Flexible combined machine tool control system

Abstract

The invention relates to a flexible combined machine tool control system. The system comprises a multi-channel user interface module, a servo parameter monitoring module, a workpiece coordinate system management module and the like. The multi-channel user interface module is associated with a work station by means of a dynamic binding technology, automatically generates an interactive interface according to configuration parameters and visually configures an enabling state. And the servo parameter monitoring module displays and adjusts the shaft motion parameters in real time and adjusts the shaft motion parameters on line, the deviation is corrected through a self-adaptive algorithm, coordinate synchronization of multiple workstations is achieved through the algorithm and a batch writing function, and mixed analysis of an NC program and a user-defined instruction is supported. The hardware abstraction layer module encapsulates a heterogeneous control card interface, dynamically allocates hardware resources, and coordinates time sequence linkage of each part by using a state machine model. The system also combines visual inspection to correct cutter compensation parameters, and double safety protection is set. According to the invention, the problem of low equipment cooperation efficiency in multi-station flexible processing is effectively solved, and the system compatibility and the processing precision are improved.

Description

Technical Field

[0001] The present invention relates to the field of application technologies, and more specifically, to a flexible combined machine tool control system. Background Art

[0002] Traditional combined machine tool control systems generally adopt a fixed channel architecture, which has defects such as poor flexibility in workstation configuration and dependence on manual intervention for parameter adjustment. Servo control needs to be set item by item through a teach pendant and lacks real-time monitoring, resulting in low debugging efficiency and easy generation of cumulative errors. The workpiece coordinate system management depends on manual input and lacks an intelligent centering algorithm, with a significant risk of human operation errors. At the same time, the high coupling of hardware and software makes it necessary to reconstruct the system when replacing the motion control card, resulting in a sharp increase in expansion costs. When multiple workstations cooperate in operation, due to the lack of precise timing control, the synchronization error between the turntable and the fixture is relatively high, severely restricting the yield rate of precision machining. In addition, the version chaos problem caused by the extensive management of NC programs and the weak data traceability ability of the basic logging system lead to an average fault location time of up to several hours. The existing technologies in the market have not yet realized the organic integration of dynamic configuration, intelligent centering, and software-hardware decoupling, restricting the development needs of multi-variety and small-batch flexible manufacturing. Summary of the Invention

[0003] The present invention aims to overcome the above-mentioned defects of the prior art and provides a flexible combined machine tool control system, which is usually implemented based on a real-time operating system. The object of the present invention is achieved by at least one of the following technical solutions.

[0004] A flexible combined machine tool control system includes: a multi-channel user interface module for dynamically binding different workstation channels and switching the interface display content according to user selection; a servo parameter monitoring module for real-time collecting and displaying the servo parameters of the load axes of each workstation, supporting online parameter modification and zero calibration; a workpiece coordinate system management module providing a centering algorithm and batch writing function for the G5X coordinate system; an instruction parsing module for dynamically parsing the HX instruction set and controlling the processing flow; a hardware abstraction layer module for implementing the drive interface encapsulation of the motion control card and dynamic allocation of hardware resources; a workstation synchronization control module for coordinating the action timings of the turntable, fixture, and processing workstation; a tool compensation management module integrating a vision detection unit to achieve dynamic correction of tool parameters; and the system dynamically loads the workstation type parameters through a configuration file.

[0005] In one of the embodiments, the multi-channel user interface module includes: a dynamic binding unit that automatically generates a channel selection menu according to an INI configuration file; a log monitoring unit that uses a sliding window to display real-time alarm and operation logs; a handwheel control unit that integrates a multi-mode switching function; a workstation enabling configuration interface that provides checkbox controls for the participation status of each workstation. Further, the flexible combined machine tool control system realizes the dynamic binding and interface switching of workstation channels through the multi-channel user interface module. When the user selects a workstation, the corresponding configuration parameters are automatically loaded; the servo parameter monitoring module collects parameters such as the acceleration, speed, and limit of the load axis in real time and modifies them online through the motion control card interface, and combines the zero-point calibration function to eliminate mechanical errors; the workpiece coordinate system management module calculates the workpiece center coordinates using the geometric centering algorithm, supports batch writing to the G5X coordinate system of multiple workstations, and ensures the unity of the machining reference; the instruction parsing module drives the machining process by dynamically compiling the HX instruction set (such as axis enabling, IO control instructions) and executes it in coordination with the NC program; the hardware abstraction layer module encapsulates the communication protocols of control cards from different manufacturers, maps physical axes to logical axes through virtualization technology, and realizes the dynamic allocation of hardware resources; the workstation synchronization control module coordinates the timing of turntable indexing and fixture actions based on the state machine model, and uses the timestamp synchronization mechanism to control the error within ±2 ms; the tool compensation management module detects the tool wear amount through the vision system, dynamically corrects the tool compensation parameters in combination with the material property prediction model, and triggers dual shutdown protection when the compensation amount exceeds the limit; the system dynamically loads the workstation type and parameters by reading the INI configuration file, realizing the decoupling of software and hardware.

[0006] In one of the embodiments, the servo parameter monitoring module includes: a parameter visualization unit that displays acceleration, speed, limit position, and feedback position in real time in tabular form; an adaptive adjustment unit that automatically corrects motion parameters when the deviation between the actual position and the theoretical value is detected to exceed a preset threshold; a limit protection unit that dynamically adjusts the soft limit range according to the real-time position of the load axis. Further, the dynamic binding unit in the multi-channel user interface module parses the predefined station channel parameters in the INI file, automatically generates an interactive channel selection menu, and binds the corresponding data source; the log monitoring unit uses a circular buffer to store the operation logs, dynamically displays the latest alarm information and operation records through a sliding window, and supports clicking to expand the historical logs; the handwheel control unit integrates three modes: jog, continuous, and step, and parses the handwheel pulse signal into an axis motion command through a digital signal conversion module; the station enable configuration interface controls the participation status of each station through a checkbox matrix, and automatically updates the station enable register of the motion control card after being checked, realizing the dynamic scheduling of the processing flow. When the servo parameter monitoring module is initialized, it loads the hardware timer driver, collects the parameters of each axis at a 10ms cycle, and refreshes them to the visualization table; the adaptive adjustment unit compares the difference between the theoretical position and the actual feedback position, and when the deviation exceeds the preset threshold (such as ±0.01mm), it dynamically adjusts the acceleration curve using the PID algorithm; the limit protection unit dynamically calculates the soft limit range according to the real-time position of the axis, automatically reduces the motion range and triggers a warning when the axis approaches the physical limit; the zero calibration function locates the mechanical origin through the zeroing pulse signal and writes the zero offset value into the non-volatile memory of the control card.

[0007] In one of the embodiments, the workpiece coordinate system management module includes: a centering algorithm unit that automatically calculates the workpiece center coordinates based on two-point positioning; a batch writing unit that synchronously writes the same G5X parameter to multiple stations; a coordinate verification unit that detects the legality of the coordinate data through a preset tolerance range. Further, the centering algorithm unit of the workpiece coordinate system management module drives the load axis to contact the two sides of the workpiece, records the coordinates of the two points, and calculates the center position through linear interpolation, and generates the final G5X coordinate by superimposing a preset offset; the batch writing unit writes the calculated coordinate values to the specified G5X registers of multiple stations at the same time, and ensures the transmission integrity through the data check code; the coordinate verification unit compares the written value with the theoretical range, and if it exceeds the tolerance, it triggers a coordinate anomaly alarm and locks the processing flow.

[0008] In one embodiment, the tool compensation management module includes: a wear detection unit that calculates the tool wear amount through image analysis; a compensation prediction unit that generates compensation parameters in combination with material properties; and a dual protection unit that triggers shutdown protection when the compensation amount exceeds the safe range. Further, the wear detection unit of the tool compensation management module collects the tool edge image through an industrial camera, calculates the wear area through an edge detection algorithm, and predicts the remaining life in combination with the machining duration; the compensation prediction unit dynamically adjusts the compensation amount according to the hardness of the workpiece material, adopts a negative compensation strategy for soft materials such as aluminum alloy, and enables positive compensation for hardened steel; when the compensation amount exceeds the safety threshold, the dual protection unit first reduces the spindle speed and issues an audible and visual alarm, and if the limit is exceeded continuously, it cuts off the servo enable signal to force a shutdown.

[0009] In one embodiment, the instruction parsing module includes: an HX instruction library unit that includes an axis enable sub-unit, an IO control sub-unit, and a structured instruction set sub-unit for motion instructions; a multi-threaded execution engine that supports parallel parsing of NC programs and HX instructions; and a conflict detection unit that checks for instruction logic conflicts through pre-compilation. Further, the HX instruction library of the instruction parsing module pre-defines a structured instruction template, converts text instructions into binary control instructions through a syntax parser; the multi-threaded execution engine creates independent threads to separately process NC code parsing and HX instruction execution, and realizes data synchronization through shared memory; the conflict detection unit checks for spatial interference of motion instructions in the pre-compilation stage, and if it detects an overlap in the axis motion range, it marks the conflicting instructions and interrupts the loading.

[0010] In one embodiment, the hardware abstraction layer module includes: a driver interface pool that encapsulates the communication protocols of control cards from different manufacturers; a resource allocator that dynamically allocates axis numbers and IO ports; and a virtualization unit that maps physical axes to logical axes for operation.

[0011] Further, the driver interface pool of the hardware abstraction layer module integrates the SDKs of mainstream control cards such as Zhengyun and GuGao, and calls underlying functions through a unified API; the resource allocator maps physical axis numbers to logical axis indexes according to the configuration file, and supports hot swapping of the same logical axis between different control cards; the virtualization unit creates a logical axis operation interface, and the application only needs to call the "LogicAxis_Move()" function to trigger the physical axis motion, shielding hardware differences.

[0012] In one embodiment, the workstation synchronization control module includes: a state machine model that defines multi-stage states such as ready, machining, and retraction; a timing coordinator that controls the millisecond-level synchronization of turntable indexing and workstation actions; and a safety interlock unit that aborts the machining process when it detects that the fixture is not in place.

[0013] Furthermore, the state machine model of the workstation synchronization control module defines a state chain of "Ready → Moving → Working

[0014] → Return", and each state is bound to a specific instruction set; the timing coordinator aligns the indexing pulses of the turntable and the workstation start signal based on a high-precision clock source (such as the IEEE 1588 protocol), and sends a processing enable instruction after the turntable positioning is completed; the safety interlock unit monitors the signal of the fixture vacuum pressure sensor in real time. If the pressure value does not reach the set threshold, an emergency stop instruction is sent to all workstations through the CAN bus.

[0015] In one embodiment, it further includes an NC file management module, and the module includes: a dynamic loading unit that automatically identifies the storage path of the most recently used NC file; a file association unit that binds a specific NC program to the corresponding fixture arrival action; a version control unit that records the file modification history and supports the version rollback function. Further, the dynamic loading unit of the NC file management module monitors the most recently accessed folder path and captures user operation records through a file system hook; the file association unit parses special comments in the NC program (such as "#FIXTURE=3") and automatically binds the HX action file of the corresponding fixture; the version control unit uses the Git underlying engine to record the file modification history, supports backtracking to any version according to the timestamp, and realizes file difference comparison through a hash algorithm.

[0016] The present invention also provides an embodiment, including a computer-readable medium on which a computer program is stored. When the computer program is executed by a processor, a flexible combined machine tool control system is implemented. When the control program stored in the computer-readable medium is started, it loads the kernel driver module and establishes a PCIe / USB communication link with the motion control card; the main thread initializes each functional module and loads the configuration file, and the real-time task thread collects sensor data at a frequency of 1 kHz; when a user interface operation instruction is detected, the business logic of the corresponding module is triggered through a message queue. For example, the G5X coordinate writing operation will call the DLL interface of the workpiece coordinate system management module, and finally be converted into a control card-specific instruction set through the hardware abstraction layer and sent for execution.

[0017] Beneficial effects

[0018] The flexible combined machine tool control system provided by the present invention, in a complex system operation environment, the stability and accuracy of the high-precision timer are crucial. The present invention has outstanding advantages in many aspects, providing a strong guarantee for the efficient operation of the system. During the system operation, long-term interrupt disabling operations often have an adverse impact on the high-precision timer. However, the present invention, with its unique design concept, ingeniously avoids this problem. In a system that does not support interrupt nesting, other interrupts are very likely to interfere with the normal operation of the high-precision timer, resulting in timing deviations. But the present invention, through innovative technical means, successfully avoids such interference, ensuring that the high-precision timer can operate stably under various complex system conditions and maintain extremely high timing accuracy. Whether it is a single-shot timer scenario or a periodic timer scenario, the present invention can be perfectly adapted. In the application of a single-shot timer, it can accurately trigger a single timing operation, meeting the need for precise control of a specific moment. In the application scenario of a periodic timer, it can continuously work at a stable periodic frequency, providing a continuous and accurate time reference for the system. In a hard real-time scenario, the high-precision timer provided by the present invention demonstrates unparalleled accuracy advantages. In hard real-time systems with strict requirements for time accuracy, such as industrial automation control, aerospace and other fields, the present invention can provide more precise time control, greatly improving the system's response speed and operation stability, reducing potential risks caused by timing errors, and providing reliable technical support for the efficient and safe operation of various industries. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, the following drawings are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on the structures shown in these drawings.

[0020] Figure 1 For the system module block diagram of the embodiment of the present invention;

[0021] Figure 2 For the general unit configuration communication schematic diagram of the embodiment of the present invention;

[0022] Figure 3 For the equipment structure diagram of the embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0023] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts belong to the scope of protection of the present invention.

[0024] It should be noted that if there are directional indications (such as up, down, left, right, front, back...) involved in the embodiments of the present invention, the directional indications are only used to explain the relative positional relationship and movement conditions between components in a certain specific posture. If the specific posture changes, the directional indications will also change accordingly.

[0025] In addition, if there are descriptions such as "first" and "second" involved in the embodiments of the present invention, the descriptions of "first", "second", etc. are only for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include at least one such feature. In addition, if "and / or" or "and / or" appears throughout the text, its meaning includes three parallel scenarios. Taking "A and / or B" as an example, it includes scenario A, scenario B, or the scenario where A and B are satisfied simultaneously. In addition, the technical solutions between various embodiments can be combined with each other, but it must be based on the ability of those of ordinary skill in the art to implement. When the combination of technical solutions results in contradictions or cannot be implemented, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0026] Embodiment 1

[0027] In the prior art, traditional combined machine tool control systems generally adopt a fixed channel architecture, with poor flexibility in workstation configuration and parameter adjustment relying on manual intervention. Servo control needs to be set item by item through a teach pendant and lacks real-time monitoring, resulting in low debugging efficiency and easy generation of cumulative errors. The workpiece coordinate system management relies on manual input and lacks an intelligent centering algorithm, with a significant risk of human operation errors. The high coupling of hardware and software leads to the need to reconstruct the system when replacing the motion control card, and the expansion cost surges. When multiple workstations cooperate in operation, due to the lack of precise timing control, the synchronization error between the turntable and the fixture often exceeds the allowable range, severely restricting the yield rate of precision machining. The tool compensation adopts a static setting method and cannot adapt to the dynamic changes during the machining process. The rough management of NC programs causes version confusion problems, and the fault location takes a long time.

[0028] Reference Figures 1 - 3, to solve the above problems, the present application proposes a flexible combination machine tool control system including a multi-channel user interface module, a servo parameter monitoring module, a workpiece coordinate system management module, an instruction parsing module, a hardware abstraction layer module, a station synchronization control module, and a tool compensation management module. The system dynamically loads station type parameters through a configuration file.

[0029] Among them, the multi-channel user interface module refers to a configurable interface module that can automatically generate channel options according to the configuration file, which can be specifically implemented by using dynamic menu generation technology and interface content switching components, and is used to realize the dynamic binding of the station channel and the switching of display content. The servo parameter monitoring module refers to a monitoring unit with real-time data acquisition and parameter adjustment functions, which can be specifically implemented by using a sensor data stream processing engine and a parameter writing interface, and is used to collect the servo parameters of the load axis and support online modification. The workpiece coordinate system management module refers to a coordinate processing unit integrating centering algorithms and batch writing functions, which can be specifically implemented by using two-point positioning algorithms and data batch transfer protocols, and is used to automatically calculate the workpiece center coordinates and synchronously configure multiple stations. The instruction parsing module refers to a control unit that can parse structured instruction sets, which can be specifically implemented by using a syntax parser and a multi-threaded execution engine, and is used to convert HX instructions into device-executable instructions. The hardware abstraction layer module refers to an interface layer that encapsulates the motion control card driver, which can be specifically implemented by using a driver protocol conversion library and a logical axis mapping component, and is used to shield hardware differences and dynamically allocate resources. The station synchronization control module refers to a controller that coordinates the action timing of multiple devices, which can be specifically implemented by using a state machine model and a time synchronization algorithm, and is used to ensure the precise coordination of the turntable, fixture, and station. The tool compensation management module refers to a compensation parameter generation unit that combines visual detection, which can be specifically implemented by using image analysis algorithms and compensation amount prediction models, and is used to dynamically correct tool parameters.

[0030] The multi-channel user interface module is used to achieve rapid switching of different workstation configurations. Operators can select the corresponding channel according to production requirements, and the interface display content automatically matches the current workstation parameters. The servo parameter monitoring module continuously collects the operating data of each axis. When parameter deviations are detected, the operation interface synchronously displays the abnormal values and provides an immediate modification entry, enabling parameter optimization without interrupting the processing flow. The workpiece coordinate system management module automatically calculates the machining origin through two-point positioning. After verification, the calculation results are batch-written into the G5X coordinate system configurations of multiple workstations, avoiding coordinate deviations caused by manual input. The instruction parsing module decomposes HX instructions into specific axis control instructions and IO instructions, and uses a multi-threaded execution engine to parallel-process different machining instructions, improving the program execution efficiency. The hardware abstraction layer module uniformly encapsulates the communication protocols of control cards from different manufacturers. The system resource allocator dynamically allocates axis numbers and IO ports according to workstation requirements, achieving flexible configuration of hardware resources. The workstation synchronization control module establishes an action timing model to precisely coordinate the time nodes of turntable indexing and fixture positioning, ensuring the precise connection of machining actions at each workstation. The tool compensation management module detects the tool wear status through a vision system, predicts the compensation amount in combination with material properties, and automatically updates the tool parameters and triggers a protection mechanism when abnormal wear is detected.

[0031] This application further proposes that the multi-channel user interface module includes a dynamic binding unit, a log monitoring unit, a handwheel control unit, and a workstation enabling configuration interface. Among them, the dynamic binding unit is a functional module that automatically generates a channel selection menu according to a preset configuration file. Specifically, it can be implemented by cooperating an INI file parser and a menu generator, and dynamically constructs user interface elements by reading the workstation type parameters in the configuration file. The log monitoring unit is a module that uses a sliding window technology to display real-time information. Specifically, it can be implemented by combining a circular buffer and a graphical interface control, and realizes the scrolling display of alarm information and operation records. The handwheel control unit is an interactive device that integrates multiple operation modes. Specifically, it can be implemented by cooperating a multiplexer and a mode switching switch, and supports the rapid switching of different axial movements and incremental modes. The workstation enabling configuration interface is an interactive interface that centrally controls the activation status of workstations. Specifically, it can be implemented by mapping a checkbox control and a status register, and realizes the batch setting of the participation status of multiple workstations. After being parsed by the dynamic binding unit, the configuration file generates a channel selection menu, eliminating the operation of manually programming to construct a menu in the traditional architecture. The log monitoring unit uses the sliding window technology to continuously update the alarm and operation information, breaking through the information capacity limit of the traditional fixed display area. The handwheel control unit integrates the functions of multi-axis switching and incremental mode selection, enabling a single handwheel device to adapt to the requirements of different machining scenarios. The workstation enabling configuration interface realizes the parallel setting of the activation status of multiple workstations through a group of checkbox controls, avoiding the efficiency bottleneck of the traditional single-by-single operation for each workstation.

[0032] This application further proposes that the servo parameter monitoring module includes a parameter visualization unit, an adaptive adjustment unit, and a limit protection unit. Among them, the parameter visualization unit refers to a component that synchronously displays multi-dimensional servo parameters through a structured data interface. Specifically, it can use a table form to display acceleration, speed, limit position, and feedback position in real time, realizing centralized monitoring of multiple parameters and solving the problem of cumbersome operation of traditional single-point parameter viewing. The adaptive adjustment unit refers to an automatic optimization module based on dynamic deviation analysis. Specifically, it can use a position deviation threshold trigger mechanism to automatically correct motion parameters when the deviation between the actual position and the theoretical value exceeds the set range, eliminating the response delay of manual adjustment. The limit protection unit refers to a dynamic safety protection mechanism. Specifically, it can adjust the soft limit range according to the real-time position data of the load axis to avoid the risk of hardware collision caused by a fixed threshold.

[0033] The parameter visualization unit synchronously displays acceleration, speed, limit position, and feedback position in a table form, enabling operators to monitor the change trends of multiple key parameters simultaneously. The adaptive adjustment unit continuously compares the deviation between the actual position and the theoretical value. When the deviation exceeds the set threshold, it automatically adjusts the acceleration and speed parameters of the servo system to make the motion trajectory return to the theoretical value range. The limit protection unit dynamically calculates the safe travel according to the current position of the load axis and adjusts the soft limit boundary while retaining a reasonable motion margin to prevent mechanical collisions caused by cumulative errors. These three units form a closed-loop control and trigger a linkage mechanism when parameters are abnormal, which not only corrects the motion trajectory but also ensures hardware safety.

[0034] This application further proposes that the workpiece coordinate system management module includes a center-finding algorithm unit, a batch writing unit, and a coordinate verification unit. Among them, the center-finding algorithm unit refers to an operation module that automatically calculates the center coordinates of the workpiece based on two-point positioning. Specifically, it can be realized by using a coordinate transformation algorithm combined with a sensor data acquisition interface. By selecting the coordinates of two diagonal feature points on the workpiece surface for geometric center calculation, it replaces the traditional manual measurement and input method. Among them, the batch writing unit refers to a communication module that synchronously writes the same G5X parameter to multiple workstations. Specifically, it can be realized by using a broadcast communication mechanism based on the Ethernet protocol. By establishing a workstation parameter mapping table, multi-target synchronous distribution is achieved. Among them, the coordinate verification unit refers to a verification module that detects the legality of coordinate data through a preset tolerance range. Specifically, it can be realized by using an interval comparison algorithm combined with a machine tool travel parameter database for logical judgment before parameter writing.

[0035] The centering algorithm unit obtains the coordinate data of two positioning points of the workpiece through a contact probe installed on the workstation, automatically generates the geometric center coordinates of the workpiece using the vector superposition principle, and fills the calculation result into the G5X coordinate system register. The batch writing unit sends the current coordinate system parameters to the motion controllers of multiple workstations simultaneously through the hardware abstraction layer module according to the process requirements to synchronously update the reference coordinate systems of each workstation. The coordinate verification unit compares the coordinate values with the preset range of the machine tool stroke parameter database in real time during the parameter transmission process. For example, it detects whether the X-axis coordinate exceeds the effective stroke of the guide rail, or whether the Y-axis coordinate offset exceeds the clamping range of the fixture. When an abnormal value is detected, it triggers data interception and generates an alarm log. The three units form a closed-loop control process to gradually eliminate operation risks from coordinate generation, parameter synchronization to data verification.

[0036] Furthermore, this application includes a tool compensation management module. The wear detection unit calculates the tool wear amount through image analysis, the compensation prediction unit generates compensation parameters in combination with material properties, and the dual protection unit triggers shutdown protection when the compensation amount exceeds the safe range. Among them, the wear detection unit is a device that collects tool morphology data through a vision detection unit and establishes a wear amount calculation model. Specifically, it can be implemented using a high-resolution industrial camera combined with an edge detection algorithm to eliminate the subjective error of manual detection. Among them, the compensation prediction unit is a data processing module that uses material property parameters as input variables for the compensation algorithm. Specifically, it can be implemented by establishing an association model between tool wear amount and material hardness and ductility to avoid over-compensation or under-compensation problems caused by a fixed compensation mode. Among them, the dual protection unit is a control module that triggers hardware-level shutdown according to a dynamic safety threshold. Specifically, it can be implemented by real-time monitoring of the compensation amount and comparing it with the preset allowable limit value of material properties to prevent processing accidents caused by excessive tool wear. The wear detection unit collects real-time tool surface image data through the vision detection unit, extracts the change amount of tool contour features using image processing algorithms, and generates wear amount values; the compensation prediction unit generates compensation parameters based on the hardness and ductility parameters in the material database and combines the current wear amount; the dual protection unit continuously monitors the change trend of the compensation amount. When it detects that the compensation amount exceeds the allowable limit value of material properties, it directly cuts off the power output of the processing axis through the hardware interface. The three units achieve information interaction through the data bus to form a closed-loop control link.

[0037] This application includes an instruction parsing module, which includes an HX instruction library unit, a multi-threaded execution engine, and a conflict detection unit. The HX instruction library unit contains an axis enabling subunit, an IO control subunit, and a structured instruction set subunit for motion instructions. The multi-threaded execution engine supports parallel parsing of NC programs and HX instructions, and the conflict detection unit checks for instruction logic conflicts through pre-compilation. Among them, the axis enabling subunit is a unit that realizes servo axis activation control through a preset instruction format, and can specifically be implemented using a communication protocol with status code verification to ensure the rapid effectiveness of axis control instructions. The IO control subunit is a functional module that manages digital signal input and output, and can specifically be implemented using an interrupt trigger mechanism to ensure the real-time performance and reliability of signal transmission. The structured instruction set subunit is a set of instructions that encapsulates motion parameters by function grouping, and can specifically be defined using the XML format for parameter structure to reduce the complexity of instruction parsing. The multi-threaded execution engine is a parallel processing architecture that simultaneously processes NC program flows and HX instruction flows, and can specifically be implemented using thread pool technology to break through the single-thread processing speed limit. The conflict detection unit is a preprocessing module that performs logical verification before program execution, and can specifically be implemented using a syntax tree traversal algorithm to identify the mutual exclusion relationship between motion instructions and IO operations.

[0038] The axis enabling subunit in the HX instruction library unit sends an enabling signal to the servo drive through a predefined instruction format. The IO control subunit uses a priority queue to process high-priority instructions such as emergency stop signals. The structured instruction set subunit groups and encodes motion parameters according to categories such as axis number, speed, and acceleration to form a standard instruction packet. When the multi-threaded execution engine is working, it distributes the G code parsing task of the NC program and the binary data parsing task of the HX instruction to different processing threads and realizes data synchronization through shared memory. The conflict detection unit constructs an instruction execution flow chart in the pre-compilation stage and uses a depth-first search algorithm to traverse the instruction combinations that may cause conflicts. For example, a spindle start instruction issued when the fixture clamping action is not completed will be marked as a dangerous operation.

[0039] The system also includes a hardware abstraction layer module, which includes a driver interface pool, a resource allocator, and a virtualization unit. Among them, the driver interface pool refers to a technical module that standardizes and encapsulates various control card communication protocols. Specifically, it can be implemented by integrating API interfaces of different manufacturers in the form of dynamic link libraries, which is used to eliminate the direct dependence of the upper-layer system on the underlying hardware. Among them, the resource allocator refers to a scheduling unit that dynamically configures hardware resources according to real-time task requirements. Specifically, it can be implemented by combining a priority queue algorithm with a real-time task queue, which is used to avoid manual allocation errors and improve the utilization rate of axis numbers and IO ports. Among them, the virtualization unit refers to a conversion module that establishes a mapping relationship between physical hardware and the logical operation layer. Specifically, it can be implemented by combining a two-way mapping table with a parameter conversion algorithm, which is used to mask the physical parameter differences of different control cards.

[0040] Specifically, the driver interface pool converts the communication instructions of control cards from different manufacturers into a unified format through protocol encapsulation, so that the system does not need to distinguish the hardware type when calling instructions. The resource allocator dynamically allocates idle axis numbers according to the processing task priority, and automatically activates standby axis resources when a new workstation is added, eliminating the problem of resource idleness caused by fixed allocation in traditional systems. The virtualization unit converts the physical axis parameters of different control cards into standard operation instructions by establishing a logical axis operation interface, and the operator only needs to set the logical axis parameters to complete the coordinated control of multiple types of hardware.

[0041] This application further proposes a workstation synchronization control module, which includes a state machine model, a timing coordinator, and a safety interlock unit. Among them, the state machine model refers to a control model that predefines the logical relationship of the workstation operation stage. Specifically, it can be implemented by a finite state machine, which divides the processing flow into discrete states and defines the state transition conditions, which is used to ensure the process standardization of the workstation actions. The timing coordinator refers to a controller that realizes the synchronization of multi-device actions based on the hardware clock signal. Specifically, it can be implemented by an FPGA chip to achieve nanosecond-level timestamp comparison, which is used to eliminate the timing deviation between the turntable indexing and the workstation actions. The safety interlock unit refers to a protection device that judges the device state in real time through sensor signals. Specifically, it can be implemented by an optoelectronic sensor and a PLC interlock circuit, which is used to immediately terminate the processing flow when abnormal fixture positioning is detected.

[0042] During the operation of the workstation, the state machine model is constructed as a three-stage logical framework including a ready state, a processing state, and a fallback state, and each state corresponds to specific allowable conditions for workstation actions. The timing coordinator aligns the timestamps of the start moments of the turntable indexing motor and the workstation feed axis by receiving the synchronization pulse signal sent by the motion control card. For example, the tool feed action of the workstation is triggered 200 microseconds before the rotation angle of the turntable reaches the target position. The safety interlock unit continuously monitors the voltage signal of the fixture in-place sensor. When the signal level does not reach the threshold within the predetermined time window, an emergency stop command is immediately sent to the motion controller, and at the same time, the enable power supply of the servo drive is cut off.

[0043] This application includes an NC file management module, which includes a dynamic loading unit, a file association unit, and a version control unit. The dynamic loading unit refers to a component that automatically identifies the storage path of the most recently used NC file. Specifically, it can be implemented by combining a file system listener with a recently accessed timestamp sorting algorithm to quickly locate the most recently operated file. The file association unit refers to a component that establishes the logical relationship between the NC program and the corresponding fixture arrival action. Specifically, it can be implemented by establishing a mapping relationship between the program name and the fixture action code using an XML configuration file to ensure the correlation between the program and the hardware action. The version control unit refers to a component that records the file modification history and supports the restoration of historical versions. Specifically, it can be implemented using a Git version control tool or a differential backup mechanism to track the file change trajectory. The dynamic loading unit automatically generates a list of frequently used files by monitoring file access records, and operators can call the most recently used NC program without manually retrieving the storage path. The file association unit automatically retrieves the binding relationship in the configuration file when the program starts. When it detects that the fixture does not match the current program, an alarm prompt is triggered to prevent the mismatch between the program and the hardware action. The version control unit generates a timestamped backup copy every time the file is saved, and the operation interface provides a version comparison function, allowing the selection of a specific historical version for overwrite restoration. The three units form a closed-loop management mechanism: the dynamic loading unit ensures the program call efficiency, the file association unit guarantees the coordination between the program and the hardware, and the version control unit maintains the traceability of the program, jointly solving the problems of version chaos and data traceability.

[0044] Embodiment 2

[0045] This application also proposes another embodiment, a computer-readable medium, on which a computer program is stored. When the computer program is executed by a processor, it implements a flexible combination machine tool control system, and the system includes a multi-channel user interface module, a servo parameter monitoring module, a workpiece coordinate system management module, an instruction parsing module, a hardware abstraction layer module, a workstation synchronization control module, a tool compensation management module, and a configuration file dynamic loading mechanism.

[0046] Among them, the hardware abstraction layer module refers to the functional layer that realizes the encapsulation of the motion control card driver interface and the dynamic allocation of hardware resources. Specifically, it can encapsulate the communication protocols of control cards from different manufacturers through a driver interface pool, and dynamically allocate axis numbers and IO ports through a resource allocator, thereby solving the problem that the traditional system needs to reconstruct the system when replacing the motion control card. The dynamic parsing of the HX instruction set refers to the process of real-time processing of the structured instruction set. Specifically, it can support the parallel parsing of NC programs and HX instructions through a multi-threaded execution engine, and cooperate with a conflict detection unit to pre-compile and check the instruction logic conflicts, so as to improve the processing flow control efficiency. The centering algorithm unit refers to the functional module that automatically calculates the center coordinates of the workpiece based on two-point positioning. Specifically, it can calculate the coordinate parameters programmatically and batch write them into multiple workstations to avoid the error risk caused by manual input. The state machine model refers to the logical control mechanism that defines the multi-stage states of the processing flow. Specifically, it uses a timing coordinator to control the synchronization of the turntable indexing and the actions of the workstations, and detects the in-place state of the fixture through a safety interlock unit to achieve millisecond-level action coordination. The dynamic loading mechanism of the configuration file refers to the function of initializing the system configuration according to external file parameters. Specifically, it automatically generates a channel selection menu and workstation type parameters by reading the INI configuration file to achieve plug-and-play configuration.

[0047] When the computer program is executed by the processor, the hardware abstraction layer module maps the physical axes to logical axes, enabling control cards from different manufacturers to be called through a unified interface. The instruction parsing module parses the HX instruction set to generate motion instructions and synchronously processes the NC program through a multi-threaded engine. The workpiece coordinate system management module calls the centering algorithm unit to automatically calculate the center coordinates of the workpiece and batch write the G5X parameters into the specified workstations. The workstation synchronization control module coordinates the turntable indexing and the fixture actions based on the state machine model, and the timing coordinator triggers the operation instructions of each workstation through an interrupt signal. The dynamic loading mechanism of the configuration file initializes the channel selection menu and the workstation function configuration according to external configuration parameters to achieve rapid switching of different processing tasks.

[0048] Compared with the prior art, the traditional system relies on a fixed hardware architecture, resulting in the need to re-develop the driver interface when replacing the control card. However, this solution realizes protocol encapsulation through the hardware abstraction layer module, supporting the plug-and-play of different control cards. The prior art uses a manual teach pendant to set servo parameters and cannot correct them in real time. This solution online corrects the motion parameters through the adaptive adjustment unit of the servo parameter monitoring module. The traditional workpiece coordinate system relies on manual measurement and input. This solution realizes automatic calculation of two-point positioning through the centering algorithm unit, eliminating human operation errors. The multi-workstation synchronization control of the existing system relies on fixed timing logic. This solution realizes the dynamic adjustment of the action stage through the state machine model and the timing coordinator, solving the problem of cumulative errors.

[0049] Through the above technical solutions, the present application realizes the standardized encapsulation of the motion control card drive protocol, reducing the system reconstruction cost caused by hardware replacement; reduces the workpiece coordinate system setting time through the programmed centering algorithm, avoiding manual operation errors; precisely controls the timing synchronization of the turntable and workstation actions through the state machine model, improving the stability of the processing flow; the configuration file dynamic loading mechanism supports the rapid deployment of different workstation types, enhancing the flexible expansion ability of the system; the multi-threaded instruction parsing engine improves the parallel processing efficiency of NC programs and special instruction sets, shortening the processing cycle.

[0050] The above are only the preferred embodiments of the present invention, and do not limit the patent scope of the present invention accordingly. Any equivalent structural transformation made under the inventive concept of the present invention by using the content of the specification and drawings of the present invention, or direct / indirect application in other related technical fields, is included in the patent protection scope of the present invention.

Claims

1. A flexible combined machine tool control system, characterized in that, Including: A multi-channel user interface module for dynamically binding different workstation channels and switching the interface display content according to user selection; A servo parameter monitoring module for real-time collecting and displaying the servo parameters of the load axes of each workstation, supporting online parameter modification and zero calibration; A workpiece coordinate system management module providing centering algorithms and batch writing functions for the G5X coordinate system; An instruction parsing module for dynamically parsing the HX instruction set and controlling the machining process; A hardware abstraction layer module for implementing the driver interface encapsulation of the motion control card and dynamic allocation of hardware resources; A workstation synchronization control module for coordinating the action timing of the turntable, fixture, and machining workstation; A tool compensation management module integrating a vision detection unit to dynamically correct tool parameters; The flexible combination machine tool control system dynamically loads the workstation type parameters through a configuration file.

2. The flexible combined machine tool control system according to claim 1, characterized in that, It also includes: The multi-channel user interface module includes: a dynamic binding unit for automatically generating a channel selection menu according to the INI configuration file; a log monitoring unit for displaying real-time alarms and operation logs using a sliding window; a handwheel control unit integrating multi-mode switching functions; a workstation enabling configuration interface providing checkbox controls for the participation status of each workstation.

3. The flexible combined machine tool control system according to claim 1, characterized in that The servo parameter monitoring module includes: a parameter visualization unit for real-time displaying acceleration, speed, limit position, and feedback position in tabular form; an adaptive adjustment unit for automatically correcting motion parameters when the detected deviation between the actual position and the theoretical value exceeds a preset threshold; a limit protection unit for dynamically adjusting the soft limit range according to the real-time position of the load axis.

4. The flexible combined machine tool control system according to claim 1, characterized in that, The workpiece coordinate system management module includes: a centering algorithm unit for automatically calculating the workpiece center coordinates based on two-point positioning; a batch writing unit for synchronously writing the same G5X parameters to multiple workstations; A coordinate verification unit for detecting the legality of coordinate data through a preset tolerance range.

5. The flexible combined machine tool control system according to claim 1, characterized in that, The tool compensation management module includes: a wear detection unit for calculating the tool wear amount through image analysis; a compensation prediction unit for generating compensation parameters in combination with material properties; a dual protection unit for triggering shutdown protection when the compensation amount exceeds the safe range.

6. The flexible combined machine tool control system according to claim 1, characterized in that, The instruction parsing module includes: an HX instruction library unit containing an axis enabling sub-unit, an IO control sub-unit, and a structured instruction set sub-unit for motion instructions; a multi-threaded execution engine supporting parallel parsing of NC programs and HX instructions; a conflict detection unit for checking instruction logic conflicts through pre-compilation.

7. The flexible combined machine tool control system according to claim 1, characterized in that, The hardware abstraction layer module includes: a driver interface pool for encapsulating the communication protocols of control cards from different manufacturers; a resource allocator for dynamically allocating axis numbers and IO ports; a virtualization unit for mapping physical axes to logical axes for operation.

8. The flexible combined machine tool control system according to claim 1, characterized in that, The workstation synchronization control module includes: a state machine model defining multi-stage states such as ready, machining, and retracting; a timing coordinator for controlling the millisecond-level synchronization of turntable indexing and workstation actions; a safety interlock unit for aborting the machining process when the fixture is detected to be not in place.

9. The flexible combined machine tool control system according to claim 6, characterized in that It also includes an NC file management module, and the module includes: a dynamic loading unit for automatically identifying the storage path of the most recently used NC file; a file association unit for binding a specific NC program to the corresponding fixture arrival action; a version control unit for recording the file modification history and supporting the version rollback function.

10. A computer-readable medium having a computer program stored thereon, characterized in that, When the computer program is executed by a processor, it implements the flexible combined machine tool control system as described in claim 1.

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