An error compensation method and system for compression spring manufacturing

Abstract

This invention provides an error compensation method and system for compression spring manufacturing, relating to the field of feedback control technology. The method includes: analyzing compression spring design drawings and functional parameter targets; decomposing the compression spring structure to obtain structural functional zones; analyzing the relationship between manufacturing parameters and the response of the compression spring manufacturing materials and structure to establish the process-compression spring structure influence relationship; configuring processing compensation dimensional space; allocating space to obtain the compensation gradient for each structural functional zone; collecting real-time processing flow data during compression spring manufacturing; identifying manufacturing errors; and performing process analysis compensation based on the compensation gradient to obtain error compensation control parameters. This invention solves the technical problem in traditional compression spring manufacturing processes where each processing node is often treated as an independent process step, lacking a systematic analysis of the relationships between process steps, leading to incomplete or ineffective compensation, thus failing to achieve the expected product quality.

Description

Technical Field

[0001] This invention relates to the field of feedback control technology, and specifically to an error compensation method and system for the manufacture of compression springs. Background Technology

[0002] Compression springs are crucial components widely used in various mechanical equipment, automobiles, and home appliances. Due to their excellent elasticity under pressure and deformation, the precise manufacturing of compression springs is essential to the overall quality and performance of the product. As processing progresses, manufacturing errors gradually accumulate. For example, during molding, mold wear or uneven temperature may cause slight deviations in the spring's dimensions; and during heat treatment, uneven heating and cooling may lead to changes in the spring's hardness and size. These errors are often difficult to detect and correct in a timely manner, ultimately potentially causing the product to exceed tolerance limits.

[0003] In the traditional compression spring manufacturing process, each processing node is often regarded as an independent process step, and there is a lack of systematic analysis of the relationship between these process steps. The impact of the processing parameters of each process node on different structural parts of the compression spring is often not accurately quantified and optimized. Due to the lack of in-depth understanding and analysis of the response relationship between process and structure, it is difficult to achieve targeted compensation. Even if compensation is performed in some nodes, the impact of early or late processing on other parts of the compression spring may not be taken into account, resulting in incomplete compensation or failure, thus failing to achieve the expected product quality. Summary of the Invention

[0004] This application provides an error compensation method and system for compression spring manufacturing, aiming to solve the technical problem that in the traditional compression spring manufacturing process, each processing node is often treated as an independent process step, lacking a systematic analysis of the relationship between process steps, resulting in incomplete or failed compensation, and thus failing to achieve the expected product quality.

[0005] The first aspect disclosed in this application provides an error compensation method for compression spring manufacturing. The method includes: analyzing compression spring design drawings and functional parameter targets; decomposing the compression spring structure to obtain structural functional partitions; analyzing the relationship between processing parameters of the manufacturing process and the response of the compression spring manufacturing materials and the compression spring structure to establish a process-compression spring structure influence relationship; configuring processing compensation dimension space based on the process-compression spring structure influence relationship; allocating space to the structural functional partitions according to the processing compensation dimension space to obtain the compensation gradient of each structural functional partition; collecting real-time processing flow data during the compression spring manufacturing process, identifying manufacturing errors, and performing process analysis compensation for the manufacturing errors based on the compensation gradient of each structural functional partition to obtain error compensation control parameters.

[0006] The second aspect of this application discloses an error compensation system for compression spring manufacturing. This system is used in the aforementioned error compensation method for compression spring manufacturing. The system includes: a compression spring structure decomposition module for analyzing compression spring design drawings and functional parameter targets, decomposing the compression spring structure to obtain structural functional partitions; a response relationship analysis module for analyzing the response relationship between processing parameters of the manufacturing process and the compression spring manufacturing materials and structure, establishing a process-compression spring structure influence relationship; a compensation space configuration module for configuring processing compensation dimension space based on the process-compression spring structure influence relationship; a space allocation module for allocating space to the structural functional partitions according to the processing compensation dimension space, obtaining the compensation gradient of each structural functional partition; and a process analysis compensation module for collecting real-time processing flow data during compression spring manufacturing, identifying manufacturing errors, and performing process analysis compensation on the manufacturing errors based on the compensation gradient of each structural functional partition to obtain error compensation control parameters.

[0007] One or more technical solutions provided in this application have at least the following beneficial effects:

[0008] By analyzing the design drawings and functional parameters of the compression spring, the spring structure is decomposed and functional zones are obtained. This ensures targeted correction of errors in each area during subsequent compensation, avoiding over- or under-compensation and improving overall machining accuracy. Analyzing the response relationship between machining parameters and the spring manufacturing material and structure establishes the process-spring structure influence relationship. This analysis identifies and quantifies the impact of each node in the machining process on the spring structure, providing data support for further error compensation. Based on the process-spring structure influence relationship, machining compensation dimensional space is configured to reserve necessary correction space for potentially error-prone areas during machining, thereby preventing and mitigating machining errors in advance and ensuring the final product meets design requirements. Based on the machining compensation dimensional space, the structural functional zones are then... By allocating space and obtaining compensation gradients for each structural functional zone, necessary dimensional compensation is provided for each compression spring component. This not only helps to precisely control each area during the processing but also enables gradual compensation throughout the manufacturing process, thereby reducing the impact of errors on the final product performance. By collecting real-time processing flow data, errors occurring during manufacturing can be identified in real time. This real-time capability allows compensation to be dynamically adjusted during processing without relying on later corrections, avoiding error accumulation. By using the established compensation gradients to perform process analysis compensation for manufacturing errors and combining them with actual errors for real-time compensation control, precise error compensation control parameters are obtained. This ensures that errors during processing are corrected to the greatest extent possible, thereby reducing deviations in the final product, improving the control capability of the manufacturing process, and ultimately enhancing the overall quality and consistency of the compression springs.

[0009] The above description is only an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, specific embodiments of this application are given below. Attached Figure Description

[0010] Figure 1 This is a schematic flowchart of an error compensation method for manufacturing compression springs, provided as an embodiment of this application.

[0011] Figure 2 This is a schematic diagram of an error compensation system for manufacturing compression springs, provided as an embodiment of this application.

[0012] Explanation of reference numerals in the attached diagram: 10 for compression spring structure decomposition module, 20 for response relationship analysis module, 30 for compensation space configuration module, 40 for space allocation module, and 50 for process analysis and compensation module. Detailed Implementation

[0013] This application provides an error compensation method and system for compression spring manufacturing, which solves the technical problem that in the traditional compression spring manufacturing process, each processing node is often regarded as an independent process step, lacking a systematic analysis of the relationship between process steps, resulting in incomplete or ineffective compensation, and thus failing to achieve the expected product quality.

[0014] After introducing the basic principles of this application, various non-limiting embodiments of this application will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative of this application and are not intended to limit this application.

[0015] Example 1, as Figure 1 As shown in the figure, this application provides an error compensation method for compression spring manufacturing, the method comprising:

[0016] Analyze the design drawings and functional parameters of the compression spring, decompose the compression spring structure, and obtain the structural functional partitions.

[0017] Using drawing reading and recognition tools, key data in the design drawings are extracted. Common design drawings include the shape, number of coils, diameter, length, and material of the compression spring. The functional parameter targets in the drawings are determined, such as pressure, elasticity, and lifespan. Each target corresponds to a specific functional requirement that the compression spring must meet during use. Based on the spring's structure and design requirements, the spring is divided into zones, for example, based on functions such as the end coils, effective coils, and support coils. Each functional zone has different stress requirements and deformation behaviors. Functional constraints and target parameters for each zone are defined. For example, the end coil zone involves compressive stress, while the support coil zone focuses on stability. Since the design objectives for each zone are different, the manufacturing process for each region needs to consider its structural response separately.

[0018] The relationship between the processing parameters of the manufacturing process and the response of the compression spring manufacturing material and compression spring structure is analyzed to establish the influence relationship between process and compression spring structure.

[0019] The purpose of analyzing the relationship between processing parameters and the response of the compression spring structure is to analyze how different processing parameters affect the structural characteristics of the compression spring, thereby providing data support for subsequent error compensation. Specifically, the manufacturing process involves multiple processing steps, such as stretching, bending, and compression. The parameters of each processing step, such as temperature, pressure, and processing speed, directly affect the final product characteristics. Detailed analysis of different processing nodes is conducted to identify how processing parameters affect different structural functional areas of the compression spring. For example, deformation and stress distribution that may occur during processing will affect the final performance of the compression spring.

[0020] Besides processing parameters, the manufacturing material of the compression spring is also an important factor affecting the quality of the finished product. The physical properties of different materials, such as elastic modulus and hardness, will affect their response during processing. By analyzing the elasticity, plasticity, strength and other properties of different materials, we can understand their deformation behavior during processing. In combination with the characteristics of different materials, we can analyze the influence of different processing parameters on the materials. For example, heating temperature and cooling rate may affect the hardness of the material, thereby affecting the strength and elasticity of the compression spring.

[0021] Through the analysis in the first two steps, the relationship between processing parameters, material properties and compression spring structure is systematically analyzed and modeled. Experimental data, numerical simulation and other means can be used to quantify the impact of each processing step on the compression spring structure, establish the influence relationship between processing technology and compression spring structure, and provide a theoretical basis for error compensation.

[0022] Based on the aforementioned process-compression spring structure influence relationship, the machining compensation dimension space is configured.

[0023] Based on the established process-compression spring structure influence relationship, we can understand the impact of different processing techniques (such as tension, bending, compression, etc.) on the compression spring dimensions. By collecting data during the processing, such as processing parameters, material properties, processing temperature, and the dimensions of the compression spring sample, we can calculate the possible error range of different processing steps. By comprehensively analyzing the dimensional error and influencing factors of each processing node, we can construct a dimensional space for processing compensation. This space includes how to compensate for errors by adjusting processing parameters at each processing node so that the final compression spring dimensions meet the design requirements.

[0024] Based on the processing compensation size space, the structural functional partitions are spatially allocated to obtain the compensation gradient of each structural functional partition.

[0025] Based on the processing compensation space, the space of each structural functional zone of the compression spring is allocated. This means that, based on the structural characteristics, functional requirements and processing errors of each zone, the range of dimensions that need to be adjusted for each zone is determined. For example, the end zone plays a more critical role in the function of the compression spring and requires more precise compensation, while the support ring zone has a higher tolerance for errors and can appropriately reduce the amount of compensation.

[0026] The compensation gradient can be understood as the amount of compensation required for each functional zone based on the actual error. Calculating the compensation gradient is a quantification process of how much compensation is needed for each functional zone. The compensation gradient is calculated based on the error magnitude and design requirements of each zone. For example, if the error of a certain structural functional zone is large, such as non-compliance with roundness standards, then the compensation gradient for that zone will be larger, requiring more processing and adjustments. Conversely, zones with smaller errors will have smaller compensation gradients. Ultimately, through calculation and allocation, the compensation gradient for each structural functional zone is obtained. These compensation gradients directly guide subsequent error compensation control parameters, ensuring that the compression spring can be adjusted according to predetermined targets during processing to achieve the final functional requirements.

[0027] Real-time processing flow data during the compression spring manufacturing process is collected to identify manufacturing errors. Based on the compensation gradient of each structural functional partition, the manufacturing errors are analyzed and compensated to obtain error compensation control parameters.

[0028] At various processing nodes of the compression spring, monitoring points are selected, such as key locations during the bending, stretching, or compression processes. Sensors and measuring tools, such as displacement sensors, pressure sensors, and temperature sensors, are installed to collect data in real time during the compression spring manufacturing process. This data includes parameters such as dimensional changes, deformation, processing accuracy, temperature, and pressure of the compression spring, and is integrated to obtain real-time processing flow data. The real-time processing flow data is analyzed to identify errors in the manufacturing process. For example, if the dimensional deviation of the compression spring exceeds the preset allowable error range, or if shape deformation occurs during processing, such as poor roundness, these are identified as manufacturing errors.

[0029] Based on the compensation gradient of each structural functional zone, manufacturing errors are compensated at the process level. That is, error compensation is carried out step by step according to different manufacturing processes. For example, if the size is found to be too large in a certain stage of the compression spring, such as the stretching process, the processing parameters of that process can be adjusted according to the compensation gradient, or adjustments can be made in subsequent processing to ensure that the final compression spring meets the design requirements.

[0030] Finally, through process analysis and compensation of error compensation, error compensation control parameters for real-time control are generated. These control parameters will adjust the processing in real time during the manufacturing process to ensure that the compression spring ultimately meets the design requirements and functional objectives.

[0031] Furthermore, by analyzing the compression spring design drawings and functional parameters, the compression spring structure is decomposed to obtain structural functional zones, including:

[0032] The compression spring design drawings are identified and segmented according to the standard functions of the end area, effective coil area, and support coil area to obtain the functional zones of each standard compression spring; the structural response target is analyzed for the functional parameter target to obtain the structural constraint characteristics of each standard compression spring functional zone; based on the structural constraint characteristics, the functional zones of the standard compression spring are constrained by partition feature constraints to obtain the structural functional zones.

[0033] Define different functional areas of the compression spring, including the end area, effective coil area, and support coil area. The end area comprises the two ends of the compression spring, typically requiring consideration of end-face flatness and contact surface accuracy. The effective coil area is the working part of the compression spring, involved in important functions such as elasticity and load distribution. The support coil area, located at both ends of the compression spring, primarily supports and bears the load, ensuring stability. Using CAD tools or automated drawing recognition software, extract the dimensions and locations of relevant areas from the design drawings. By setting standard zoning rules, divide the different parts of the design drawings into end areas, effective coil areas, and support coil areas, forming a standardized compression spring functional zoning diagram. This ensures that the design requirements and constraints of each area can be analyzed and processed individually.

[0034] Each functional zone has different functional requirements. Structural response analysis is performed on the functional objectives of each zone. For example, for the end zone, the analysis addresses how to ensure end-face flatness and how to avoid unevenness during processing; for the effective ring zone, the analysis addresses how to control elasticity and deformation to ensure uniform load transfer; and for the support ring zone, the analysis addresses how to ensure stability and prevent deformation or instability caused by external forces. Based on these functional parameter objectives, structural constraint characteristics are defined for each zone. For example, the end zone may have a constraint of "end-face accuracy error not exceeding 0.1mm," and the effective ring zone may have a constraint of "within the elastic modulus range," etc.

[0035] Based on the structural response objectives and constraint characteristics of each functional partition, detailed characteristic constraints are defined for each functional partition. By applying these constraints, the structural characteristics and functional requirements of each partition are finally determined, forming standardized structural functional partitions. These partitions will become the basis for subsequent error compensation and optimization.

[0036] Furthermore, structural response target analysis is performed on the aforementioned functional parameter targets to obtain the structural constraint characteristics of each standard compression spring functional zone, including:

[0037] The structural characteristics of the compression springs are analyzed by performing structural characteristic tests on the functional parameter targets to obtain the structural characteristics corresponding to each functional parameter target. The structural constraint requirements of each standard compression spring functional area are analyzed using the structural characteristics to obtain the structural constraint characteristics of each standard compression spring functional area, including flatness, pitch uniformity, roundness standard, and surface quality.

[0038] Each functional zone has different functional parameter targets, which need to be achieved through structural features. For example, the achievement of end face flatness is closely related to processing accuracy and equipment adjustment, while the elastic modulus of the effective coil area is directly related to material selection and processing technology. A series of experiments are conducted on the compression spring to obtain its structural characteristics. For example, end zone tests are conducted to evaluate the processing accuracy of the end face by measuring end face flatness and contact surface quality; effective coil zone tests are conducted to evaluate structural characteristics such as elastic modulus and stress distribution through loading tests; and support coil zone tests are conducted to evaluate the deformation of the compression spring under load through load tests to ensure its stability. Experimental data can be collected using various measuring equipment, such as laser measuring instruments, electron microscopes, and universal testing machines. Through experimental data analysis, the structural characteristics corresponding to each functional parameter target are determined.

[0039] Based on the obtained structural characteristics, specific structural constraint analysis is performed for each functional zone of the compression spring, and the constraint requirements and standards of each functional zone are transformed into specific structural constraint characteristics. Among these, flatness is required to ensure good contact surface during use, avoiding uneven pressure distribution caused by uneven end faces. This can be controlled by measuring the height difference of the end areas and the flatness of the contact surfaces. The quality of the contact surface in the end areas affects the stress performance of the compression spring, and the roughness of the contact surface must meet the design requirements. Pitch uniformity is crucial to the elasticity and working load distribution of the compression spring. Uniformity is ensured by accurately measuring the pitch difference between each coil; uneven pitch may lead to unbalanced loading and deformation of the compression spring. Roundness standard affects the uniform deformation and stress distribution of the compression spring. The effective coils of the compression spring should have strict roundness requirements to avoid uneven load transmission caused by roundness deviations. The surface quality of the support coil area is directly related to the stability and load-bearing capacity of the compression spring.

[0040] Furthermore, based on the structural constraint features, the standard compression spring functional partitions are subjected to partition feature constraints to obtain the structural functional partitions, including:

[0041] Based on the structural constraint features, the standard compression spring functional partition is projected to determine the structural constraint partition; the partition is then uniformly divided according to the position distribution range of the constraint structure to obtain structural constraint slices; the constraint structure features are then projected and allocated to the structural constraint slices to establish constraint mapping relationships and obtain the structural functional partition.

[0042] Mapping the structural constraint features of each functional zone to the actual structural position of the compression spring means projecting the previous structural constraint requirements onto the corresponding functional zones in the design drawings. For example, the flatness error requirement of the end zone will be projected onto the end position of the compression spring, and the pitch uniformity requirement will be projected onto each coil of the effective coil zone. Through projection, the specific constraint range of each zone can be clarified, forming structural constraint zones.

[0043] Based on the constraint partitions, the constraint intervals of each partition are evenly divided into several smaller intervals. These smaller intervals are called structural constraint slices. For example, in the effective ring area, according to the pitch uniformity requirements, each ring in the effective ring area is divided into several slices. Each slice is responsible for a specific pitch uniformity requirement. The end area can also be sliced ​​according to the flatness error requirements.

[0044] Each structural constraint feature is projected onto each slice region according to the distribution of the slices, and each slice region obtains the corresponding structural constraint feature. For example, the constraint of pitch uniformity is evenly distributed to each slice of the effective coil region, and the constraint of end flatness is distributed to each slice of the end region. This slice distribution can be achieved through mathematical models, simulation software or CAD tools to ensure that the constraint features of each slice region are accurately projected and distributed.

[0045] After projection allocation, a constraint mapping relationship is established, that is, the correspondence between the structural features and constraint requirements of each slice area in each compression spring functional partition. This mapping relationship ensures that the design of each partition can accurately meet its functional requirements and provides a detailed basis for subsequent production and quality control.

[0046] Furthermore, the relationship between the processing parameters of the manufacturing process and the response of the compression spring manufacturing material and the compression spring structure is analyzed to establish the influence relationship between the process and the compression spring structure, including:

[0047] Collect monitoring samples from each node of the processing flow, including processing technology monitoring data of compression spring samples of different quality grades; analyze the influence parameters of different processing flow nodes on the compression spring structure based on the monitoring samples; use the compression spring manufacturing material as the test sample, analyze the influence relationship of process parameters on the compression spring manufacturing material by adjusting the process parameters of the processing flow nodes; fuse the influence parameters and the influence relationship to obtain the process-compression spring structure influence relationship.

[0048] The manufacturing process of compression springs typically includes multiple stages, such as forming, heat treatment, and surface treatment. Each stage involves different processing parameters, and monitoring data is collected at each processing node. For example, at the forming node, pressure, temperature, and deformation are collected; at the heat treatment node, heating temperature, cooling rate, and hardness testing are collected; and at the surface treatment node, surface roughness and coating thickness are collected. These monitoring data are collected on compression springs of different quality grades to analyze the impact of different processes on the quality grade of the compression springs.

[0049] Statistical analysis was performed on the collected monitoring samples to identify the impact of each stage of the processing on the compression spring structure. For example, the effects of pressure and temperature applied during molding on the spring's size, shape, and stress distribution; the effects of temperature changes, heating and cooling rates during heat treatment on material properties such as spring hardness, toughness, and elastic modulus; and the effects of surface treatment on the spring's surface quality, corrosion resistance, and surface hardness. Different process parameters at each processing stage lead to different structural changes, and these changes were quantified as influencing parameters.

[0050] Using the material for manufacturing compression springs as the test sample, process parameters were adjusted at different points in the processing flow. For example, during the molding process, molding pressure and temperature were changed, and the deformation and dimensional changes of the material were recorded. During the heat treatment process, the heating temperature, holding time, and cooling rate were adjusted, and changes in material hardness, strength, and elastic modulus were measured. During the surface treatment process, surface treatment methods, such as coating thickness and coating materials, were changed, and surface roughness and corrosion resistance were measured. Various material performance testing methods, such as hardness testing, tensile testing, and corrosion testing, were used to quantify the impact of process parameters on material properties and obtain the relationship between process parameters and material properties.

[0051] By combining influencing parameters with influencing relationships, for example, by integrating the relationship between the influencing parameters of processing nodes and material properties through mathematical modeling methods, a process-compression spring structure influence relationship can be established. This influence relationship can describe how the process parameters of different process nodes affect the structural characteristics of the compression spring.

[0052] Furthermore, obtaining the influence relationship between the process and the compression spring structure also includes:

[0053] Based on the processing sequence of the processing flow nodes, the influence relationship between the process and the compression spring structure is longitudinally segmented to establish a longitudinal slice of the influence relationship of the compression spring structure.

[0054] The influence relationship between the process and the compression spring structure is longitudinally divided according to the temporal relationship of the processing flow. This means that the entire compression spring processing process is divided into several key time periods or processing stages, and each stage represents the structural changes that may occur during the processing.

[0055] Specifically, during the processing of compression springs, each processing node occurs sequentially over time. Each node may affect the structural characteristics of the compression spring. Based on the actual process steps, key processing points that are prone to deviation or have a significant impact on the compression spring structure are identified. For example, the pressure applied during molding, the temperature curve during heat treatment, and the uniformity of the coating during surface treatment are all key nodes that may affect the quality of the compression spring. If each key processing node cannot be clearly identified in the actual process, some rules can be preset for segmentation. For example, the entire processing process can be evenly divided according to the total span, such as preset to 5 or 10 parts, or an equal division point can be set every 5 millimeters or other appropriate distances. These division points are used to analyze the structural changes of the compression spring at different process stages. Through the analysis of the processing flow sequence and the identification of key nodes, several longitudinal slices are formed. Each slice represents the structural characteristics of the compression spring at a specific processing stage or specific position, such as size, shape, hardness, and surface quality.

[0056] Furthermore, based on the aforementioned process-compression spring structure influence relationship, the machining compensation dimension space is configured, including:

[0057] Based on the monitoring samples, the average dimensional error of each processing node is calculated; based on the test samples, the dimensional error of the spring manufacturing material is calculated; the dimensional error of the spring manufacturing material is used to fuse and correct the average dimensional error of each processing node to obtain the dimensional error; based on the dimensional error, the spring structure and processing nodes are matched and positioned, and the processing compensation dimensional space of each structural process of the spring is configured.

[0058] Based on the collected processing monitoring samples, the actual dimensional error of each processing node is first calculated. For example, after the molding process, the shape and size of the compression spring are measured and compared with the design specifications to calculate the dimensional error generated during the molding process. For each processing node, the dimensional error of all measured samples is statistically analyzed, and its average error value is calculated. This will reflect the common dimensional errors in the processing of that node.

[0059] Select typical spring manufacturing materials, such as spring steel or stainless steel, and measure the dimensional changes that may occur in the material during processing through experiments. For example, the changes in the thickness, width and other dimensions of the material before and after molding. Calculate the dimensional changes in the test samples and quantify the dimensional error of the material during processing. The sources of this error include the physical properties of the material itself, thermal expansion during processing, cooling and contraction and other factors.

[0060] The average dimensional error of each processing node is combined with the material dimensional error. This can be achieved using methods such as weighted average and regression analysis, which comprehensively consider the influence of material error and processing error. If the influence weights of material error and processing error are different, they can be weighted according to the actual situation to obtain a more accurate dimensional error. Through this fusion correction, a comprehensive dimensional error is obtained, which reflects the combined influence of material and each processing node on the final dimensional accuracy of the compression spring.

[0061] The corrected dimensional error is matched and positioned with different processing nodes and structures of the compression spring. Based on the processing characteristics of each node, it is determined which parts require dimensional compensation. For example, if the compression spring is too large due to uneven pressure during the forming stage, compensation is needed during the forming process to ensure that the formed dimensions meet specifications. If there is a trend of shrinkage or expansion during heat treatment, process parameters such as cooling rate and heating temperature are adjusted to compensate based on the heat treatment error. If there is an error in the coating thickness during surface treatment, the coating process is adjusted to compensate for these errors based on the dimensional error. Based on the characteristics of each processing node, it is determined how much processing space needs to be reserved for compensation at each node, generating a processing compensation dimensional space.

[0062] Furthermore, based on the processing compensation size space, the structural functional zones are spatially allocated to obtain the compensation gradient for each structural functional zone, including:

[0063] Using the structural partition features of the aforementioned structural functional partitions as horizontal partitions, and the vertical slices of the influence relationship of the compression spring structure as vertical partitions, the horizontal and vertical partitions are aligned and combined according to the process-compression spring structure influence relationship to establish a relationship grid. According to the process correspondence between the processing compensation size space and the compression spring structure and processing flow nodes, the data is projected onto the relationship grid to obtain the compensation gradient of each structural functional partition.

[0064] Based on the structural function of the compression spring, the compression spring is divided into different regions as transverse partitions, such as the spring body, the joints at both ends, and the surface coating. Each structural partition represents a functional area of ​​the compression spring, with different process requirements and structural characteristics. The longitudinal slices of the compression spring at each processing node are used as longitudinal partitions. Each slice represents the structural characteristics of the compression spring, such as size, hardness, and stress, at different processing stages.

[0065] Based on the processing of the compression spring, the transverse and longitudinal sections are aligned. This means that there will be a clear relationship between each structural area and each processing stage. For example, during the forming process, the spring body of the compression spring will undergo dimensional changes, while the joint may be affected during the heat treatment process. By mapping each section to the corresponding processing stage, a grid structure is formed. This grid shows the relationship between each structural section and processing node. Each grid point represents the influence or change of a structural functional section at a certain processing node.

[0066] The machining compensation dimension space and process correspondence are projected onto the established relational grid. Each grid point displays the corresponding compensation dimension according to different structural partitions and machining nodes. Based on the projection data in the grid, the compensation gradient of each structural functional partition is calculated. The compensation gradient represents the compensation requirement of each region at different machining nodes. These compensation gradients provide optimization directions for each machining node of the compression spring, which are used to accurately adjust the machining parameters in subsequent processes to ensure that the dimensional error of each structural region is effectively corrected.

[0067] Furthermore, obtaining the error compensation control parameters includes:

[0068] Based on the real-time processing flow data, the spring manufacturing location and processing flow nodes are matched with the relationship grid to obtain the matching compensation gradient and the compensation gradient of subsequent process nodes. Structural feature errors are compared according to the horizontal partitions of the relationship grid to obtain the manufacturing error between the monitoring data and the target structural features. The matching compensation gradient is analyzed for compensation parameters based on the manufacturing error to obtain the current error compensation control parameters. These error compensation control parameters are then used for real-time compensation of the current control parameters to meet the functional parameter targets of the current processing flow node and the current spring structure. Using the compensation results of the error compensation control parameters, the compensation gradient of subsequent process nodes is marked and reset for subsequent process tracking compensation, ensuring that all spring structures at all processing flow nodes achieve their functional parameter targets.

[0069] During the compression spring manufacturing process, processing data is collected in real time, especially the processing status of the compression spring at different locations. For example, data on dimensional changes, shape changes, and hardness changes at each processing node are acquired. Based on the collected real-time processing data, the manufacturing location and current processing node of the compression spring are determined. By matching with an established relational mesh, the current processing node of each manufacturing location is located to the corresponding mesh position. After the location matching is completed, the matching compensation gradient of the current processing node is obtained by combining it with the previously obtained compensation gradient. This gradient reflects the compensation requirements for dimensional or shape deviations at the current processing stage. At the same time, the compensation gradient of subsequent processing nodes is obtained to ensure that errors are gradually corrected throughout the entire processing flow.

[0070] The horizontal partitions represent different functional areas of the compression spring. These areas have different processing requirements and targets. Real-time monitoring data is compared with the target structural features. For example, at the molding node, there may be dimensional deviations in the spring body of the compression spring. The actual measurement data can be compared with the target dimensions to calculate the error generated during the molding process. The comparison result is the manufacturing error, which represents the difference between the actual processing process and the target structural features in each horizontal partition. The identification of manufacturing errors provides a basis for the next step of error compensation and process adjustment.

[0071] Based on the manufacturing error, a corresponding compensation gradient is matched. These compensation gradients can be interfaced with the processing nodes in the relational grid to obtain the compensation amount for the current error. For example, if the size is too large during the molding process, appropriate adjustments need to be made to the pressure. Based on the current manufacturing error and the compensation gradient, error compensation control parameters are analyzed. These control parameters involve key process parameters such as pressure, temperature, cooling rate, and time. Using the obtained error compensation control parameters, real-time compensation is performed for the current processing node. This means that processing parameters are dynamically adjusted according to the error of the current node to ensure that the error of the current processing node is eliminated, thereby enabling the current compression spring structure to achieve the predetermined functional parameter target.

[0072] Based on the current compensation results, the compensation gradient for subsequent processing nodes is marked and reset. That is, if dimensional compensation was completed at the previous processing node, the compensation strategy for subsequent heat treatment or surface treatment nodes needs to be adjusted according to the new dimensional and hardness conditions. The marked and reset compensation gradient will become the basis for subsequent process adjustments. Each subsequent processing node will be adjusted based on the compensation results of the previous node, thereby gradually eliminating the errors generated at each node. Through the compensation adjustment of each node, it is ensured that every structural part of all compression springs in the entire processing flow ultimately achieves the predetermined functional parameter targets.

[0073] In summary, the error compensation method for compression spring manufacturing provided in this application has the following technical effects:

[0074] By analyzing the design drawings and functional parameters of the compression spring, the spring structure is decomposed and functional zones are obtained. This ensures targeted correction of errors in each area during subsequent compensation, avoiding over- or under-compensation and improving overall machining accuracy. Analyzing the response relationship between machining parameters and the spring manufacturing material and structure establishes the process-spring structure influence relationship. This analysis identifies and quantifies the impact of each node in the machining process on the spring structure, providing data support for further error compensation. Based on the process-spring structure influence relationship, machining compensation dimensional space is configured to reserve necessary correction space for potentially error-prone areas during machining, thereby preventing and mitigating machining errors in advance and ensuring the final product meets design requirements. Based on the machining compensation dimensional space, the structural functional zones are then... By allocating space and obtaining compensation gradients for each structural functional zone, necessary dimensional compensation is provided for each compression spring component. This not only helps to precisely control each area during the processing but also enables gradual compensation throughout the manufacturing process, thereby reducing the impact of errors on the final product performance. By collecting real-time processing flow data, errors occurring during manufacturing can be identified in real time. This real-time capability allows compensation to be dynamically adjusted during processing without relying on later corrections, avoiding error accumulation. By using the established compensation gradients to perform process analysis compensation for manufacturing errors and combining them with actual errors for real-time compensation control, precise error compensation control parameters are obtained. This ensures that errors during processing are corrected to the greatest extent possible, thereby reducing deviations in the final product, improving the control capability of the manufacturing process, and ultimately enhancing the overall quality and consistency of the compression springs.

[0075] Example 2, based on the same inventive concept as the error compensation method for compression spring manufacturing in the foregoing examples, such as... Figure 2 As shown in the figure, this application embodiment provides an error compensation system for compression spring manufacturing, the system comprising:

[0076] The compression spring structure decomposition module 10 is used to analyze the compression spring design drawings and functional parameter targets, decompose the compression spring structure, and obtain structural functional partitions; the response relationship analysis module 20 is used to analyze the response relationship between the processing parameters of the manufacturing process and the compression spring manufacturing materials and the compression spring structure, and establish the process-compression spring structure influence relationship; the compensation space configuration module 30 is used to configure the processing compensation size space based on the process-compression spring structure influence relationship; the space allocation module 40 is used to allocate the space of the structural functional partitions according to the processing compensation size space, and obtain the compensation gradient of each structural functional partition; the process analysis compensation module 50 is used to collect real-time processing flow data during the compression spring manufacturing process, identify manufacturing errors, and perform process analysis compensation for the manufacturing errors based on the compensation gradient of each structural functional partition, and obtain error compensation control parameters.

[0077] Furthermore, the compression spring structure disassembly module 10 is used to perform the following operation steps:

[0078] The compression spring design drawings are identified and segmented according to the standard functions of the end area, effective coil area, and support coil area to obtain the functional zones of each standard compression spring; the structural response target is analyzed for the functional parameter target to obtain the structural constraint characteristics of each standard compression spring functional zone; based on the structural constraint characteristics, the functional zones of the standard compression spring are constrained by partition feature constraints to obtain the structural functional zones.

[0079] Furthermore, the compression spring structure disassembly module 10 is used to perform the following operation steps:

[0080] The structural characteristics of the compression springs are analyzed by performing structural characteristic tests on the functional parameter targets to obtain the structural characteristics corresponding to each functional parameter target. The structural constraint requirements of each standard compression spring functional area are analyzed using the structural characteristics to obtain the structural constraint characteristics of each standard compression spring functional area, including flatness, pitch uniformity, roundness standard, and surface quality.

[0081] Furthermore, the compression spring structure disassembly module 10 is used to perform the following operation steps:

[0082] Based on the structural constraint features, the standard compression spring functional partition is projected to determine the structural constraint partition; the partition is then uniformly divided according to the position distribution range of the constraint structure to obtain structural constraint slices; the constraint structure features are then projected and allocated to the structural constraint slices to establish constraint mapping relationships and obtain the structural functional partition.

[0083] Furthermore, the response relationship analysis module 20 is used to perform the following operation steps:

[0084] Collect monitoring samples from each node of the processing flow, including processing technology monitoring data of compression spring samples of different quality grades; analyze the influence parameters of different processing flow nodes on the compression spring structure based on the monitoring samples; use the compression spring manufacturing material as the test sample, analyze the influence relationship of process parameters on the compression spring manufacturing material by adjusting the process parameters of the processing flow nodes; fuse the influence parameters and the influence relationship to obtain the process-compression spring structure influence relationship.

[0085] Furthermore, the response relationship analysis module 20 is used to perform the following operation steps:

[0086] Based on the processing sequence of the processing flow nodes, the influence relationship between the process and the compression spring structure is longitudinally segmented to establish a longitudinal slice of the influence relationship of the compression spring structure.

[0087] Furthermore, the compensation space configuration module 30 is used to perform the following operation steps:

[0088] Based on the monitoring samples, the average dimensional error of each processing node is calculated; based on the test samples, the dimensional error of the spring manufacturing material is calculated; the dimensional error of the spring manufacturing material is used to fuse and correct the average dimensional error of each processing node to obtain the dimensional error; based on the dimensional error, the spring structure and processing nodes are matched and positioned, and the processing compensation dimensional space of each structural process of the spring is configured.

[0089] Furthermore, the space allocation module 40 is used to perform the following operation steps:

[0090] Using the structural partition features of the aforementioned structural functional partitions as horizontal partitions, and the vertical slices of the influence relationship of the compression spring structure as vertical partitions, the horizontal and vertical partitions are aligned and combined according to the process-compression spring structure influence relationship to establish a relationship grid. According to the process correspondence between the processing compensation size space and the compression spring structure and processing flow nodes, the data is projected onto the relationship grid to obtain the compensation gradient of each structural functional partition.

[0091] Furthermore, the process analysis and compensation module 50 is used to perform the following operation steps:

[0092] Based on the real-time processing flow data, the spring manufacturing location and processing flow nodes are matched with the relationship grid to obtain the matching compensation gradient and the compensation gradient of subsequent process nodes. Structural feature errors are compared according to the horizontal partitions of the relationship grid to obtain the manufacturing error between the monitoring data and the target structural features. The matching compensation gradient is analyzed for compensation parameters based on the manufacturing error to obtain the current error compensation control parameters. These error compensation control parameters are then used for real-time compensation of the current control parameters to meet the functional parameter targets of the current processing flow node and the current spring structure. Using the compensation results of the error compensation control parameters, the compensation gradient of subsequent process nodes is marked and reset for subsequent process tracking compensation, ensuring that all spring structures at all processing flow nodes achieve their functional parameter targets.

[0093] Through the foregoing detailed description of an error compensation method for compression spring manufacturing, those skilled in the art can clearly understand the error compensation system for compression spring manufacturing in this embodiment. Since it corresponds to the method disclosed in the embodiment, the description is relatively simple, and relevant parts can be referred to the method section.

[0094] The above description of the disclosed embodiments enables those skilled in the art to make or use this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An error compensation method for manufacturing compression springs, characterized in that, The method includes: Analyze the design drawings and functional parameters of the compression spring, decompose the compression spring structure, and obtain the structural functional partitions; The relationship between the processing parameters of the manufacturing process and the response of the compression spring manufacturing material and compression spring structure is analyzed to establish the influence relationship between process and compression spring structure. Based on the aforementioned process-compression spring structure influence relationship, the machining compensation dimension space is configured; Based on the processing compensation size space, the structural functional partitions are spatially allocated to obtain the compensation gradient of each structural functional partition; Real-time processing flow data during the compression spring manufacturing process is collected to identify manufacturing errors. Based on the compensation gradient of each structural functional partition, the manufacturing errors are analyzed and compensated to obtain error compensation control parameters. This includes analyzing the relationship between manufacturing parameters and the response of the compression spring material and structure, establishing the influence relationship between the manufacturing process and the compression spring structure, including: Collect monitoring samples at each stage of the processing flow, including processing technology monitoring data for compression spring samples of different quality grades; Based on the monitoring samples, the influence parameters of different processing nodes on the compression spring structure were analyzed. Using the compression spring manufacturing material as the test sample, the influence of process parameters on the compression spring manufacturing material is analyzed by adjusting the process parameters of the processing flow nodes. By fusing the influencing parameters with the influencing relationships, the process-compression spring structure influence relationship is obtained; Obtaining the influence relationship between the process and the compression spring structure also includes: Based on the processing sequence of the processing flow nodes, the influence relationship between the process and the compression spring structure is longitudinally segmented to establish a longitudinal slice of the influence relationship of the compression spring structure. Among them, based on the aforementioned process-compression spring structure influence relationship, the processing compensation dimension space is configured, including: Based on the monitoring samples, the average dimensional error of each processing node is calculated; Calculate the dimensional error of the compression spring manufacturing material based on the test sample; The average dimensional error of each processing node is fused and corrected using the dimensional error of the spring manufacturing material to obtain the dimensional error amount. Based on the dimensional error, the compression spring structure and processing nodes are matched and positioned, and the processing compensation dimensional space for each structural process of the compression spring is configured.

2. The error compensation method for manufacturing compression springs according to claim 1, characterized in that, Analyze the design drawings and functional parameters of the compression spring, decompose the compression spring structure, and obtain the structural functional partitions, including: The compression spring design drawings are identified and segmented according to the standard functions of the end area, effective coil area, and support coil area to obtain the functional zones of each standard compression spring. Structural response target analysis is performed on the functional parameter targets to obtain the structural constraint characteristics of each standard compression spring functional zone; Based on the structural constraint features, the standard compression spring functional partitions are subjected to partition feature constraints to obtain the structural functional partitions.

3. The error compensation method for manufacturing compression springs according to claim 2, characterized in that, Structural response target analysis is performed on the functional parameter targets to obtain the structural constraint characteristics of each standard compression spring functional zone, including: The structural features of the compression spring were analyzed by performing a compression spring structural feature test on the functional parameter targets to obtain the structural features corresponding to each functional parameter target. Structural constraint requirements of each standard compression spring functional zone are analyzed using structural features to obtain the structural constraint features of each standard compression spring functional zone, including flatness, pitch uniformity, roundness standard, and surface quality.

4. The error compensation method for manufacturing compression springs according to claim 3, characterized in that, Based on the structural constraint features, the standard compression spring functional partitions are subjected to partition feature constraints to obtain the structural functional partitions, including: Based on the structural constraint characteristics, the structural position of the standard compression spring functional partition is projected to determine the structural constraint partition; The structure is uniformly divided according to the location distribution interval of the constraint structure to obtain structural constraint slices. The constraint structure features are then projected and assigned to the structural constraint slices to establish constraint mapping relationships and obtain the structural functional partitions.

5. The error compensation method for manufacturing compression springs according to claim 1, characterized in that, Based on the processing compensation size space, the structural functional zones are spatially allocated to obtain the compensation gradient for each structural functional zone, including: Using the structural partitioning features of the aforementioned structural functional partitions as horizontal partitions, and the vertical slices of the influence relationship of the compression spring structure as vertical partitions, the horizontal partitions and vertical partitions are aligned and combined according to the process-compression spring structure influence relationship to establish a relationship grid; Based on the process correspondence between the processing compensation size space and the compression spring structure and processing flow nodes, the data is projected onto the relationship grid to obtain the compensation gradient of each structural functional partition.

6. The error compensation method for manufacturing compression springs according to claim 5, characterized in that, Obtain error compensation control parameters, including: Based on the compression spring manufacturing location and processing node of the real-time processing flow data, the relationship grid is used for positioning and matching to obtain the matching compensation gradient and the compensation gradient of the subsequent process node. By comparing the structural feature errors according to the horizontal partitions of the relational grid, the manufacturing error between the monitoring data and the target structural features can be obtained. Based on the manufacturing error, the compensation parameters of the matching compensation gradient are analyzed to obtain the current error compensation control parameters. The current control parameters are then compensated in real time using the error compensation control parameters to meet the functional parameter targets of the current processing node and the current compression spring structure. Using the compensation results of the error compensation control parameters, the compensation gradient of the subsequent process node is marked and reset for subsequent process tracking compensation, so that all compression spring structures of all processing process nodes achieve the functional parameter target.

7. An error compensation system for manufacturing compression springs, characterized in that, For implementing the error compensation method for manufacturing compression springs according to any one of claims 1-6, the system comprises: The compression spring structure decomposition module is used to analyze the compression spring design drawings and functional parameter targets, decompose the compression spring structure, and obtain the structural functional partitions. The response relationship analysis module is used to analyze the response relationship between the processing parameters of the manufacturing process and the spring manufacturing materials and spring structure, and to establish the process-spring structure influence relationship. The compensation space configuration module is used to configure the processing compensation dimension space based on the process-compression spring structure influence relationship; The space allocation module is used to allocate space to the structural functional partitions according to the processing compensation size space, and obtain the compensation gradient of each structural functional partition. The process analysis and compensation module is used to collect real-time processing flow data during the compression spring manufacturing process, identify manufacturing errors, and perform process analysis and compensation on the manufacturing errors based on the compensation gradient of each structural functional partition to obtain error compensation control parameters.

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