A gear-shaving machine tool axis synchronization control method, system and machine tool

Abstract

The present invention relates to the field of machine tool control technology, specifically to a method, system, and machine tool for synchronous control of the axes of a gear-shaving machine tool. The synchronous control method comprises: monitoring the state of chips generated during the gear-shaving process; analyzing the synchronization error of the machine tool axes based on the chip state; and regulating the rotational speed of the machine tool axes based on the synchronization error. This synchronous control method effectively addresses the existing problem of axis synchronization error caused by factors on the transmission and cutting sides, achieving more precise axis synchronization control and improving gear machining accuracy, surface quality, and efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of machine tool control, and in particular to a gear skiving machine tool axis synchronization control method, system and machine tool. Background Art

[0002] In gear machining, gear skiving involves cutting the tooth profile directly from the blank using a gear-shaped tool. During machining, the workpiece axis and tool axis operate at a set speed ratio, and their synchronization is crucial for ensuring machining accuracy. Loss of synchronization directly impacts the gear's tooth profile accuracy, surface quality, and machining efficiency.

[0003] Currently, ensuring precise synchronization between the workpiece axis and the tool spindle primarily relies on a drive-side rotary encoder monitoring system. This system collects real-time rotational data from the workpiece and tool spindle's drive sides throughout the gear-shaving process. This data is analyzed to identify errors and then synchronized with the system. However, this approach has limitations: it struggles to effectively map axis synchronization errors induced by intermediate links in the drive chain (on the drive side) and those caused by the cutting operation (on the cutting side).

[0004] The causes of synchronization errors between the transmission and cutting sides are complex, difficult to measure, and challenging to monitor. While adding a large number of sensors on both sides can effectively monitor synchronization errors, this increases the structural complexity of the gear skiving machine and significantly increases both manufacturing and maintenance costs. Summary of the Invention

[0005] To solve the above problems, the present invention provides a gear skiving machine tool axis synchronization control method, system and machine tool, which are used to perform more precise synchronization control on the machine tool axis based on the synchronization error between the transmission side and the cutting side of the gear skiving machine tool.

[0006] In one aspect, the present invention provides a method for synchronously controlling an axis of a gear cutting machine tool, comprising:

[0007] Analyze the synchronization error of machine tool axes based on the chip state generated during gear skiving;

[0008] The chip state is the motion trajectory information of the chips generated during the gear skiving process after separation from the workpiece blank; the motion trajectory information is the trajectory path points; by setting at least one sensing area on the chip motion trajectory, the position information of the chips when they reach the sensing area is monitored, which is defined as the actual trajectory path point; the position information of the chips when they reach the sensing area in the theoretical motion trajectory is extracted and defined as the theoretical trajectory path point; the theoretical trajectory path points are compared with the actual trajectory path points to analyze the synchronization error of the machine tool axis;

[0009] The rotation speed of the machine tool axis is regulated based on the synchronization error.

[0010] Furthermore, the chip state includes a theoretical chip state and an actual chip state. The theoretical chip state is the theoretical motion trajectory information of the chips generated during the gear skiving process after separation from the workpiece blank. The actual chip state is the actual motion trajectory information of the chips generated during the gear skiving process after separation from the workpiece blank. The acquisition method is as follows:

[0011] The chip state generated when there is no synchronization error in the theoretical state is obtained, which is defined as the theoretical chip state. The chip state generated during the actual gear cutting process is monitored, which is defined as the actual chip state.

[0012] Furthermore, the actual chip state is monitored. When the difference between the actual chip state and the theoretical chip state is greater than a threshold, it is determined that there is a synchronization error in the machine tool axis. The amount of synchronization error in the machine tool axis is proportional to the difference between the actual chip state and the theoretical chip state.

[0013] Furthermore, before synchronous control, a basic control amplitude is set; when there is a synchronization error in the machine tool axis, the basic control amplitude is adjusted based on the chip state difference generated when the machine tool axis has a synchronization error, and the machine tool axis to be controlled is selected randomly or according to the set priority, and the adjusted basic control amplitude and the machine tool axis to be controlled are output as the first control strategy. After the first control strategy is executed, the first control strategy is updated based on the change in the machine tool axis synchronization error.

[0014] Furthermore, the chip state generated when there is a synchronization error in the machine tool axis and the operating parameters of the gear cutting machine tool are used as samples, and a control strategy model is constructed and trained using a machine learning algorithm or a deep learning algorithm. When there is a synchronization error in the machine tool axis, the second control strategy is output through the control strategy model.

[0015] Furthermore, the chip status and gear skiving machine operating parameters are collected, and the pre-control strategy is output through the control strategy model.

[0016] Furthermore, based on the precision requirement of the workpiece to be processed, the synchronization control response sensitivity is set, and the synchronization control response sensitivity is proportional to the precision requirement of the workpiece to be processed.

[0017] Furthermore, when the rotary encoder monitoring system does not detect any synchronization error on the gear cutting machine tool drive side and is not performing synchronization control, the machine tool axis is allowed to be adjusted; when the rotary encoder monitoring system detects any synchronization error on the gear cutting machine tool drive side or is performing synchronization control, the adjustment of the machine tool axis is terminated.

[0018] Further, it is analyzed whether there is continuous overlap between the actual chip state and the theoretical chip state regardless of time; if there is continuous overlap between the actual chip state and the theoretical chip state regardless of time within a preset time period, it is determined that there is a speed error in the machine tool axis; if there is no continuous overlap between the actual chip state and the theoretical chip state regardless of time within a preset time period, it is determined that there is a speed ratio error in the machine tool axis.

[0019] Furthermore, the machine tool axis includes a workpiece axis and a tool axis;

[0020] If there is a speed error in the machine tool axis, the workpiece axis and tool axis are regulated synchronously;

[0021] If there is a speed ratio error in the machine tool axes, the workpiece axis or tool axis can be controlled independently.

[0022] Furthermore, the movement trajectory information of the chips is part or all of the movement trajectory of the chips from the time when the chips are separated from the workpiece to the time when the chips come into contact with any object.

[0023] Furthermore, the sensing area covers the movement trajectory of the chips generated during the gear skiving process, and a redundant sensing area is set at the edge of the sensing area.

[0024] Furthermore, a monitoring coordinate system is established, each sensing point in the sensing area is converted into the monitoring coordinate system, and the position and angle of the sensing area are adjusted so that the theoretical motion trajectory of the chips in the entire tooth scraping process passes through the sensing area.

[0025] Furthermore, a monitoring coordinate system is established, each sensing point in the sensing area is converted into the monitoring coordinate system, and an adjustment strategy for the sensing area is calculated; the adjustment strategy is the adjustment position and angle of several groups of sensing areas;

[0026] After the gear skiving process begins, the sensing area is adjusted according to the adjustment strategy.

[0027] Furthermore, the moment of each chip generation is calculated based on the cutting model, which is defined as the theoretical chip generation moment. Each chip generation moment is sorted within the chip generation time period. A chip generation sequence is constructed based on the chip generation order. A chip trajectory sequence is constructed based on the theoretical motion trajectory corresponding to each chip in the chip generation sequence. A mapping relationship between the chip generation sequence and the chip trajectory sequence is established.

[0028] Based on the moment after the gear skiving process begins, the theoretical motion trajectory of the chips generated at the corresponding moment is obtained, and the synchronization error of the machine tool axis is analyzed by comparing the actual motion trajectory monitored at the same moment.

[0029] Furthermore, a chip position sequence is constructed based on the theoretical position of each chip arriving in the sensing area corresponding to the theoretical motion trajectory of each chip in the chip trajectory sequence; a mapping relationship between the chip generation sequence, the chip trajectory sequence, and the chip position sequence is established;

[0030] Based on the time after the gear skiving process starts, the theoretical position of the chips generated at the corresponding moment in the sensing area is obtained, and the synchronization error of the machine tool axis is analyzed by comparing the actual position in the sensing area monitored at the same time.

[0031] Furthermore, the control strategy is sent to the rotary encoder monitoring system, and the rotary encoder monitoring system updates the normal rotation speed of the machine tool shaft drive side.

[0032] On the other hand, the present invention provides a gear cutting machine tool axis synchronization control system, comprising:

[0033] Error analysis module, which analyzes the synchronization error of the machine tool axis based on the chip state generated during the gear skiving process;

[0034] The chip state is the motion trajectory information of the chips generated during the gear skiving process after separation from the workpiece blank; the motion trajectory information is the trajectory path points; by setting at least one sensing area on the chip motion trajectory, the position information of the chips when they reach the sensing area is monitored, which is defined as the actual trajectory path point; the position information of the chips when they reach the sensing area in the theoretical motion trajectory is extracted and defined as the theoretical trajectory path point; the theoretical trajectory path points are compared with the actual trajectory path points to analyze the synchronization error of the machine tool axis;

[0035] The control module controls the rotation speed of the machine tool axis based on the synchronization error.

[0036] Furthermore, the error analysis module signal is connected to the rotary encoder monitoring system and the machine tool axis drive control device, and the error analysis module obtains the synchronization error situation of the machine tool axis drive side through the rotary encoder monitoring system;

[0037] The control module is used to control the rotation speed of the machine tool axis based on the synchronization error when there is a synchronization error in the machine tool axis and there is no synchronization error on the driving side of the machine tool axis.

[0038] Furthermore, the error analysis module is used to monitor the trajectory of the chips generated during the gear skiving process. The error analysis module includes a movable monitoring surface, which is composed of several substrates. Adjacent substrates are hinged by flexible connectors. An angle adjustment mechanism for adjusting the angle of any substrate is integrated on the back of the substrate, and flexible thin film pressure sensors are provided on the surface of the substrate.

[0039] Furthermore, the angle adjustment mechanism is used to adjust the substrate according to the theoretical movement trajectory of the chips so that the chips flow toward the collection area.

[0040] On the other hand, the present invention provides a gear cutting machine tool, including a rotary encoder monitoring system and a machine tool axis drive and control device, and integrating the above-mentioned gear cutting machine tool axis synchronization control system, which is used to synchronize the machine tool axis.

[0041] Compared with existing technologies, the technical solution of the present invention has the following advantages: By monitoring the chip state generated during gear skiving, the present invention analyzes the synchronization error between the workpiece axis and the cutter axis, and adjusts the rotational speed accordingly. This effectively solves the existing problem of axis synchronization error caused by factors on the transmission side and the cutting side, achieving more precise axis synchronization control, and improving gear processing accuracy, surface quality, and processing efficiency. It is applicable to a variety of gear types, including internal, external, spur, and helical gear skiving, without being restricted to specific types, and has strong versatility and adaptability.

[0042] When performing synchronous monitoring and control on gear skiving machines, there is no need to add a large number of sensors on the transmission side and cutting side, avoiding the problem of increased machine tool structure complexity, significant increase in manufacturing costs and maintenance costs due to the addition of sensors. While achieving high-precision synchronous control, it also reduces the manufacturing and maintenance costs of the machine tool.

[0043] In addition, the control strategy output method based on machine learning can quickly and accurately output the control strategy based on the collected chip arrival data and machine tool operating parameters, achieve efficient synchronous control, reduce the number of controls, and meet the needs of high-quality and high-precision gear processing. It can also predict possible synchronization errors and generate pre-control strategies in advance to further improve processing accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Figure 1 This is the main flow chart of the gear skiving machine tool axis synchronization control method of the present invention;

[0045] Figure 2 Schematic diagram 1 of the gear cutting principle of the gear cutting machine tool axis synchronization control method according to the present invention;

[0046] Figure 3 FIG2 is a gear cutting principle diagram II of an embodiment of a gear cutting machine tool axis synchronization control method of the present invention;

[0047] Figure 4 Detailed flow chart of an embodiment of the gear skiving machine tool axis synchronization control method of the present invention;

[0048] Figure 5 Schematic diagram of the gear cutting motion coordinate system of an embodiment of the gear cutting machine tool axis synchronization control method of the present invention;

[0049] Figure 6 Schematic diagram of the expanded chip geometry model of an embodiment of the gear skiving machine tool axis synchronization control method of the present invention;

[0050] Figure 7 Schematic diagram of the structure of an embodiment of the gear skiving machine tool axis synchronization control system of the present invention;

[0051] Figure 8This is a schematic diagram of the back side of the active monitoring surface of an embodiment of the gear skiving machine tool axis synchronization control system of the present invention;

[0052] Figure 9 This is a front view of the active monitoring surface of an embodiment of the gear skiving machine tool axis synchronization control system of the present invention;

[0053] Figure 10 Schematic diagram I of the monitoring principle of the active monitoring surface of the gear skiving machine shaft synchronization control system according to the present invention;

[0054] Figure 11 Schematic diagram II of the monitoring principle of the active monitoring surface of the gear skiving machine shaft synchronization control system embodiment of the present invention;

[0055] Figure 12 It is a structural schematic diagram of an embodiment of a gear skiving machine tool of the present invention.

[0056] The figure marks in the drawings of the specification include: 101, error analysis module; 102, control module; 103, rotary encoder monitoring system; 104, machine tool axis drive control device; 200, movable monitoring surface; 201, substrate; 202, flexible connector; 203, angle adjustment mechanism; 204, flexible film pressure sensor. DETAILED DESCRIPTION

[0057] Gear skiving machines are specialized equipment used for gear processing. Gears processed by gear skiving machines have high tooth surface accuracy and surface quality, and are commonly used for processing high-precision gears such as automotive transmissions, planetary gearboxes, and industrial reducers. Gear skiving technology differs from other gear processing technologies in that the machine axes of gear skiving machines primarily consist of a workpiece axis and a cutter axis. Prior to gear skiving, the workpiece must be secured to the workpiece axis, and the cutter must be secured to the cutter axis. During gear skiving, the workpiece axis and cutter axis must be tilted at a certain angle, and both must rotate synchronously. The workpiece is also micro-fed synchronously along the axis of the workpiece axis, thereby enabling gear skiving. Compared to traditional gear processing technologies such as gear shaping and hobbing, gear skiving is more flexible and can process a wide range of gear products.

[0058] Since the workpiece shaft and cutter shaft must rotate at a set speed ratio during the gear-scratching process, any error in the actual speed ratio between the workpiece shaft and cutter shaft may affect gear processing accuracy, gear surface quality, tool life, and other factors. Therefore, existing gear-scratching machines typically perform synchronous control of the cutter shaft and workpiece shaft during gear-scraping, establishing a coupling relationship between the two to ensure that their rotational speeds change synchronously and maintain the set speed ratio. When performing synchronous control, existing gear-scratching machines collect rotation data from the drive side (workpiece shaft motor, cutter shaft motor) as the basis for synchronous control, ignoring influencing factors such as the transmission side (transmission chain) and the cutting side (tool wear, cutting heat). Existing synchronous control methods can accurately control the synchronization errors caused by the drive side, but the synchronization errors caused by the transmission and cutting sides cannot be accurately and effectively controlled.

[0059] Combining gear skiving theory with the actual operating conditions of gear skiving machines, the inventors discovered that when synchronization errors occur in any one or more of the drive, transmission, and cutting sides, abnormal vibrations and chips are generated. Based on this, they proposed a method for controlling the synchronization of gear skiving machine axes. This method analyzes the synchronization errors of the machine axes based on the chip state generated during the gear skiving process and regulates the rotational speed of the machine axes based on these synchronization errors.

[0060] The following is a detailed description of the specific embodiment of the present invention in conjunction with the accompanying drawings. The embodiment of the present invention divides the gear cutting machine tool axis synchronization control steps into S11, S12 and S13, and the order of each step can be adjusted according to actual conditions. Preferably, refer to Figure 1 , the steps are as follows:

[0061] S11, monitoring the state of chips generated during the gear skiving process;

[0062] In an embodiment of the present invention, the chip state generated during the tooth skiving process is the chip discharge state, and the discharge state is specifically the motion trajectory after separation from the workpiece blank for tooth skiving. The chip motion trajectory described subsequently corresponds to the chip state, the theoretical motion trajectory corresponds to the theoretical chip state, and the actual motion trajectory corresponds to the actual chip state; this technical solution does not limit the type of tooth skiving of the workpiece, and is applicable to tooth skiving of internal teeth, external teeth, straight teeth, helical teeth, etc.

[0063] Reference Figure 2 The dotted filling area in the figure is the chip that will be produced; during the tooth skiving process, the workpiece is slightly fed in the axial direction, that is, the direction f in the figure; the rotation direction of the tool and the blank refers to the direction indicated by the arrow in the figure. Figure 3, during the generation hobbing process, the cutting edge of the tool obliquely cuts into the bottom of the tooth groove from the right side of the blank. Subsequently, each point on the cutting edge participates in cutting in sequence. Under the extrusion of the cutting edge, the material in the tooth groove undergoes plastic deformation to form chips. The formed chips do not immediately separate from the workpiece blank but are continuously pushed by the rake face of the tool until the cutting edge completely leaves the tooth groove of the workpiece blank. The chips are correspondingly pushed and cut off by the rake face of the tool and discharged along the tooth profile direction. The finally discharged chip shape is similar to a "ji" character, thereby achieving continuous and efficient tooth processing. The entire generation hobbing process is dry cutting, and the chips generated in adjacent tooth grooves are discharged from the tooth grooves one by one along the tooth profile. In the embodiment of the present invention, the movement trajectory of the chips after separating from the workpiece blank is used as the monitoring object to judge whether there are abnormal chips, and further judge whether there is a synchronous error between the current tool axis and the workpiece axis.

[0064] The detailed process of the embodiment of the present invention can be referred to Figure 4 , before formally monitoring the chip state, it is necessary to obtain the theoretical movement trajectory of the chips when there is no synchronous error between the tool axis and the workpiece axis based on the above generation hobbing principle, as the basis for judging the synchronous error after monitoring the actual movement trajectory of the chips. The acquisition of the theoretical movement trajectory of the chips depends on the basic parameters such as the mass, initial position, initial velocity, and chip cross-sectional area of each chip generated by generation hobbing when there is no synchronous error. In the embodiment of the present invention, by establishing a cutting model and obtaining the chip geometric model of each chip therefrom, the above basic parameters are obtained, specifically as follows:

[0065] S111, obtain the generation hobbing tool model, the workpiece model to be processed, the tool running parameters and the workpiece blank running parameters through the numerical control machining program, and establish a cutting model based on the tool running parameters and the workpiece blank running parameters.

[0066] In the specific implementation, first, establish a generation hobbing motion coordinate system, referring to Figure 5 :

[0067] The generation hobbing process involves three motions: the rotational motion of the workpiece , the rotational motion of the tool and the feed motion along the workpiece axis direction . During the movement of the tool and the workpiece, there is always a shaft intersection angle between the tool axis and the workpiece axis. The difference between generating internal gear workpieces and external gear workpieces lies in the center distance value and the tool axis direction.

[0068] Coordinate system is the workpiece coordinate system, where the unit vector is ; Coordinate system is the tool coordinate system, where the unit vector is ; Coordinate system is coordinate system The auxiliary coordinate system of , where the unit vector is ; Coordinate system Is the coordinate system The auxiliary coordinate system of , where the unit vector is .

[0069] Coordinate system Used to establish the workpiece tooth surface model, coordinate system Used to establish tool model, auxiliary coordinate system and The spatial position of is fixed and does not change over time. Indicates the vertical distance between the tool axis and the workpiece axis, the axis angle Indicates the angle between the tool axis and the workpiece axis. Represents the coordinate system As the workpiece rotates relative to the 0-second position, Represents the coordinate system Relative to the auxiliary coordinate system Along the workpiece axis ( The distance moved in the positive direction of the axis, Represents the coordinate system The angle as the tool rotates relative to the time 0 position.

[0070] The edge sweep is the cutting edge in the workpiece coordinate system The swept surface is formed in the tool coordinate system, while the cutting edge of the tooth cutting tool is usually in the tool coordinate system In order to express the blade sweep surface, the workpiece coordinate system To build a chip model, coordinate system conversion is required. To coordinate system The transformation matrix:

[0071]

[0072] Each matrix in the formula is a coordinate transformation matrix:

[0073]

[0074]

[0075]

[0076] Where, Represents the coordinate system To coordinate system The transformation matrix, Represents the coordinate system To coordinate system The transformation matrix, Represents the coordinate system To coordinate system The transformation matrix. and Represent the angular velocities of the workpiece and tool during the skiving process respectively.

[0077] Represents the displacement of the workpiece or tool along the axial direction of the workpiece:

[0078]

[0079] and Represent the number of teeth of the workpiece and tool respectively, and satisfy the following relationship:

[0080]

[0081] Then, create a blade sweep model:

[0082] In order to obtain the blade scanning model, it is necessary to use the coordinate transformation matrix to transform the tool coordinate system The cutting edge in the workpiece coordinate system is transformed into the workpiece coordinate system middle:

[0083]

[0084] Where, express Point on the cutting edge, Indicates the tool coordinate system Middle The distance from a point on the cutting edge of a blade sweep to the tool axis, 、 、 Respectively In the tool coordinate system middle axis, axis, Component in the axial direction. Transform the cutting edge into the workpiece coordinate system The blade sweep surface can be obtained by calculating according to the following formula:

[0085]

[0086] Where, express The point on the middle blade sweep surface, Indicates the coordinate system from the tool To the workpiece coordinate system The transformation matrix of . Equation (8) can be expanded to obtain the parametric equation of the blade scanning surface:

[0087]

[0088] Where,

[0089]

[0090] Then, create a blade sweep family model:

[0091] During tooth scraping, a certain tooth on the tool will first contact and scrape a tooth groove of the workpiece to perform the first edge sweep. Let this tooth be tooth No. 1. The edge sweep surface generated by the relative motion The time for sweeping the tooth groove is When the workpiece rotates one circle, The blade sweeps the tooth groove, that is, the second blade sweep process, the blade sweeps the surface of the tooth groove relative to the tooth groove. The sweep time is , according to the periodicity of the skiving process, the following relationship is satisfied:

[0092]

[0093] Where, represents the remainder, from which we can conclude that when the workpiece rotates Week later, Secondary blade sweeping process, blade sweeping surface Contact tooth groove The time is ,satisfy:

[0094]

[0095] According to the above formula, it can be deduced that when the workpiece rotates After one week, the first tooth groove was cut The No. 1 and No. Secondary tooth cutting of The angle between the teeth is:

[0096]

[0097] Combining formulas (7) and (13), we can get the tooth cutter Parametric equation of the cutting edge on tooth No.:

[0098]

[0099] Combining formulas (8) and (14), The parameter equation of the blade sweep surface formed by the secondary scraping tooth groove is as follows:

[0100]

[0101] Where,

[0102]

[0103] According to equations (15) and (16), several blade sweep surfaces can be calculated, and their collection constitutes the blade sweep surface family.

[0104] Finally, the open chip model is established:

[0105] Combined with the analysis of chip generation process, the expanded chip in the complete cutting state is a spatial geometric body surrounded by three surfaces, namely the tooth surface to be machined (The first one in the family of the previous cutting edge is swept by the The tooth surface is composed of three blade sweeps), the machined tooth surface (The first one in the family of edge sweeping in this machining process blade sweeps) and the first blade sweep family in this processing Blade sweep .

[0106]

[0107] Reference Figure 6 , through discrete cutting edges , the combined equations (15) and (17) can be used to solve the coordinates of the intersection point with the surface during the blade sweep process, that is, 、 、 Then, using curve fitting, we obtain the intersection lines A, B, and C of the three surfaces, which are the boundaries of the unfolded geometric chip. Based on this, we determine the boundaries of the machined tooth surface, the tooth surface to be machined, and the edge sweep surface that constitute the chip outline, and thus establish the chip geometric model.

[0108] S112, based on the chip geometry model obtained above, calculate the chip geometry model after the start of the gear cutting process. Cross-sectional area and volume of each chip:

[0109] In the specific implementation, first, the chip is discretized into several chip elements, each chip element corresponds to a micro-segment cutting edge, and the length of the micro-segment cutting edge is defined as ,set up and They are the coordinate values ​​of the two end points of a certain micro segment edge in the tool coordinate system. According to their position relationship, the length of any micro segment cutting edge on the cutting edge at time t can be obtained. , tool-chip contact edge length and the infinitesimal area :

[0110]

[0111]

[0112]

[0113] Where, is the micro-element chip thickness, the intersection of the tooth surface to be processed and the processed tooth surface As the dividing point, the chip section is divided into two areas, and the chip thickness is expressed as and It means that the microelement chip thickness can be solved by the following formula:

[0114]

[0115] Combining formulas (18), (19) and (20), we can get the first equation corresponding to the cutting edge space trajectory: Cross-sectional area of ​​chips :

[0116]

[0117] Combining formulas (18), (19) and (20), we can get the first equation corresponding to the cutting edge space trajectory: The volume of chips :

[0118]

[0119] Where, , Indicates the The first blade sweep and the The initial contact moment of the blade sweep surface, Indicates the The initial contact moment between the edge sweep surface and the tooth surface formed by the previous radial feed cutting, Indicates the The initial contact moment between the edge sweep surface and the tooth surface formed by the previous radial feed cutting, and Both can be obtained through formula (17).

[0120] S113, based on Chip volume The calculation can be done from the start of the gear cutting process The quality of the chips :

[0121]

[0122] Where, is the metal density, that is, the density of the workpiece blank; The first time after the gear cutting process starts The volume of a chip can be calculated using formula (23).

[0123] S114, then obtain the The initial position of the first chip and the initial speed of the chip after separation from the workpiece blank are used to calculate the Theoretical motion trajectory of a chip.

[0124] For the Initial position of the chip :

[0125] In some embodiments, the cutting model established above is used to directly calculate the first The initial position of a chip in the workpiece coordinate system or tool coordinate system In other embodiments, the cutting model established above is used to directly calculate the first The initial position of a chip in the auxiliary coordinate system of the workpiece coordinate system or the auxiliary coordinate system of the tool coordinate system In some further embodiments, an additional coordinate system is established, and the position of the mth chip in the workpiece coordinate system, the tool coordinate system, the auxiliary coordinate system of the workpiece coordinate system, or the auxiliary coordinate system of the tool coordinate system is calculated using the cutting model established above with reference to the additional coordinate system, and then the position is converted to the additional coordinate system to obtain the mth chip. The initial position of the chip in the additional coordinate system It should be noted that the actual movement trajectory of the chips and the initial position of the chips are monitored. Should be in the same coordinate system.

[0126] For the The initial speed after the chip is separated from the workpiece blank ( ) can be calculated as follows:

[0127] In the embodiment of the present invention, first, the cutting speed when the cutting edge contacts the workpiece during the tooth skiving process is calculated:

[0128]

[0129] Where,

[0130] and are the vector and scalar of the workpiece blank rotation speed, and are the vector and scalar of tool speed respectively, and are the vector and scalar of feed rate respectively, is the workpiece tooth surface in the workpiece coordinate system, is the conjugate surface in the tool coordinate system; 、 、 are the unit vectors of the three coordinate axes of the workpiece coordinate system, is the unit vector of the z-axis of the tool coordinate system, is the center distance between the tool and the workpiece blank.

[0131] Then, the initial speed of the chip after separation from the workpiece blank is:

[0132]

[0133]

[0134]

[0135]

[0136] Where, is the equivalent section shear angle, is the equivalent cross-sectional rake angle, is the angle between the force direction and the y-axis during chip separation, The angle between the force direction during chip separation and the x-axis in the xz plane.

[0137] S115, after obtaining basic parameters such as the mass, initial position, initial velocity, and cross-sectional area of ​​each chip, the theoretical motion trajectory of the chip can be calculated. Taking air resistance into account, the motion equation of each chip is as follows:

[0138]

[0139] Where, is the air density, take 1.225 ; is the acceleration due to gravity, take 9.81 ;

[0140] Define the derivative functions of velocity and position:

[0141]

[0142]

[0143]

[0144]

[0145]

[0146]

[0147] Then, the numerical integration method is used to iteratively calculate the position at each moment, and there is no closed-form solution; the theoretical motion trajectory of the chip is obtained. The numerical integration method used in the embodiment of the present invention is the Runge-Kutta method (fourth order), which is specifically implemented as follows:

[0148]

[0149]

[0150]

[0151]

[0152]

[0153]

[0154]

[0155]

[0156]

[0157]

[0158]

[0159]

[0160]

[0161]

[0162]

[0163]

[0164]

[0165]

[0166]

[0167]

[0168]

[0169]

[0170]

[0171]

[0172] Update chip speed and position:

[0173]

[0174]

[0175]

[0176]

[0177]

[0178]

[0179] Where, is the time step; 、 and Respectively indicate the chips in 、 and acceleration in direction; 、 、 Corresponding respectively 、 and Rate of change of velocity in a direction 、 and The value at the current time step; 、 、 The velocity change rate corresponding to the next half time step; 、 、 Another set of velocity change rates corresponding to the next half time step; 、 、 The rate of change of velocity corresponding to the next full time step.

[0180] The position of each chip at each time step can be obtained by the above numerical integration method, and then the theoretical motion trajectory of each chip can be obtained.

[0181] In order to facilitate the subsequent comparison of the theoretical motion trajectory of a certain chip with the actual motion trajectory, in an embodiment of the present invention, the moment when each chip is generated is calculated based on the above-mentioned cutting model, which is defined as the theoretical moment of the chip ; and calculate the moment when the first chip is generated in the entire workpiece processing time period, and the moment when the last chip is generated in the entire workpiece processing time period, which are defined as the starting time and end time , the time period when chips are generated During the period of chip generation Sort each chip generation time; set the total generation time Chips are marked according to the order in which they are generated. , construct the chip generation sequence; according to the chip generation sequence, their theoretical motion trajectories are marked as , construct the chip trajectory sequence.

[0182] When comparing the theoretical motion trajectory of a chip with the actual motion trajectory, we only need to use the time as the basis to find the chip number in the chip generation sequence that is generated at the corresponding moment in the entire processing process, and then obtain its corresponding theoretical motion trajectory. The chips generated by the tooth-scratching process at this time are The theoretical trajectory of a chip is .

[0183] In the process of formally monitoring the chip status, it can be carried out through the trajectory monitoring method (the monitoring object is the trajectory path) and the point monitoring method (the monitoring object is the trajectory passing point). For the trajectory monitoring method, the chip trajectory path can be monitored by computer vision technology, laser tracking technology, infrared sensing technology, etc. For the point monitoring method, fixed-point monitoring technology can be used to monitor whether the chips pass through a certain point. Regardless of which of the above chip status monitoring methods is used, the collected chip motion trajectory information must be the motion trajectory information of the chips after they are separated from the blank and before they come into contact with any object. After the chips are separated from the blank, if they come into contact with other objects, their motion trajectory is affected by many complex factors and should no longer be used as the basis for chip abnormality detection.

[0184] In some embodiments, computer vision technology is employed. Specifically, a high-speed camera or multi-camera system captures a sequence of images of chip motion. Image processing algorithms (such as optical flow or feature point tracking in the OpenCV library) are then used to determine the chip's positional changes within the image. This in turn calculates the chip's trajectory in the spatial coordinate system, with the monitoring results directly output as trajectory information. This approach is suitable for gear skiving operations in stable ambient lighting conditions, minimizing the impact of ambient lighting on monitoring results.

[0185] In the embodiment of the present invention, a fixed-point monitoring technology is adopted, and its specific implementation method is as follows: after obtaining the theoretical motion trajectory of the chips during the tooth skiving process, a sensing part is set on its theoretical motion trajectory, and the sensing area of ​​the sensing part needs to cover the motion trajectory of the chips, and a certain redundant sensing area is set to ensure that the chips moving along the theoretical motion trajectory and the error motion trajectory can be effectively covered and collected when they reach the points in the sensing area, and the monitoring results are output in the form of position information.

[0186] In the embodiment of the present invention, a monitoring coordinate system is established to determine whether there is an error in the chip trajectory, and the theoretical motion trajectory of the chip is converted to the actual value. Convert to the monitoring coordinate system, and convert each sensing point in the sensing area to the monitoring coordinate system. Then adjust the position and angle of the sensing piece once more to make the theoretical motion trajectory of the chips in the whole tooth scraping process If the position and angle of the sensor are adjusted once, the theoretical movement trajectory of the chips in the entire tooth scraping process cannot be achieved. If all chips pass through the sensing area, the adjustment strategy of the sensing part is calculated and generated. The adjustment strategy is the multiple adjustment positions and angles of the sensing part, including the position and angle that the sensing part should be at at a certain moment or time period. After the tooth skiving process begins, the position and angle of the sensing part are adjusted according to the adjustment strategy so that the theoretical motion trajectory of the chips generated at each moment passes through the sensing area, ensuring that the position of the chips generated at each moment when they arrive in the sensing area can be effectively obtained, and the theoretical positions of the chips arriving in the sensing area are marked according to the order in which the chips are generated as follows: , construct the chip position sequence. The generation time, theoretical trajectory and position of each chip passing through the sensing area form a one-to-one mapping relationship Y among the chip generation sequence, chip trajectory sequence and chip position sequence, that is: , , .

[0187] Since gear skiving may involve both internally and externally toothed gears, the size of the sensor can be reduced to avoid hindering the gear skiving process by overly large sensing areas. This can be accomplished by generating a sensor adjustment strategy through the aforementioned steps. In some embodiments, the sensing area of ​​the sensor can be automatically adjusted in position and angle as the workpiece advances. In short, the goal is to ensure that all generated chips pass through the sensing area.

[0188] S12, analyzes the synchronization error of the machine tool axes (workpiece axis and tool axis) based on the chip state;

[0189] In the actual gear skiving process, the synchronization error of the machine tool axis mainly includes: the speed ratio error between the workpiece axis and the tool axis; or the speed ratio between the workpiece axis and the tool axis does not produce an error, but the speeds of both are offset. For the former, it will directly affect the workpiece processing accuracy and surface quality. At a certain moment, the actual chips differ from the theoretical chips, and the chip movement trajectory after discharge deviates from the theoretical movement trajectory. For the latter, it will directly affect the workpiece processing efficiency, increase cutting heat or reduce tool life. At a certain moment, the actual chips differ from the theoretical chips, and the chip movement trajectory after discharge deviates from the theoretical movement trajectory. However, it is only the offset of the chip generation time. The chip generation from the start of gear skiving is the first error. The motion trajectory of each chip will not deviate from its corresponding theoretical motion trajectory, only the occurrence time of the monitored actual motion trajectory of the chip will be offset.

[0190] In the embodiment of the present invention, the chip state is the actual motion trajectory of the chip. In a specific implementation, the above two synchronization error conditions are defined as a speed ratio error and a speed error.

[0191] The actual motion trajectory of the chips is recorded sequentially, and the actual position of each chip at the sensing area is recorded using a point-by-point monitoring method. Based on the current moment or several moments within a time period, and according to a mapping relationship Y, the deviation between the actual position of the chip at the sensing area and the theoretical position is compared to determine whether the current workpiece axis and tool axis are synchronized. When the workpiece axis and tool axis are synchronized, the chips are normal. When the workpiece axis and tool axis are synchronized, the chips are abnormal, with variations in chip shape, mass, initial position, and initial velocity. The actual motion trajectory after being ejected from the workpiece tooth groove differs from the theoretical motion trajectory, and the actual position of the chip at the sensing area differs from the theoretical position at the time of arrival. Therefore, if the deviation between the actual position of the chip at the sensing area and the theoretical position is greater than an allowable threshold, synchronization error is determined to exist between the current workpiece axis and tool axis. In some embodiments, the allowable threshold is determined based on the cross-sectional area of ​​the chip. When a chip with a smaller cross-sectional area arrives at the sensing area, the position error detected by the sensing area is smaller, and vice versa. Therefore, the allowable threshold is positively correlated with the cross-sectional area of ​​the chip. Furthermore, the allowable threshold is negatively correlated with the desired synchronization control response sensitivity.

[0192] After determining that the current machine tool axis is in an asynchronous state, it is necessary to judge the synchronization error situation in order to accurately perform synchronization control later. For the speed ratio error, it is sufficient to control the drive side of the axis where the error occurs separately. For the speed error, it is necessary to synchronously control and adjust the drive sides of the workpiece axis and the tool axis. According to the recorded positions of each chip actually arriving at the sensing area, it is prioritized to analyze whether the position of each chip arriving at the sensing area is continuously overlapped with the position of each chip theoretically arriving at the sensing area in the chip position sequence without considering the arrival time. If there is continuous overlap between the two without considering the arrival time within the preset time period, the current synchronization error situation is determined to be a speed error; if there is no continuous overlap between the two without considering the arrival time within the preset time period, the current synchronization error situation is determined to be a speed ratio error.

[0193] After determining the synchronization error, it's also necessary to determine the machine axis (workpiece axis or tool axis) to be synchronized and the control amount. Since the causes of synchronization errors on the transmission and cutting sides are complex, accurate determination is difficult. Therefore, in this embodiment of the present invention, the synchronization error amounts for the workpiece and tool axes are not precisely determined. Instead, a fuzzy control approach is employed to supplement the existing encoder monitoring system of the gear skiving machine tool, compensating for the monitoring and control of synchronization errors on the transmission and cutting sides, thereby achieving more precise synchronization control.

[0194] One implementation method involves outputting a basic control strategy (the first control strategy): Based on the precision requirements of the workpiece to be machined, a synchronization control response sensitivity and a basic control amplitude are set. While the synchronization control response sensitivity is typically fixed, the control amplitude is dynamically generated throughout the gear-shaving process using a PID-like control method. Specifically, the greater the synchronization error between the workpiece axis and the tool axis, the greater the control amplitude. The synchronization error between the workpiece axis and the tool axis is proportional to the deviation between the actual position of the chip at the sensing area and its theoretical position at the sensing area. In addition to the synchronization control response sensitivity and control amplitude, the control strategy also includes the axes to be controlled. In specific implementation, the workpiece axis and tool axis are controlled randomly or according to a set priority, thereby outputting a complete control strategy. For speed errors, the workpiece axis and tool axis are controlled simultaneously according to the control amplitude. For speed ratio errors, either the workpiece axis or the tool axis is controlled independently, either randomly or according to a set priority.

[0195] After the control strategy is executed, the synchronization error between the workpiece axis and the tool axis is continuously monitored. Based on the synchronization error between the workpiece axis and the tool axis after the control strategy is executed, the controlled axis is generated and the latest control amplitude is dynamically generated. For example, if the synchronization error between the workpiece axis and the tool axis decreases after the control strategy is executed, the controlled axis will continue to be controlled with a smaller control amplitude until the synchronization error between the workpiece axis and the tool axis is eliminated.

[0196] Obviously, the basic control strategy output method has the problem of multiple output control strategies and multiple control strategies, which is difficult to meet the requirements of workpiece tooth processing with extremely high quality and precision requirements. Another implementation method is to output a control strategy (second control strategy) based on a machine learning algorithm or a deep learning algorithm. In the specific implementation, a machine learning algorithm is used:

[0197] First, it is necessary to build a control strategy model, which can be built based on existing machine learning models such as linear regression models, support vector machines, and neural network models.

[0198] Next, the constructed machine learning model needs to be trained to collect several sets of chip arrival data and gear-skimming machine operating parameters when synchronization errors occur between the workpiece axis and the cutter axis. Specifically, chip arrival data includes: the actual position of the chip at the sensing area, the actual time the chip arrives at the sensing area, the deviation between the actual position of the chip at the sensing area and the theoretical position of the chip at the sensing area (deviation amount, deviation direction, etc.), and the deviation between the actual position of the chip at the sensing area and the theoretical time of arrival (lead amount, delay amount, etc.). Gear-skimming machine operating parameters include: cutter axis rotation speed, workpiece axis rotation speed, feed speed, feed rate, continuous operation time of the gear-skimming machine, current workpiece gear processing time, workpiece gear type, workpiece normal module, etc. Furthermore, when synchronization errors occur between the workpiece axis and the cutter axis, control amplitude data output according to the basic control strategy output method is collected, as well as the corresponding synchronization control response sensitivity, the selection of the controlled axis (workpiece axis or cutter axis), and the change in synchronization error after control.

[0199] The collected data is cleaned to remove noise and outliers. Feature extraction is performed, with synchronization error, position deviation, etc. as input features, and control amplitude and control axis selection as output labels. At the same time, the data is normalized or standardized to adapt it to the input and output requirements of the model. The preprocessed data is divided into training set, validation set, and test set. The training set data is input into the control strategy model, and the loss function is minimized through the optimization algorithm. For the output of the control amplitude, a regression loss function such as mean square error is used; for the output of the control axis selection, a classification loss function such as the cross entropy loss function is used. During the training process, the output is calculated through forward propagation, and then the backpropagation algorithm is used to calculate the gradient and update the model parameters. The performance of the model is evaluated on the validation set, and then the model is fully tested using the test set to obtain the trained control strategy model.

[0200] The control strategy model, based on chip arrival data when synchronization errors occur between the workpiece axis and the cutter axis, as well as the operating parameters of the gear-skimming machine, can efficiently output an accurate control strategy. The control amplitude and controlled axes included in the control strategy are more accurate, and the number of control cycles is low, enabling efficient and precise synchronization of the workpiece axis and the cutter axis, meeting the requirements for gear-skimming operations requiring extremely high quality and precision. In some embodiments, the model can also predict potential synchronization errors between the workpiece axis and the cutter axis based on chip arrival data when synchronization errors occur between the workpiece axis and the cutter axis, as well as the operating parameters of the gear-skimming machine, thereby generating a pre-control strategy in advance to avoid certain synchronization errors and further improve the accuracy of the gear-skimming operation.

[0201] S13, regulating the rotation speed of the machine tool axis (workpiece axis and / or tool axis) based on the synchronization error;

[0202] The tool spindle of a gear-shaving machine tool is typically driven by a tool spindle motor, while the workpiece spindle is typically driven by a workpiece spindle motor. Both the tool spindle motor and the workpiece spindle motor are equipped with an integrated rotary encoder monitoring system 103, which can monitor synchronization errors between the motors and provide timely synchronization control. Synchronization errors between the workpiece spindle and tool spindle can still occur on both the transmission and cutting sides of the workpiece spindle and tool spindle. These errors are primarily caused by manufacturing errors in transmission components, assembly errors in transmission components, elastic deformation and backlash in transmission components after long-term use, thermal deformation of transmission components, and tool wear and deformation.

[0203] The causes of synchronization errors, as described above, are complex and difficult to quantify. However, any synchronization errors between the workpiece axis and the tool spindle will result in abnormal chips during gear skiving. S11 monitors chip anomalies, and S12 determines the synchronization error between the workpiece axis and the tool spindle, outputting a corresponding control strategy. Executing this control strategy allows for the synchronization errors between the workpiece axis and the tool spindle on both the transmission and cutting sides to be controlled.

[0204] Before executing the control strategy, it is necessary to rule out the possibility that the chip anomaly is caused by a synchronization error on the drive side. This can be determined based on the monitoring data and synchronization control status of the rotary encoder monitoring system 103. If the rotary encoder monitoring system 103 does not detect a synchronization error on the drive side and does not perform synchronization control, it is determined that the chip anomaly is caused by a synchronization error on the non-drive side, and the control strategy can be executed.

[0205] After the control strategy is executed, it ultimately affects the workpiece axis motor and / or the cutter axis motor, primarily regulating their speed. Gear-shaving machine tool motor speed control is typically achieved through devices such as frequency converters, servo drives, and DC speed regulators. Therefore, speed control of the machine tool motor is achieved by converting the strategy execution into commands readable by these devices and having them execute the commands.

[0206] During the execution phase of the control strategy, since the rotary encoder monitoring system 103 does not detect the presence of a synchronization error on the drive side, that is, the rotary encoder monitoring system 103 believes that the current workpiece shaft motor and the cutter shaft motor are at normal speeds and there is no synchronization error. However, after the control strategy is executed, the speed of the workpiece shaft motor and / or the cutter shaft motor will change. If the rotary encoder monitoring system 103 is not informed in advance, the change in the speed of the workpiece shaft motor and / or the cutter shaft motor will be determined by the system as the presence of a synchronization error on the drive side, resulting in a conflict between the synchronization error control on the transmission side and the cutting side and the synchronization error control on the drive side. Therefore, it is necessary to send the control strategy to the rotary encoder monitoring system 103, inform it of the speed of the workpiece shaft motor and / or the cutter shaft motor after the control strategy is executed, and let the rotary encoder monitoring system 103 update the normal speed of the workpiece shaft motor and the cutter shaft motor.

[0207] In a specific implementation, when the control strategy is not received, the normal rotation speeds of the workpiece shaft motor and the tool shaft motor stored in the rotary encoder monitoring system 103 are defined as the default driving speed; when the rotation speeds of the workpiece shaft motor and the tool shaft motor deviate from the default driving speed, the rotary encoder monitoring system 103 executes drive-side synchronization error control.

[0208] After receiving the control strategy for the first time, the default driving speed is updated to the primary control driving speed. When the speeds of the workpiece shaft motor and the tool shaft motor deviate from the primary control driving speed, the rotary encoder monitoring system 103 performs drive-side synchronization error control.

[0209] After receiving the control strategy for the second time, the default drive speed is updated to the secondary control drive speed. When the speeds of the workpiece shaft motor and the tool shaft motor deviate from the secondary control drive speed, the rotary encoder monitoring system 103 performs the drive side synchronization error control.

[0210] This process continues in this way until the gear skiving process is complete for a single workpiece, and the rotary encoder monitoring system 103 is reset. Building on the precise control of drive-side synchronization errors, this system is further expanded to compensate for synchronization errors on both the transmission and cutting sides, building a comprehensive, high-precision synchronization control system. This ensures precise coordination between the workpiece axis and the tool axis throughout the gear skiving process, comprehensively improving the overall accuracy and workpiece quality of the gear skiving process.

[0211] In order to enable those skilled in the art to better understand and implement the technical solution of the present invention, the system and machine tool based on the above method are described in detail below:

[0212] Reference Figure 7The present invention also provides a gear-shaving machine tool axis synchronization control system, comprising an error analysis module 101 and a control module 102. The error analysis module 101 is used to monitor the chip state generated during the gear-shaving process; based on the chip state, it analyzes the synchronization error of the machine tool axes (the workpiece axis and the tool axis); and the control module 102 is used to control the rotational speed of the machine tool axes (the workpiece axis and / or the tool axis) based on the synchronization error.

[0213] In a specific implementation, the error analysis module 101 first collects parameters of the workpiece to be machined and the tool used to machine it. These parameters can be obtained through the CNC machining program to generate a corresponding theoretical chip state, which in the embodiment of the present invention is the theoretical motion trajectory after the chips are discharged. Gearing begins, and the error analysis module 101 collects the actual chip state, which in the embodiment of the present invention is the actual motion trajectory after the chips are discharged. The error analysis module 101 interacts with the control module 102, which in turn interacts with the rotary encoder monitoring system 103. The error analysis module 101 compares the actual chip state with the theoretical chip state to determine whether the chips are abnormal, and further determines whether there is a synchronization error between the workpiece axis and the tool axis, and generates a corresponding control strategy. After receiving the control strategy, the control module 102 verifies whether there is a synchronization error on the current drive side from the rotary encoder monitoring system 103. If there is a synchronization error on the drive side, the control strategy is terminated and the rotary encoder monitoring system 103 performs synchronization control. If there is no synchronization error on the drive side, the control strategy is sent to the rotary encoder monitoring system 103 and then executed. Both the control module 102 and the rotary encoder monitoring system 103 interact with the machine tool shaft drive control device 104. The synchronous error control on the driving side is controlled by the rotary encoder monitoring system 103 to control the machine tool shaft drive control device 104, and the synchronous error control on the transmission side and the cutting side is controlled by the control module 102 to control the machine tool shaft drive control device 104.

[0214] In a specific implementation, the error analysis module 101 is the sensing component in the above method. The error analysis module 101 corresponds to the data type of the monitored chip state. If the collected chip state is the actual movement trajectory of the chip, the error analysis module 101 can be a high-speed camera, an infrared camera, a multi-sensor fusion device, etc., which can collect the actual movement trajectory of the chip. If the collected chip state is the arrival point of the chip, the collection unit of the error analysis module 101 can be a sensing device such as a photoelectric sensor or an inductive sensor. However, the above-mentioned devices as the collection units of the error analysis module 101 are all susceptible to interference from the complex environment of the tooth scraping process. For this reason, the embodiment of the present invention proposes a collection unit of the error analysis module 101 that is adapted to the auxiliary environment of the tooth scraping process, which is composed of a movable monitoring surface 200 and a flexible film pressure sensor 204.

[0215] Reference Figure 8 and Figure 9 In a specific implementation, the movable monitoring surface 200 is composed of six substrates 201. Adjacent substrates 201 are hinged by flexible connectors 202. The flexible connectors 202 can realize bending and twisting between the substrates 201 within a certain range. An angle adjustment mechanism 203 is integrated on the back of the substrate 201. The angle adjustment mechanism 203 is used to adjust the angle of any substrate 201. In some embodiments, the angle adjustment mechanism 203 is designed with reference to the flexible finger structure of the flexible air gripper, which can realize the angle adjustment of the substrate 201 by filling and deflating air. In other embodiments, the angle adjustment mechanism 203 is designed with a mechanical angle adjustment structure. Flexible film pressure sensors 204 are provided on the surface of the substrate 201. The coverage area of ​​the flexible film pressure sensor 204 is the sensing area in the above method. The arrival position of the chips is detected by the pressure points on the surface of the flexible film pressure sensor 204. With reference to Figure 10 In a specific implementation, the angle adjustment mechanism 203 is controlled to adjust the angle of each substrate 201, so that the front of the substrate 201 faces the direction of the chip trajectory as much as possible, and the chips reach the surface of the flexible film pressure sensor 204 vertically, which can improve the accuracy of chip arrival position detection. Figure 11 When the tooth groove of the workpiece reaches the dotted line position, the initial position of separation between the chip and the workpiece is The chip movement trajectory follows the arrow direction and reaches the surface position of the flexible film pressure sensor 204 as the circled position. Figure 10 and Figure 11 The middle-bent active monitoring surface 200 is formed according to the theoretical movement trajectory of the chips through the angle adjustment mechanism 203, which is conducive to collecting chips, making the chips flow in the collection direction, and reducing chip splashing.

[0216] Reference Figure 12 An embodiment of the present invention further provides a gear scraping machine tool, which is integrated with the above-mentioned gear scraping machine tool axis synchronization control system. The acquisition unit of the error analysis module 101 of the embodiment of the present invention is set on the tool shaft device and is equipped with a position adjustment mechanism and an angle adjustment mechanism 203. The acquisition unit of the error analysis module 101 can perform position and angle adjustment so that the theoretical motion trajectory of the chips in the gear scraping process passes through the sensing area to ensure effective monitoring of the chip status.

[0217] Obviously, the above embodiments are merely examples for clarity of explanation and are not intended to limit the implementation methods. Those skilled in the art will readily appreciate that other variations or modifications based on the above descriptions are possible. It is not necessary and impossible to enumerate all implementation methods here. Obvious variations or modifications arising therefrom remain within the scope of protection of the present invention.

Claims

1. A gear cutting machine tool axis synchronization control method, characterized in that: include: Analyze the synchronization error of machine tool axes based on the chip state generated during gear skiving; The chip state is the motion trajectory information of the chips generated during the gear skiving process after they are separated from the workpiece blank; The motion trajectory information is the trajectory waypoints. By setting at least one sensing area on the motion trajectory of the chip, the position information of the chip when it reaches the sensing area is monitored, which is defined as the actual trajectory waypoint. The position information of the chip when it reaches the sensing area in the theoretical motion trajectory is extracted and defined as the theoretical trajectory waypoint. The synchronization error of the machine tool axis is analyzed by comparing the theoretical trajectory waypoints with the actual trajectory waypoints. The rotation speed of the machine tool axis is regulated based on the synchronization error.

2. The gear cutting machine tool axis synchronization control method according to claim 1, characterized in that: The chip state includes theoretical chip state and actual chip state. The theoretical chip state is the theoretical motion trajectory information of the chips generated during the gear skiving process after separation from the workpiece blank. The actual chip state is the actual motion trajectory information of the chips generated during the gear skiving process after separation from the workpiece blank. The acquisition method is as follows: The chip state generated when there is no synchronization error in the theoretical state is obtained, which is defined as the theoretical chip state. The chip state generated during the actual gear cutting process is monitored, which is defined as the actual chip state.

3. The gear cutting machine tool axis synchronization control method according to claim 2, characterized in that: Monitor the actual chip state. When the difference between the actual chip state and the theoretical chip state is greater than a threshold, it is determined that there is a synchronization error in the machine tool axis. The amount of synchronization error in the machine tool axis is proportional to the difference between the actual chip state and the theoretical chip state.

4. The gear cutting machine tool axis synchronization control method according to claim 1, characterized in that: Before synchronous control, the basic control amplitude is set; when there is a synchronization error in the machine tool axis, the basic control amplitude is adjusted based on the chip state difference generated when the machine tool axis has a synchronization error, and the machine tool axis to be controlled is selected randomly or according to the set priority. The adjusted basic control amplitude and the machine tool axis to be controlled are output as the first control strategy. After the first control strategy is executed, the first control strategy is updated based on the change in the machine tool axis synchronization error.

5. The gear cutting machine tool axis synchronization control method according to claim 1, characterized in that: Taking the chip state generated when there is a synchronization error in the machine tool axis and the operating parameters of the gear skiving machine tool as samples, a control strategy model is constructed and trained using a machine learning algorithm or a deep learning algorithm. When there is a synchronization error in the machine tool axis, the second control strategy is output through the control strategy model.

6. The gear cutting machine tool axis synchronization control method according to claim 5, characterized in that: The chip status and gear skiving machine operating parameters are collected, and the pre-control strategy is output through the control strategy model.

7. The gear cutting machine tool axis synchronization control method according to any one of claims 1 to 6, characterized in that: Based on the precision requirement of the workpiece to be processed, the synchronous control response sensitivity is set, and the synchronous control response sensitivity is proportional to the precision requirement of the workpiece to be processed.

8. The gear cutting machine tool axis synchronization control method according to any one of claims 4 to 6, characterized in that: When the rotary encoder monitoring system does not detect any synchronization error on the gear cutting machine tool drive side and is not performing synchronization control, the machine tool axis is allowed to be adjusted; when the rotary encoder monitoring system detects any synchronization error on the gear cutting machine tool drive side or is performing synchronization control, the machine tool axis adjustment is terminated.

9. The gear cutting machine tool axis synchronization control method according to claim 2, characterized in that: Analyze whether there is continuous overlap between the actual chip state and the theoretical chip state regardless of time; if there is continuous overlap between the actual chip state and the theoretical chip state regardless of time within a preset time period, it is determined that there is a speed error in the machine tool axis; if there is no continuous overlap between the actual chip state and the theoretical chip state regardless of time within a preset time period, it is determined that there is a speed ratio error in the machine tool axis.

10. The gear cutting machine tool axis synchronization control method according to claim 9, characterized in that: The machine tool axis includes the workpiece axis and the tool axis; If there is a speed error in the machine tool axis, the workpiece axis and tool axis are regulated synchronously; If there is a speed ratio error in the machine tool axes, the workpiece axis or tool axis can be controlled independently.

11. The gear cutting machine tool axis synchronization control method according to claim 1, characterized in that: The motion trajectory information of the chips is part or all of the motion trajectory of the chips from the time they are separated from the workpiece to the time they come into contact with any object.

12. The gear cutting machine tool axis synchronization control method according to claim 1, characterized in that: The sensing area covers the movement trajectory of the chips generated during the gear skiving process, and a redundant sensing area is set at the edge of the sensing area.

13. The gear skiving machine tool axis synchronization control method according to claim 12, characterized in that: A monitoring coordinate system is established, and each sensing point in the sensing area is converted into the monitoring coordinate system. The position and angle of the sensing area are adjusted so that the theoretical motion trajectory of the chips in the entire tooth scraping process passes through the sensing area.

14. The gear cutting machine tool axis synchronization control method according to claim 12, characterized in that: Establish a monitoring coordinate system, convert each sensing point in the sensing area into the monitoring coordinate system, and calculate the adjustment strategy of the sensing area; the adjustment strategy is the adjustment position and angle of several groups of sensing areas; After the gear skiving process begins, the sensing area is adjusted according to the adjustment strategy.

15. The gear cutting machine tool axis synchronization control method according to claim 1, characterized in that: The moment of each chip generation is calculated based on the cutting model, which is defined as the theoretical chip generation moment, and each chip generation moment is sorted within the chip generation time period; A chip generation sequence is constructed according to the chip generation order; a chip trajectory sequence is constructed according to the theoretical motion trajectory corresponding to each chip in the chip generation sequence; and a mapping relationship between the chip generation sequence and the chip trajectory sequence is established; Based on the moment after the gear skiving process begins, the theoretical motion trajectory of the chips generated at the corresponding moment is obtained, and the synchronization error of the machine tool axis is analyzed by comparing the actual motion trajectory monitored at the same moment.

16. The gear skiving machine tool axis synchronization control method according to claim 15, characterized in that: A chip position sequence is constructed based on the theoretical position of each chip in the chip trajectory sequence corresponding to the theoretical motion trajectory of each chip in the sensing area; a mapping relationship between the chip generation sequence, the chip trajectory sequence, and the chip position sequence is established; Based on the time after the gear skiving process starts, the theoretical position of the chips generated at the corresponding moment in the sensing area is obtained, and the synchronization error of the machine tool axis is analyzed by comparing the actual position in the sensing area monitored at the same time.

17. The gear skiving machine tool axis synchronization control method according to any one of claims 4 to 6, characterized in that: The control strategy is sent to the rotary encoder monitoring system, which updates the nominal speed of the machine tool axis drive side.

18. A gear-shaving machine tool axis synchronization control system, characterized in that: include: Error analysis module, which analyzes the synchronization error of the machine tool axis based on the chip state generated during the gear skiving process; The chip state is the motion trajectory information of the chips generated during the gear skiving process after they are separated from the workpiece blank; The motion trajectory information is the trajectory passing point; by setting at least one sensing area on the motion trajectory of the chip, the position information of the chip when it reaches the sensing area is monitored, which is defined as the actual trajectory passing point; the position information of the chip when it reaches the sensing area in the theoretical motion trajectory is extracted and defined as the theoretical trajectory passing point; Compare the theoretical trajectory path points with the actual trajectory path points to analyze the synchronization error of the machine tool axis; The control module controls the rotation speed of the machine tool axis based on the synchronization error.

19. The gear skiving machine tool axis synchronization control system according to claim 18, characterized in that: The error analysis module signal is connected to the rotary encoder monitoring system and the machine tool axis drive control device. The error analysis module obtains the synchronization error situation of the machine tool axis drive side through the rotary encoder monitoring system; The control module is used to control the rotation speed of the machine tool axis based on the synchronization error when there is a synchronization error in the machine tool axis and there is no synchronization error on the driving side of the machine tool axis.

20. The gear skiving machine tool axis synchronization control system according to claim 18 or 19, characterized in that: The error analysis module is used to monitor the trajectory of the chips generated during the gear skiving process. The error analysis module includes a movable monitoring surface, which is composed of several substrates. Adjacent substrates are hinged by flexible connectors. An angle adjustment mechanism for adjusting the angle of any substrate is integrated on the back of the substrate, and flexible thin film pressure sensors are provided on the surface of the substrate.

21. The gear skiving machine tool axis synchronization control system according to claim 20, characterized in that: The angle adjustment mechanism is used to adjust the base plate according to the theoretical movement trajectory of the chips so that the chips flow toward the collection area.

22. A gear skiving machine tool, comprising a rotary encoder monitoring system and a machine tool axis drive control device, characterized in that: The gear cutting machine tool axis synchronization control system according to claim 18 is integrated, and the gear cutting machine tool axis synchronization control system is used to synchronize the machine tool axis.

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