm;

[0092] The power turret lathe is configured to integrate multi-process machining functions and can perform machining of the flat surface, positioning holes, threaded holes, lateral suction holes, spring holes, and enthalpy-increasing holes of the cylinders for the three-cylinder compressor;

[0093] The truss robotic arm is cooperatively arranged with the disk magazine, the power turret lathe, and the turning and transfer device and is used for the automatic transfer of workpieces;

[0094] The turning and transfer device is arranged between adjacent machining processes and is configured to adjust the direction of the workpiece within a preset time to shorten the subsequent machining preparation time;

[0095] The gripper is installed at the end of the truss robot arm to grab the workpiece, and the structural design can reduce the damage of cutting fluid to the workpiece and the gripper itself;

[0096] The workpiece positioning module integrates a laser displacement sensor, an industrial camera, and a visual processing unit. It is installed on the truss robot arm and the U-turn transfer device. It is configured to perform multi-source data error characteristic modeling, dynamic adjustment of Kalman filter parameters, adaptive correction of reflectivity compensation parameters, and positioning reliability verification. It outputs the final positioning coordinates and angle compensation values to identify the workpiece position.

[0097] The control system is connected to the disc hopper, power turret CNC lathe, truss robot arm, U-turn transfer device, gripper and workpiece positioning module, and is configured to perform fusion analysis including multimodal data time-frequency domain feature fusion and random forest model dynamic evolution to obtain the tool usage status. When abnormal tool usage status (such as wear and overheating) is detected, the processing parameters are adjusted to ensure product quality.

[0098] In one possible embodiment, the disc hopper is equipped with a core shaft, a rotary indexing device and a contact sensor; the contact sensor is integrated at a key position where the side of the core shaft contacts the inner hole of the workpiece, and the sampling frequency is ≥10Hz to ensure that the contact status of the workpiece and the core shaft is captured in real time.

[0099] In one possible embodiment, the workpiece positioning module is equipped with a laser displacement sensor and an industrial camera. The laser displacement sensor is used to scan the workpiece surface to obtain the workpiece's initial spatial coordinates and contour features. The industrial camera is used to capture images of the workpiece within the pre-positioning area.

[0100] In a possible embodiment, the truss robot arm is equipped with joint servo motors for dynamically adjusting the posture of the gripper.

[0101] In a possible embodiment, the clamping jaw adopts a composite structure of a corrosion-resistant alloy matrix (such as 316L stainless steel) + an elastic sealing layer (such as fluororubber), a guide groove (groove depth 0.5-0.7mm, groove width 1-2mm) is set on the inside of the clamping jaw, and an oleophobic coating (contact angle ≥110°) is wrapped on the outside; when grasping, the clamping jaw guides the cutting fluid remaining on the surface of the workpiece to both sides through the guide groove, and the oleophobic coating prevents the cutting fluid from adhering to the surface of the clamping jaw.

[0102] In a possible embodiment, the power turret CNC lathe is equipped with a built-in contact probe for online detection of the flatness of the lathe surface and the position of each hole.

[0103] In a possible embodiment, the U-turn transfer device is equipped with a rotating platform and a pneumatic clamping assembly. The pneumatic clamping assembly is installed on the rotating platform and has a built-in tilting axis.

[0104] In a possible embodiment, the turret of the power turret type CNC lathe is evenly distributed with 6 independent tool positions along the circumference (which can be expanded according to processing requirements), and a face turning tool (such as a cemented carbide turning tool), a positioning hole drill (φ3mm high-speed steel drill), a threaded hole tap (M6×1), a lateral suction hole drill (φ5mm deep hole drill), a spring hole milling cutter (R2mm ball nose milling cutter), and an enthalpy-increasing hole reamer (φ8H7) are respectively installed; the installation angles and positions of each tool are pre-adjusted through 3D simulation (such as the angle between the cutting plane of the turning tool and the axis of the drill being 90°) to ensure no spatial interference during synchronous processing.

[0105] In a possible embodiment, the positioning platform is internally provided with a groove body adapted to the outer contour of the workpiece and a contact positioning block (the material is polyurethane to avoid scratching the workpiece).

[0106] In a possible embodiment, the power turret type CNC lathe is equipped with a vibration sensor, a current sensor, and a temperature sensor. Among them, the vibration sensor is installed on the tool holder of the turret, the current sensor is connected in series to the circuit of the turret drive motor, and the temperature sensor is embedded in the joint of the tool head and the tool holder.

[0107] Example 2, refer to Figure 1 the production method step diagram of the high-efficiency three-cylinder compressor parts, the present invention provides a Figure 1 production method of high-efficiency three-cylinder compressor parts as shown in

[0108] Step S1, loading and positioning: Manually place the cylinder for the three-cylinder compressor in the disc magazine in a preset direction, position the workpiece through the core shaft of the disc magazine, and automatically supply the workpiece to the truss robot arm.

[0109] Step S2, workpiece position finding and transfer: After quickly determining the position of the workpiece by using the workpiece position finding module, the truss robot arm grabs the workpiece with the gripper and transfers it to the power turret type CNC lathe.

[0110] Step S3, multi-process integrated machining: Perform face turning, positioning hole, threaded hole, lateral suction hole, spring hole, and enthalpy-increasing hole machining through the power turret type CNC lathe.

[0111] Step S4, direction adjustment between processes: Between adjacent machining processes, the workpiece direction is adjusted by the turning and transfer device within a preset time to provide an adapted orientation for subsequent machining.

[0112] Step S5, machining process monitoring: The control system monitors the tool usage status in real time. When an abnormality (such as wear, temperature exceeding the threshold) is detected, the machining parameters (such as feed rate, rotational speed) are adjusted to ensure the quality stability of the product.

[0113] Step S6, Automatic cycle: Repeat the above steps to complete the automatic machining of the cylinder for a three-cylinder compressor, without manual intervention in the middle.

[0114] In the above step S1, when positioning the workpiece and automatically feeding it to the truss robot arm, it includes:

[0115] By inserting the mandrel into the inner hole of the workpiece, the radial positioning (restricting the horizontal offset) and circumferential positioning (restricting the rotational angle deviation) of the workpiece are achieved simultaneously, so that the workpiece is fixed on the surface of the disk magazine in the preset machining direction, avoiding the operation of manual secondary direction adjustment;

[0116] Through the rotary indexing device configured on the disk magazine, according to the grasping cycle of the truss robot arm, the positioned workpiece is conveyed to the grasping area of the truss robot arm at a preset beat (such as every 15 - 20 seconds / piece);

[0117] During the feeding process, the cooperation state between the workpiece and the mandrel is monitored through a contact sensor (such as a pressure sensor). If it is detected that the workpiece is not fully sleeved on the mandrel, the disk magazine is alarmed and the feeding is paused to avoid the risk of defective products caused by unpositioned workpieces entering the processing flow;

[0118] Among them, the grasping area is pre-programmed and matched with the movement trajectory of the truss robot arm, and the truss robot arm can directly execute the grasping action without additional path adjustment.

[0119] Refer to Figure 2 the conveying flow chart of the workpiece facing the robot arm. In a possible embodiment, when being conveyed to the grasping area of the truss robot arm, it includes:

[0120] Through the real-time interaction between the magazine controller and the control system, the actual grasping cycle T1 of the truss robot arm is obtained;

[0121] Compare the difference ΔT (ΔT = T1 - T0) between the actual grasping cycle T1 and the theoretical grasping cycle T0 pre-stored in the magazine controller, and dynamically adjust the rotational speed of the rotary indexing device to make the matching error between the actual feeding beat T2 and the actual grasping cycle T1 ≤ ±1 second, avoiding the feeding accumulation or waiting caused by the temporary acceleration and deceleration of the truss robot arm (such as after the fault recovery);

[0122] Define the grasping area of the truss robot arm as the zero-position grasping point (X3, Y3, Z3) and pre-program it to be bound with the initial reset position of the truss robot arm and the starting coordinate of the movement trajectory;

[0123] When the disc hopper is feeding, the positioned workpiece is pre-delivered to the cache position of the grabbing area by one beat cycle (e.g. 15 seconds) in advance through the rotary indexing device. After the truss robot arm completes grabbing the previous workpiece and returns to the initial position, the rotary indexing device pushes the workpiece from the cache position to the zero-position grabbing point, realizing zero-wait synchronization of the truss robot arm grabbing as soon as it is in place.

[0124] Among them, N workpiece placement positions are evenly distributed along the circumferential direction of the silo surface of the disc silo, and each placement position corresponds to a unique number (1-N); the silo controller records the number of the currently fed workpiece (such as No. k) through a counter, and dynamically plans the feeding queue according to the grasping order of the truss robot arm (such as sequential grasping 1→2→3... or intermittent grasping 1→3→5...) to ensure that there is always one and only one workpiece to be grasped in the grasping area, avoiding the risk of accidental grasping by the robot arm due to multiple workpieces entering the grasping area at the same time.

[0125] Background: In the automated production of three-cylinder compressor parts (such as cylinders), the coordination between the feeding system and the gripping action of the robotic arm is a key link affecting production line efficiency and processing stability. In traditional production technology, the feeding rhythm of the disc hopper and the gripping cycle of the truss robotic arm mainly rely on fixed parameter pre-settings and lack a dynamic matching mechanism. This leads to the following problems: disconnection between the feeding and gripping cycles, significant loss of production line efficiency, and weak abnormal response capabilities. Based on this:

[0126] In a possible embodiment, a pre-compensation mechanism based on a periodic fluctuation trend is used to dynamically adjust the rotation speed of the rotary indexing device, including:

[0127] Establish a historical grasping cycle database to record the actual grasping cycle sequence T1(n) within M consecutive cycles (n=1,2,…,M, M≥5);

[0128] The periodic fluctuation trend value ΔT_trend is calculated by the sliding window algorithm to reflect the long-term change trend of the crawling period;

[0129] When ΔT (current cycle difference) and ΔT_trend have the same sign, pre-compensation adjustment is triggered:

[0130] If ΔT>+1 second and ΔT_trend>0 (grasping cycle continues to extend), reduce the speed of the rotary indexing device by a factor of k1 (0.8≤k1<1), and extend the pre-delivery time of the next workpiece by ΔT_trend×t1 (t1 is the time compensation coefficient, unit: seconds / trend unit);

[0131] If ΔT < -1 second and ΔT_trend < 0 (the grasping cycle continuously shortens), increase the rotation speed coefficient k2 (1 < k2 ≤ 1.2) of the rotary indexing device, and shorten the pre-feeding time of the next workpiece by |ΔT_trend| × t2 (t2 is the time compensation coefficient, unit: second / trend unit);

[0132] Among them, k1, k2, t1, and t2 are compensation parameters pre-calibrated according to the mechanical characteristics of the equipment (such as the maximum acceleration and deceleration of the rotary indexing device and the motion inertia of the truss robot arm), and are determined by fitting experimental data.

[0133] In the embodiments of the present invention, it needs to be further explained that the above pre-compensation mechanism reduces the matching error between the actual feeding beat T2 and the actual grasping cycle T1, and shortens the response time of the system to sudden cycle fluctuations (such as the accelerated operation after the temporary failure recovery of the robot arm).

[0134] Refer to Figure 3 the monitoring flowchart of the fitting state between the workpiece and the mandrel. In a possible embodiment, when monitoring the fitting state between the workpiece and the mandrel, it includes:

[0135] Pre-store the standard pressure threshold P0 (such as 5 - 8N, set according to the workpiece weight and the interference fit tolerance between the inner hole and the mandrel) matching the cylinder for the three-cylinder compressor through the control system;

[0136] When the disk magazine starts, first calibrate the zero point of the contact sensor through no-load testing (no workpiece sleeved), and eliminate the baseline drift caused by environmental vibration or the self-weight of the mandrel;

[0137] When the workpiece is sleeved on the mandrel, the contact pressure value P is collected in real time through the contact sensor. If P ≥ P0, it is determined that it is fully sleeved. If P < P0 (such as P ≤ 3N), it is determined that it is not fully sleeved;

[0138] Among them, when it is detected that P < P0, the magazine controller triggers a three-level response mechanism:

[0139] First-level audible and visual alarm: The three-color indicator light (red / yellow / green) on the top of the disk magazine switches to red flashing, and at the same time the buzzer emits a high-frequency alarm (frequency 800 - 1000Hz, duration ≥ 2 seconds) to prompt the operator to check;

[0140] Second-level feeding pause: Immediately stop the operation of the rotary indexing device to prevent the unpositioned workpiece from entering the grasping area of the truss robot arm;

[0141] Third-level robot arm linkage: Send a pause grasping instruction to the truss robot arm through the industrial communication bus (such as PROFINET). After receiving it, the truss robot arm stops the current grasping action and stays in place to avoid mis-grasping the unpositioned workpiece;

[0142] After the operator confirms the abnormal fitting of the workpiece (such as workpiece tilt, inner hole blockage) and re-places it, a reset command is triggered through the operation panel of the disk magazine.

[0143] The pressure value P is re-collected through the contact sensor. If P≥P0, the alarm is turned off, the operation of the rotary indexing device is restored, and a recovery grasping command is sent to the truss manipulator to achieve a quick restart after the abnormal situation is handled.

[0144] In the above step S2, when using the workpiece positioning module to quickly determine the workpiece position, it includes:

[0145] The surface of the workpiece is scanned by the laser displacement sensor equipped in the workpiece positioning module to obtain the initial spatial coordinates (X0, Y0, Z0) and contour features of the workpiece, quickly narrowing the positioning range within ±2mm to provide a pre-positioning area for visual fine positioning.

[0146] The industrial camera equipped in the workpiece positioning module is used to collect images of the workpiece in the pre-positioning area (the collection frequency ≥ 30 frames per second), and the feature recognition algorithm (such as edge detection based on HOG features + SIFT feature point matching) is run through the built-in vision processing unit to identify the key positioning features of the workpiece (including the inner hole edge, end face marking line, preset positioning hole), and calculate the accurate coordinates (X1, Y1, Z1) of the workpiece and the workpiece tilt angle θ.

[0147] The initial spatial coordinates (X0, Y0, Z0) and the accurate coordinates (X1, Y1, Z1) are input into the data fusion algorithm (such as Kalman filter), combined with the workpiece material reflectivity compensation parameter (for the reflection interference caused by the residual cutting fluid), and the final positioning coordinates (X, Y, Z) and the angle compensation value φ are output.

[0148] The final positioning coordinates (X, Y, Z) and the angle compensation value φ are transmitted to the control system through the workpiece positioning module to control the truss manipulator to dynamically adjust the grasping path to ensure the precise alignment of the gripper with the part of the workpiece to be grasped.

[0149] Background description: In the automated production of cylinder - type components of a three - cylinder compressor, the precise positioning of the workpiece is the core prerequisite for ensuring subsequent machining accuracy (such as flatness and hole position accuracy). In traditional technologies, workpiece position finding mainly relies on a single sensor (such as a laser displacement sensor or an industrial camera). Three - cylinder compressor cylinders are mostly made of aluminum alloy (high reflectivity) or cast iron (low reflectivity), and cutting fluid (a transparent liquid that easily forms specular reflection) often remains on the surface after machining. When the laser irradiates a workpiece with high reflectivity or the reflective area of the cutting fluid, the sensor is prone to signal saturation due to excessive echo; while for materials with low reflectivity (such as cast iron), due to weak echo, signal loss is likely to occur. Visual positioning depends on key features on the workpiece surface (such as the edge of the inner hole and marking lines), but the residual cutting fluid will blur the feature boundaries; at the same time, the low surface contrast of materials with low reflectivity (such as cast iron) is likely to lead to failure in feature extraction. Therefore, the existing workpiece position finding is difficult to meet the manufacturing requirements of high - efficiency compressors in terms of positioning accuracy and stability. Based on this:

[0150] In a possible embodiment, when outputting the final positioning coordinates (X, Y, Z) and the angle compensation value φ, it includes:

[0151] Modeling the error characteristics of multi - source data:

[0152] Pre - establish an error characteristics database for the laser displacement sensor and the industrial camera, where:

[0153] The error model of the laser displacement sensor is: ΔL = k3·d + k4·ρ + εL (d is the measurement distance, ρ is the surface reflectivity of the workpiece, k3 and k4 are calibration coefficients, and εL is the first random noise);

[0154] The error model of the industrial camera is: ΔC = m1·θ + m2·σ1+ εC (θ is the tilt angle of the workpiece, σ1 is the reflective intensity of the cutting fluid, m1 and m2 are calibration coefficients, and εC is the second random noise);

[0155] Among them, the error model is determined by fitting through repeated positioning experiments (n≥50 times) of standard parts (such as an aluminum alloy cylinder with known surface reflectivity).

[0156] Dynamic adjustment of Kalman filter parameters:

[0157] Input the initial spatial coordinates (X0, Y0, Z0) and the exact coordinates (X1, Y1, Z1) into the Kalman filter as state variables, and the state vector is defined as [X, Y, Z, φ] (φ is the angle compensation value);

[0158] Dynamically adjust the process noise covariance matrix Q according to the current workpiece material (such as aluminum alloy / cast iron): If the material is high-reflectivity aluminum alloy (ρ≥0.6), increase the noise variance of the Z-axis in Q (σ²_Z = 0.05 mm²) to suppress the laser overexposure error; if it is low-reflectivity cast iron (ρ≤0.3), increase the noise variance of the X-Y plane (σ²_XY = 0.03 mm²) to compensate for the fuzzy visual feature recognition.

[0159] Dynamically correct the measurement noise covariance matrix R according to the degree of cutting fluid residue: Calculate the proportion S of the reflective area (S = number of reflective pixels / total number of pixels) through the gray histogram of the industrial camera image. If S≥30% (severe reflection), increase the noise variance of the visual coordinates in R (σ²_C = 0.02 mm²); if S≤10% (slight reflection), decrease the noise variance of the laser coordinates in R (σ²_L = 0.01 mm²).

[0160] Adaptive correction of reflectivity compensation parameters:

[0161] The reflectivity ρ of the workpiece material is calculated through the echo intensity I of the laser displacement sensor: ρ = α·I + β (α and β are sensor calibration coefficients);

[0162] For the reflective interference caused by cutting fluid residue, collect the RGB image of the workpiece surface through an industrial camera, extract the average gray value G of the blue channel (the characteristic color of cutting fluid), establish the compensation coefficient γ = 1 - k5·G (k5 is an empirical coefficient, with a value range of 0.01 - 0.03), and the final reflectivity compensation parameter is ρ' = ρ·γ;

[0163] If the positioning errors of 3 consecutive workpieces (the position deviation detected after actual grasping) are all > 0.03 mm, trigger the self-learning of compensation parameters: Correct the values of α, β, and k5 through the least squares method to improve the matching degree of ρ' with the actual reflective influence to ≥95%.

[0164] Verification of positioning confidence:

[0165] When outputting the final positioning coordinates (X, Y, Z) and the angle compensation value φ, synchronously calculate the confidence index C based on the positioning error output by the error model;

[0166] If C < 0.8 (low confidence), trigger secondary positioning: The laser displacement sensor scans the workpiece surface again (the scanning density is increased by 50%), the industrial camera switches to the near-focus mode (the resolution is increased from 1 million pixels to 2 million pixels), and the data fusion process is executed again until C≥0.8 and then the result is output.

[0167] In the embodiments of the present invention, it needs to be further explained that the "data fusion algorithm and the dynamic correction process of the reflectivity compensation parameter" proposed in this embodiment realizes the deep fusion of laser and vision data by establishing a multi-sensor error model, dynamically adjusting the filtering parameters, adaptively correcting the reflectivity compensation value, and introducing a confidence verification mechanism, and solves the problem of insufficient accuracy caused by reflective interference, material differences, and cutting fluid residues in traditional positioning technologies.

[0168] Refer to Figure 4 the conveying flowchart of the workpiece facing the lathe. In the above step S2, when transferring to the power turret lathe, it includes:

[0169] When the truss robot arm receives the final positioning coordinates (X, Y, Z) and the angle compensation value φ output by the workpiece positioning module, it dynamically adjusts the gripper posture through the joint servo motor, so that the gripping surface of the gripper is completely attached to the part of the workpiece to be gripped (such as the outer cylindrical surface of the cylinder). At the same time, the pressure sensor built in the gripper monitors the gripping force in real time. When the gripping force reaches the preset threshold (such as 5-8N), the gripper is locked to avoid workpiece deformation caused by over-tightening or dropping caused by over-loosening;

[0170] After the truss robot arm grabs the workpiece, it transfers to the power turret lathe along the preset lifting-translation-lowering path. During the transfer process, the gripper maintains an inclination angle of 3°-5° (the drainage groove is facing downwards), so that the residual cutting fluid continuously drains to the workshop waste liquid collection system (integrated with the production line) through the drainage groove and from the surface of the gripper, avoiding the cutting fluid from dripping onto the machine tool guide rail during the transfer process;

[0171] Before the truss robot arm reaches the lathe station, it communicates with the control system in real time through an industrial bus (such as PROFINET) to obtain the position coordinates (X2, Y2, Z2) of the current loading port of the lathe and the fixture opening state;

[0172] The truss robot arm fine-tunes the position of the gripper according to the obtained information, accurately places the workpiece in the lathe fixture, and then the gripper releases and returns to the initial position, completing the automated loading without manual intervention.

[0173] In the above step S3, during multi-process integrated machining, it includes:

[0174] Based on the structural characteristics of the cylinder for the three-cylinder compressor (such as the end face diameter and the distribution positions of each hole), the control system pre-programs to generate the master-slave parallel machining path: taking the process of turning the plane as the benchmark (processing time T3 = 8-10 seconds), the processes of positioning holes and threaded holes start 1-2 seconds after the turning tool contacts the end face of the workpiece (processing time T4 = 6-8 seconds), so that the processing time of the process of turning the plane overlaps with that of the processes of positioning holes and threaded holes by ≥4 seconds; the lateral processes of the lateral suction holes, spring holes, and enthalpy-increasing holes start when 50% of the plane turning is completed, realizing the time coordination of multi-directional machining;

[0175] According to the different process requirements of turning and drilling, the control system adjusts the parameters in real-time and synchronously: when turning the plane, the rotational speed is maintained at 1500 rpm and the feed rate is 0.1 mm / r; when drilling, the rotational speed is maintained at 800 rpm and the feed rate is 0.05 mm / r;

[0176] If it is detected that the hardness fluctuation of the workpiece material exceeds the threshold (feedback through the cutting force sensor), the feed rates of the turning tool and the drill bit are synchronously adjusted (for example, if the hardness increases by 10%, the feed rate decreases by 0.01 mm / r) to ensure that the surface roughness of the turned plane and the positional tolerance of the drilled holes meet the standards synchronously;

[0177] After the machining is completed, the flatness of the turned plane (tolerance ≤ 0.05 mm) and the positional accuracy of each hole (such as the relative positional tolerance between the threaded hole and the lateral suction hole ≤ 0.1 mm) are detected online through the contact probe built in the lathe. If the tolerance is exceeded, the abnormal tool number is automatically recorded and the compensation program is triggered to achieve the closed-loop precision control of synchronous machining.

[0178] Background description: Traditional inspections mostly use "single-point sampling" or "random sampling in key areas" (such as only detecting 4 points at the center and four corners of the plane), covering less than 30% of the workpiece surface area. For areas prone to deformation due to cutting force such as the cylinder end face (such as local protrusions at the edge due to tool deflection), single-point detection cannot capture the true deviation of flatness (the actual maximum deviation may occur in the untested edge area), resulting in a large error in flatness evaluation and unable to provide an accurate basis for tool compensation. In addition, traditional inspections only collect the center point coordinates of key holes such as threaded holes and lateral suction holes, ignoring the positional deviations in different directions around the holes (such as the offset of one side of the hole due to drill bit yaw). For example, if the actual deviation of the hole position is "0.12 mm to the left and 0.03 mm to the right", only measuring the center point will result in the wrong conclusion of "deviation 0.075 mm" (the actual positional tolerance exceeds the standard), resulting in the compensation program not being triggered or being wrongly adjusted, and there is still a risk of hole position deviation in subsequent machining. The detection path of traditional contact probes has fixed parameters and cannot adapt to cylinder workpieces of different sizes. Based on this:

[0179] In a possible embodiment, when using a composite path of global grid scanning combined with local feature fine measurement to detect the flatness of the turned plane and the positional accuracy of each hole online, it includes:

[0180] Global scanning: Taking the center of the turned plane as the origin, collecting the height data of N points (N ≥ 20) at a grid spacing of 5 mm × 5 mm (covering a plane area ≥ 90%), and calculating the flatness (fitting the reference plane by the least squares method and taking the maximum and minimum height differences);

[0181] Local precise measurement: For each hole position (such as threaded holes, lateral suction holes), 4 detection points are evenly distributed around the hole, the hole position coordinates (X_i, Y_i) are collected, and the positional tolerance is calculated (by the root mean square value of the coordinate deviation in the reference coordinate system);

[0182] The detection path is generated by pre-programming the control system and the grid spacing is dynamically adjusted according to the workpiece size (such as the plane diameter D) (the spacing is 3mm when D≤50mm, and the spacing is 5mm when D>50mm) to ensure the balance between detection coverage and efficiency.

[0183] In the embodiments of the present invention, it needs to be further explained that the above composite detection path of global grid scanning combined with local feature precise measurement ensures the comprehensiveness of flatness evaluation through grid scanning covering more than 90% of the plane area, captures the true deviation of positional tolerance through multi-point precise measurement around the hole, and dynamically adjusts the detection parameters according to the workpiece size, thoroughly solving the problems of incomplete coverage and poor adaptability of traditional detection, and providing accurate data support for closed-loop compensation.

[0184] Background description: In traditional technologies, when the flatness or the positional tolerance of the hole position is detected to be out of tolerance, compensation is triggered only through simple threshold judgment (such as "stop when out of tolerance"), without analyzing the specific type of out-of-tolerance (for example, is the flatness out of tolerance due to tool wear or abnormal cutting parameters? Is the single-hole positional tolerance out of tolerance due to drill bit deviation or fixture looseness?). This "one-size-fits-all" compensation method often leads to:

[0185] When the flatness is out of tolerance, the drill bit parameters are wrongly adjusted (unrelated to the turning tool), and the compensation is ineffective; [[ID=1...]]

[0186] When the single-hole positional tolerance is out of tolerance, the entire set of tools is blindly replaced (in fact, only a single drill bit is offset), resulting in waste of resources;

[0187] When the multi-hole correlation is out of tolerance, the fixture is not calibrated (in fact, the fixture is loose), and subsequent workpieces continue to be out of tolerance.

[0188] In a possible embodiment, a closed-loop precision control for synchronous machining is implemented by adopting multi-class compensation based on out-of-tolerance, including:

[0189] When the flatness is out of tolerance (>0.05mm): It is determined that the turning tool is worn or the cutting parameters are abnormal, the historical machining data of the turning tool (such as cumulative cutting time, cutting depth) is automatically retrieved, the tool compensation value Δd is calculated through a linear regression model, and the Z-axis compensation value of the turning tool is increased by Δd;

[0190] When the single-hole positional tolerance is out of tolerance (>0.1mm): It is determined that the positioning of the corresponding drill bit is offset, the X / Y-axis compensation amounts Δx, Δy of the drill bit are calculated through coordinate transformation, and the initial positioning coordinates of the drill bit are adjusted;

[0191] Multiple-hole position tolerance correlation out-of-tolerance (≥2 hole position deviation directions are the same): It is determined that the lathe fixture is loose or the reference coordinate system is offset, triggering the fixture calibration procedure (repositioning the fixture zero point through a standard part), and recording the fixture number and calibration time.

[0192] In the embodiments of the present invention, it needs to be further explained that the above-mentioned multiple types of compensation based on out-of-tolerance classify out-of-tolerance into three categories: flatness out-of-tolerance, single-hole position tolerance out-of-tolerance, and multiple-hole correlation out-of-tolerance, and trigger corresponding compensation, thereby improving compensation accuracy, resource utilization rate, and quality consistency, and solving the core contradiction that the compensation strategy does not match the problem in the traditional technology.

[0193] In step S4 above, when adjusting the workpiece direction, it includes:

[0194] After the previous process (such as OP1) is completed, the workpiece is placed on the positioning platform of the turning transfer device by the truss robot.

[0195] Through the pre-programmed coordinate matching between the truss robot and the positioning platform, the initial position of the workpiece on the turning transfer device is fixed, providing a reference for direction adjustment.

[0196] Through the real-time communication between the controller of the turning transfer device and the lathes of the previous and subsequent processes (such as OP1 lathe, OP2 lathe), the processing requirement data of the subsequent process (such as the target angle θ1 required by the subsequent process) is obtained, and the initial orientation data (such as the current rotation angle θ0) identified by the workpiece positioning module is synchronously received, and the required adjustment amount Δθ = θ1 - θ0 is calculated; (if OP2 needs to perform machining of the flat surface, positioning holes, threaded holes, lateral suction holes, spring holes, and enthalpy-increasing holes under the reverse plane of the workpiece, the target adjustment angle is 180° (rotation around the Z axis));

[0197] The workpiece is fixed (to prevent rotation offset) by the pneumatic clamping component on the rotating platform equipped with the turning transfer device (clamping force 10 - 15N, response time ≤0.3 seconds), and the servo motor drives the rotating platform according to Δθ, so that the workpiece completes the direction adjustment within a preset time (such as ≤5 seconds).

[0198] If tilt adjustment is required (such as OP3 needs to machine a 45° inclined hole), the built-in tilt axis of the pneumatic clamping component moves synchronously to achieve multi-dimensional orientation adaptation of horizontal rotation + tilt.

[0199] After the adjustment is completed, an industrial camera equipped with the workpiece positioning module is used to collect images of the preset marks (such as the crosshair marked by laser) on the workpiece surface, and the actual angle θ2 of the mark is calculated through visual algorithms.

[0200] If the actual angle θ2 and the target angle θ1 are less than or equal to the set value (e.g. |θ2-θ1|≤0.5°), the adjustment is considered qualified. If it exceeds the tolerance, the device automatically triggers a secondary adjustment (repeating the above steps) until the accuracy meets the standard, avoiding subsequent processing deviation caused by adjustment error;

[0201] The U-turn transfer device's adjustment time (≤5 seconds) is pre-matched with the processing cycles of the preceding and following processes (e.g., 15 seconds for OP1 and 15 seconds for OP2). Once the adjustment is complete, the truss robot arm immediately grabs the workpiece and transfers it to the subsequent process. If the preceding process is completed ahead of schedule (e.g., OP1 takes only 12 seconds), the U-turn transfer device automatically enters standby cache mode (maintaining the workpiece orientation) while waiting for the truss robot arm to trigger the transfer command, thus avoiding equipment idling or workpiece backlogs caused by cycle fluctuations.

[0202] If the workpiece is detected to be loose during the adjustment process (feedback from the pressure sensor of the pneumatic clamping component, the pressure value is <8N) or visual verification shows that the tolerance is exceeded for three consecutive times (|θ2-θ1|>0.5°), the U-turn transfer device will immediately trigger an alarm (three-color light flashes red + buzzer), and suspend the previous process processing and the adjustment work of the U-turn transfer device through the control system to prevent the workpiece that has not been adjusted into place from flowing into the subsequent links; after the operator checks for abnormalities (such as pneumatic clamping component failure, rotating platform failure, mark wear) and repairs them, the U-turn transfer device will be restarted to automatically clear the error record and resume the normal adjustment process.

[0203] In the above step S5, the real-time monitoring of the tool usage status and adjustment of the processing parameters include:

[0204] The control system collects tool status data in real time through multiple types of sensors integrated into the turret:

[0205] Vibration sensor: monitors high-frequency vibration signals during tool cutting and identifies abnormal vibrations caused by tool wear;

[0206] Current sensor: monitors the motor load current and reflects changes in tool cutting resistance (such as tool wear, chip blockage, or abnormal workpiece hardness);

[0207] Temperature sensor: monitors the cutting temperature of the tool to prevent tool annealing failure caused by excessive cutting heat;

[0208] The control system uses machine learning models (such as random forest classifiers) to fuse and analyze vibration, current, and temperature data and output tool status labels.

[0209] The control system uses the tool status labels output by the machine learning model and combines them with sensor data features (such as vibration frequency band energy, current harmonic distortion rate, and temperature change rate) to subdivide the abnormality types.

[0210] For specific abnormal types, the control system dynamically adjusts the processing parameters to maintain the processing quality.

[0211] Background description: In the precision machining of cylinder parts of a three-cylinder compressor, the real-time and accurate monitoring of the tool state is the core link to ensure the processing quality (such as flatness and hole position accuracy) and the stability of the production line. In traditional technologies, the monitoring of the tool state mainly relies on a single sensor (such as a current sensor) or simple data overlay analysis, resulting in a low accuracy rate of tool state recognition. Based on this:

[0212] In a possible embodiment, when performing fusion analysis, it includes the time-frequency domain feature fusion of multi-modal data and the dynamic evolution of the random forest model;

[0213] Among them, the time-frequency domain feature fusion of multi-modal data: Cross-scale feature extraction is performed on the original data of vibration, current, and temperature sensors:

[0214] Vibration signal: Decomposed into 6 frequency bands of 10 - 500 Hz through continuous wavelet transform (CWT), and the energy ratio of each frequency band (reflecting the high-frequency impact of tool edge micro-cracking) and kurtosis value (reflecting the non-Gaussian characteristics of abnormal impact) are extracted;

[0215] Current signal: The root mean square value of the 0 - 10 Hz low-frequency component (reflecting the motor load fluctuation caused by tool wear) and the harmonic distortion rate of the 10 - 50 Hz intermediate-frequency component (reflecting the periodic load change caused by chip jamming) are extracted through STFT (short-time Fourier transform);

[0216] Temperature signal: Calculate Δ_T / Δt (temperature change rate) and T_max (highest temperature) through a sliding window (window length 60 s), reflecting the degree of cutting heat accumulation (risk of tool annealing);

[0217] Finally, a fusion vector of multi-dimensional features (such as vibration frequency band energy ratio, current harmonic distortion rate, temperature change rate, etc.) is generated as the input of the random forest classifier.

[0218] Among them, the dynamic evolution of the random forest model: The initial model is trained based on historical data (n≥2000 groups, covering all stages of the tool life cycle), and contains 100 decision trees, each tree corresponding to an abnormal mode (initial wear, moderate wear, severe wear, chip entanglement, workpiece material abnormality);

[0219] When it is detected that the "unrecognized state" is output continuously for 3 times (that is, the model cannot match the known abnormal modes), trigger the model evolution:

[0220] Screen 10% of the unrecognized data (samples with the largest feature differences) through the active learning algorithm and push them to the operator for abnormal type annotation (such as "tool coating peeling off");

[0221] Update the random forest in an incremental learning manner (preserving the original tree structure and adding 20 new trees for new anomaly classification), and eliminate redundant features (features with importance < 0.05) through feature importance ranking (Gini index);

[0222] Through this mechanism, the model can identify new anomaly types and the model size remains stable.

[0223] In the embodiments of the present invention, it needs to be further explained that through multi-time scale feature extraction in the above fusion analysis process, the model can capture all-dimensional features of the tool state (such as vibration high-frequency energy ratio, current harmonic distortion rate), and the recognition accuracy is greatly improved; through model dynamic evolution, the ability to identify new anomaly types (such as coating peeling) is obtained, avoiding the increase in defective product rate caused by missed detection, and solving the technical problems of "one-sided feature extraction, poor model adaptability, and fuzzy anomaly attribution" in traditional tool state monitoring.

[0224] Background description: In the precision machining of cylinder parts of a three-cylinder compressor, the adjustment strategy of machining parameters when a tool anomaly occurs is the core contradiction point for balancing quality stability and production line efficiency. In traditional technologies, when a tool anomaly (such as increased vibration or current) is detected, only a unified adjustment strategy of "reducing speed and stopping" or "changing tool" is triggered through simple threshold judgment, without distinguishing the specific types of anomalies. Traditional adjustments only focus on a single parameter (such as reducing the rotational speed) and do not consider the synergistic effect of multiple parameters (such as the linked adjustment of feed rate, cutting depth, and cooling parameters), resulting in technical problems of "excessive intervention affecting efficiency" or "insufficient intervention leading to quality out of control". Based on this:

[0225] In a possible embodiment, the anomaly types can be subdivided into:

[0226] Initial wear (label A): The tool has micro-cracking (the energy ratio of the 100 - 500 Hz frequency band in vibration > 15%), and the cutting force fluctuates slightly (the root mean square value of the current ≤ 11 A);

[0227] Moderate wear (label B): The tool is dull (the energy ratio of the 50 - 100 Hz frequency band in vibration > 25%), and the motor load increases (the root mean square value of the current is 11 - 12 A);

[0228] Severe wear (label C): The tool wear amount > 0.3 mm (the temperature change rate ΔT / Δt > 2 °C / s), and the cutting heat increases significantly (the temperature T > 180 °C);

[0229] Chip clogging (label D): The chip winds around the tool tip (the current harmonic distortion rate > 15%), and the vibration signal shows periodic impacts (the energy ratio of the 10 - 50 Hz frequency band in vibration > 30%);

[0230] Insufficient cutting fluid (Label E): Cooling failure (temperature T > 200 °C), and the feedback value of the cutting fluid flow sensor < 80% of the rated flow rate.

[0231] In a possible embodiment, the control system dynamically adjusts the machining parameters according to the principle of minimum intervention - quality priority - efficiency balance, including:

[0232] Initial wear (Label A): Only adjust the feed rate F of the corresponding tool, keep the rotational speed S and the cutting depth ap unchanged, delay wear without reducing efficiency; simultaneously increase the cutting fluid flow rate Q to 110% of the rated flow rate, and reduce the accumulation of cutting heat by strengthening cooling.

[0233] Moderate wear (Label B): Coordinately adjust the feed rate and the rotational speed to reduce the cutting load; adjust the cutting depth ap to 90% of the rated cutting depth to reduce the single - cut amount; trigger the tool turret pre - tightening program to increase the hydraulic clamping force and prevent the tool from loosening and aggravating wear.

[0234] Severe wear (Label C): Immediately stop the machining of the current tool (rotational speed S = 0), but keep other tools (such as an unworn drill bit) running (multi - tool turret independent control); adjust the machining parameters of the unworn tool (such as the drill bit rotational speed S = 800 rpm → 700 rpm, feed rate F = 0.05 mm / r → 0.04 mm / r) to avoid the interruption of the entire process due to the abnormality of a single tool.

[0235] Chip blockage (Label D): Pause the supply of cutting fluid (to prevent chip adhesion), start the reverse rotation program (S = - 500 rpm, for 2 seconds), throw off the entangled chips by reverse rotation; adjust the chip conveyor rotational speed (from 100 rpm to 150 rpm) to enhance the chip removal ability; after resuming machining, reduce the feed rate by 15% to reduce the chip generation amount.

[0236] Insufficient cutting fluid (Label E): Immediately turn off the cutting fluid pump (to prevent dry cutting from damaging the tool), start the standby cutting fluid tank switching program (switching time ≤ 2 seconds); adjust the rotational speed (such as the lathe tool rotational speed S = 1500 rpm → 1200 rpm) to reduce the cutting heat generation rate.

[0237] In the embodiments of the present invention, it needs to be further explained that the above - mentioned dynamic adjustment process accurately maps the abnormal characteristics and adjustment strategies through "sub - dividing the abnormal types + three - principle adjustment", and guides the decision - making with a clear priority, solving the core contradictions of "inaccurate, uncoordinated, and unscientific" parameter adjustment in the traditional technology.

[0238] Finally: The above - mentioned are only the preferred embodiments of the present invention and are not used to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A production method of high-energy-efficiency three-cylinder compressor parts, characterized in that, The following steps are involved: The cylinders for the three-cylinder compressor are manually placed in the disc hopper according to the preset direction. The workpiece is positioned by the disc hopper mandrel and automatically fed to the truss robot arm. After the workpiece location is quickly determined using the workpiece positioning module, the workpiece is grabbed by the truss robot arm using a gripper and transferred to the power turret CNC lathe; Use power turret CNC lathe to perform machining of planes, positioning holes, threaded holes, side air intake holes, spring holes and enthalpy increase holes; Between adjacent processing steps, the workpiece direction is adjusted within a preset time through the U-turn transfer device to provide an appropriate position for subsequent processing; The control system uses a machine learning model based on multimodal data to monitor tool usage in real time and dynamically adjust machining parameters to complete the automated machining of cylinders for three-cylinder compressors. When adjusting the workpiece direction, including: After the previous process is completed, the workpiece is placed on the positioning platform of the U-turn transfer device through the truss robot arm; By matching the pre-programmed coordinates of the truss robot arm and the positioning platform, the initial position of the workpiece on the U-turn transfer device is fixed, providing a reference for direction adjustment; The controller of the U-turn transfer device communicates with the lathes of the previous and next processes in real time to obtain the target angle θ1 required by the subsequent process, and simultaneously receives the current rotation angle θ0 identified by the workpiece positioning module, and calculates the required adjustment amount Δθ=θ1-θ0; The workpiece is fixed by the pneumatic clamping assembly on the rotating platform equipped with the U-turn transfer device. The servo motor drives the rotating platform according to Δθ to complete the direction adjustment of the workpiece within the preset time. If tilt adjustment is required, the tilt axis built into the pneumatic clamping assembly will act synchronously; After the adjustment is completed, the industrial camera equipped with the workpiece positioning module is used to capture the image of the preset mark on the workpiece surface, and the actual angle θ2 of the mark is calculated by the visual algorithm; If the actual angle θ2 and the target angle θ1 are lower than the set value, the adjustment is judged to be qualified. If it exceeds the tolerance, the device automatically triggers a secondary adjustment until the accuracy meets the standard.

2. The production method of the high energy efficiency three-cylinder compressor parts according to claim 1, characterized in that, When positioning the workpiece and automatically feeding the gantry robot arm, including: By inserting the core shaft into the inner hole of the workpiece, the radial and circumferential positioning of the workpiece are achieved simultaneously, so that the workpiece is fixed on the surface of the disc silo in the preset processing direction; Through the rotary indexing device configured in the disc silo, the positioned workpiece is transported to the grasping area of the truss robot arm at a preset beat according to the grasping cycle of the truss robot arm; During the feeding process, the contact sensor monitors the matching status of the workpiece and the mandrel. If it detects that the workpiece is not completely inserted into the mandrel, the disc hopper alarm is triggered and the feeding is suspended. The contact sensor is integrated at a key position where the side surface of the core shaft contacts the inner hole of the workpiece.

3. The production method of the high-energy efficiency three-cylinder compressor component according to claim 2, characterized in that, When transported to the gripping area of the truss robot, this includes: The actual grasping cycle T1 of the truss robot arm is obtained through real-time interaction between the silo controller and the control system; Compare the difference ΔT between the actual grabbing cycle T1 and the theoretical grabbing cycle T0 pre-stored in the silo controller, and use a pre-compensation mechanism based on the cycle fluctuation trend to dynamically adjust the speed of the rotary indexing device so that the matching error between the actual feeding beat T2 and the actual grabbing cycle T1 is lower than the set value; Define the grasping area of the truss manipulator as the zero-position grasping point and pre-programmatically bind it to the initial reset position of the truss manipulator and the starting coordinates of the motion trajectory; Through the rotary indexing device, the positioned workpiece is pre-fed to the buffer position in the grasping area one beat cycle in advance. After the truss manipulator completes the grasping of the previous workpiece and returns to the initial position, the workpiece is pushed from the buffer position to the zero-position grasping point by the rotary indexing device.

4. The production method of the high-energy efficiency three-cylinder compressor component according to claim 2, characterized in that, When monitoring the mating state of the workpiece and the mandrel, it includes: The control system pre-stores the standard pressure threshold P0 matched with the cylinder for the three-cylinder compressor; When the disk magazine starts, calibrate the zero point of the contact sensor through no-load testing; When the workpiece is sleeved on the mandrel, the contact pressure value P is collected in real time by the contact sensor. If P≥P0, it is determined that the workpiece is fully sleeved. If P<P0, it is determined that the workpiece is not fully sleeved; Among them, when it is detected that P<P0, the magazine controller triggers a three-level response mechanism.

5. The production method of the high energy efficiency three-cylinder compressor parts according to claim 1, characterized in that, When using the workpiece positioning module to quickly determine the workpiece position, it includes: Use a laser displacement sensor to scan the surface of the workpiece to obtain the initial spatial coordinates and contour features of the workpiece, providing a pre-positioning area for visual fine positioning; Use an industrial camera to collect images of the workpiece in the pre-positioning area, and run a feature recognition algorithm through the visual processing unit to identify the key positioning features of the workpiece, and calculate the accurate coordinates and the inclination angle of the workpiece; Input the initial spatial coordinates and accurate coordinates into the data fusion algorithm, perform multi-source data error characteristic modeling, dynamic adjustment of Kalman filter parameters, adaptive correction of reflectivity compensation parameters, and verification of positioning confidence, and output the final positioning coordinates and angle compensation values; Through the workpiece positioning module, transmit the final positioning coordinates and angle compensation values to the control system to control the truss manipulator to dynamically adjust the grasping path.

6. The production method of the high-energy-efficiency three-cylinder compressor component according to claim 5, characterized in that When transferring to the power turret lathe, it includes: When the truss manipulator receives the final positioning coordinates and angle compensation values, dynamically adjust the jaw posture through the joint servo motor; After the truss manipulator grasps the workpiece, it transfers to the power turret lathe along the preset lifting-translation-lowering path. During the transfer process, the jaws maintain the preset inclination angle; Before the truss manipulator reaches the lathe station, communicate with the control system in real time to obtain the position coordinates and fixture opening status of the current loading port of the lathe; The truss manipulator fine-tunes the jaw position according to the obtained information and accurately places the workpiece in the lathe fixture.

7. The production method of the high energy efficiency three-cylinder compressor parts according to claim 1, characterized in that When performing multi-process integrated machining, it includes: Based on the structural characteristics of the cylinder for the three-cylinder compressor, the control system pre-programs and generates the master-slave parallel machining path; For the different process requirements of turning and drilling, the control system synchronously adjusts the parameters in real time; After machining, use the contact probe built into the lathe to perform on-line detection of the flatness of the turned plane and the position accuracy of each hole by using a composite path of global grid scanning combined with local feature fine measurement. If the tolerance is exceeded, trigger various compensation programs based on the tolerance.

8. The production method of the high-energy efficiency three-cylinder compressor parts according to claim 1, characterized in that When real-time monitoring the tool usage status and dynamically adjusting the machining parameters, it includes: The control system collects the tool status data in real time through various types of sensors integrated in the turret; The control system performs fusion analysis on vibration, current, and temperature data through a machine learning model, including multi-modal data time-frequency domain feature fusion and dynamic evolution of the random forest model, and outputs tool status labels. Based on the tool status labels output by the machine learning model and combined with the sensor data characteristics, the control system subdivides the abnormal types. For the subdivided abnormal types, the control system dynamically adjusts the processing parameters according to the principle of minimum intervention - quality priority - efficiency balance to maintain the processing quality.

9. A production system for high - energy - efficiency three - cylinder compressor components, characterized in that, During operation, the method described in claim 1 is executed, including: A disk magazine for placing and positioning the cylinder for a three-cylinder compressor to be processed and automatically feeding the truss robot arm. A power turret CNC lathe configured to integrate multi-process machining functions. A truss robot arm, cooperatively arranged with the disk magazine, the power turret CNC lathe, and the turning and transfer device, for automatic transfer of workpieces. A turning and transfer device, arranged between adjacent processing operations, configured to adjust the workpiece direction within a preset time. Jaws, installed at the end of the truss robot arm, for gripping workpieces, and the structural design can reduce the damage of cutting fluid to the workpieces and the jaws themselves. A workpiece positioning module, integrating a laser displacement sensor, an industrial camera, and a vision processing unit, and installed on the truss robot arm and the turning and transfer device, configured to perform multi-source data error characteristic modeling, dynamic adjustment of Kalman filter parameters, adaptive correction of reflectivity compensation parameters, and verification of positioning confidence, and output the final positioning coordinates and angle compensation values to identify the workpiece position. A control system, communicatively connected to the disk magazine, the power turret CNC lathe, the truss robot arm, the turning and transfer device, the jaws, and the workpiece positioning module, configured to perform fusion analysis including multi-modal data time-frequency domain feature fusion and dynamic evolution of the random forest model to obtain the tool usage status and adjust the processing parameters.

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