Multifunctional cutting base and cutting method for large fan castings

Abstract

The application discloses a multifunctional cutting base for large fan castings and a cutting method, and relates to the technical field of casting cutting processing. The base comprises an adaptive support platform, a composite damping assembly, a vibration control unit and a chip and oil mist recovery unit. The adaptive support platform is attached to the bottom of the casting through a plurality of hydraulically adjusted spherical hinge universal planes with angles and heights, forms a profiled support surface to realize multi-point adaptive clamping. The composite damping assembly adjusts the damping through a damping unit and cooperates with the vibration control unit to dynamically respond to the processing vibration to stabilize the processing posture of the casting. The chip and oil mist recovery unit is provided with a liquid-solid separation module, a dust collection cover with negative pressure suction and a chip removal channel for synchronously collecting and separating the dust, metal chips and cooling oil generated in the turning process. The application effectively improves the clamping stability and processing precision of large castings, improves the processing site environment and solves the problem of the influence of the existing large casting processing platform on the casting processing state.

Description

Technical Field

[0001] This invention relates to the field of casting cutting technology, and in particular to a multifunctional cutting base and cutting method for large fan castings. Background Technology

[0002] As one of the most important energy conversion devices in the current new energy field, wind turbines rely on large castings, such as hubs, nacelle bases, and main shaft connectors, for key structural components that bear the core functions of load-bearing and transmission. These castings are generally characterized by thick walls, complex structures, high geometric precision requirements for assembly positions, and large single-piece weight. Their manufacturing process involves multiple key technological steps, including casting, rough machining, finish machining, and heat treatment.

[0003] In the machining of large wind turbine castings, the traditional method involves hoisting the casting onto a heavy-duty vertical machine tool or heavy-duty CNC milling machine for rough machining after casting and sprue separation. The rough machining stage primarily involves pre-machining the main surfaces and mounting datum to facilitate positioning for subsequent finish machining. However, due to the enormous size and diverse structures of wind turbine castings, a single type of general-purpose machine tool or milling machine is insufficient to meet the multi-faceted machining requirements of different castings during the finish machining stage. Therefore, finish machining often requires changing to different types of machine tools or repeatedly hoisting the casting onto different clamping fixtures, resulting in longer machining cycles, lower process efficiency, and additional positioning errors introduced by multiple clamping operations.

[0004] During the finishing process, large castings of wind turbines often have irregular inner and outer contours, requiring turning tools to perform multi-axis linkage along complex curved surfaces. In addition, the castings are heavy and lack sufficient support rigidity. If the clamping stability is slightly lacking, vibration is easily generated during machining, which aggravates cutting stress and thermal deformation, directly affecting the flatness, smoothness and dimensional accuracy of the machined surface. Especially in critical areas such as high-precision mating surfaces and flange mounting surfaces, traditional clamping platforms, lacking vibration reduction and adjustable support structures, are unable to effectively suppress vibration, causing subsequent assembly errors and operating noise risks.

[0005] In addition, the machining volume of large castings is usually large, and the large amount of chips and dust generated during the cutting process is difficult to clean up quickly. They tend to accumulate around the workpiece and on the guide slide, which not only affects the smoothness of the subsequent tool path, but also aggravates the wear of the guide components and reduces the service life of the equipment. At the same time, the dusty environment at the machining site also puts forward higher requirements for the health of operators and the safety of equipment.

[0006] Although some existing improved turning tables have introduced adjustable support seats, hydraulic clamping systems or rotating base structures, they still generally suffer from problems such as insufficient rigidity, narrow adaptability, poor chip removal, and unfriendly machining environment, making it difficult to meet the comprehensive requirements of stability, precision and efficiency for large fan castings in the finishing stage.

[0007] The existing technology has the following technical problems:

[0008] (1) The casting has a complex structure and large mass, and the existing turning base is difficult to provide high rigidity support and precise positioning;

[0009] (2) When turning complex curved surfaces in the finishing stage, poor vibration control can easily lead to machining errors and affect accuracy.

[0010] (3) During the processing, a large amount of chips and dust accumulate, affecting equipment operation and environmental hygiene. There is still a lack of efficient cleaning and collection solutions.

[0011] (4) The low efficiency of process switching and clamping limits the overall processing cycle and capacity.

[0012] In summary, the existing technology has at least the following technical problems:

[0013] Existing large casting processing platforms are unable to provide high rigidity support and precise positioning for castings, and also suffer from technical problems such as poor vibration control, difficulty in cleaning chips and dust during processing, and low casting clamping efficiency. Summary of the Invention

[0014] The purpose of this invention is to provide a multifunctional cutting base and cutting method for large wind turbine castings, in order to solve the technical problems of existing large casting processing platforms that are difficult to provide high rigidity support and precise positioning for castings, as well as poor vibration control, difficulty in cleaning chips and dust during processing, and low casting clamping efficiency.

[0015] The preferred technical solutions among the many technical solutions provided by this invention can produce a variety of technical effects, which are described in detail below.

[0016] To address the aforementioned technical problems, the present invention provides the following technical solution:

[0017] This invention provides a multifunctional cutting base for large wind turbine castings, including an adaptive support platform with multiple hydraulic support units mounted on a base component. Each hydraulic support unit has a ball-and-socket universal joint. The multiple hydraulic support units are connected to the bottom of the casting to be clamped via the ball-and-socket universal joint, allowing adjustment of the support height and orientation according to the shape of the casting's bottom, forming a contour-following support surface that conforms to the casting's bottom surface, achieving multi-point adaptive clamping. It also includes a composite vibration damping assembly, comprising a rigid connecting plate on the upper layer, a vibration damping unit in the middle, and a rigid base component on the lower layer. The vibration damping unit is filled with magnetorheological fluid. The rigid connecting plate is connected to the base component of the adaptive support platform, and the rigid base component is connected to the worktable of a CNC machine tool. Finally, it includes a vibration control unit, comprising multiple acceleration sensors and... A damping regulator connected to the control valve of the magnetorheological fluid; an acceleration sensor mounted on the base component and electrically connected to the damping regulator; the damping regulator dynamically adjusts the flow resistance of the magnetorheological fluid based on the vibration signal fed back by the acceleration sensor, thereby achieving damping adjustment of the vibration reduction unit; and a chip and oil mist recovery unit, including an annular dust collection hood mounted outside the CNC machine tool spindle and capable of synchronously moving along the spindle feed direction, a chip removal channel and a liquid-solid separation module disposed within the adaptive support platform; the chip removal channel is arranged in the gap area between the ball joint universal planes of the hydraulic support unit, used to collect chips and cooling oil generated during the cutting process, and separated by the liquid-solid separation module; the dust collection hood maintains stable suction to dynamically recover dust and oil mist following the cutting tool.

[0018] In one embodiment, the adaptive support platform is further provided with a hydraulic control unit, which is connected to multiple hydraulic support units for precisely controlling the extension and support force of the hydraulic support units.

[0019] In one embodiment, the hydraulic support unit includes a hydraulic cylinder, a ball joint, a pressure sensor, and a distance sensor. Both ends of the hydraulic cylinder are connected between the base component and the ball joint plane via the ball joint, forming an adjustable hydraulic conformal support. The pressure sensor is mounted on the hydraulic cylinder, collecting real-time oil pressure data and transmitting the data to the hydraulic control unit for precise control of the hydraulic cylinder's support force. The distance sensor is mounted on the hydraulic cylinder, with its detection direction facing the extension / retraction end of the hydraulic cylinder, parallel to the extension / retraction path of the hydraulic cylinder. It collects real-time extension / retraction length data of the extension / retraction end of the hydraulic cylinder and transmits the extension / retraction length data to the hydraulic control unit for precise control of the hydraulic cylinder's extension / retraction length.

[0020] In one embodiment, three hydraulic support units are connected to a ball joint universal plane to form a set of contour groups. Multiple contour groups are distributed in a ring or matrix around the axis of the base member, and each contour group is independently controlled to independently adjust the support angle and height of the ball joint universal plane of each group.

[0021] In one embodiment, the vibration damping unit consists of multiple independent magnetofluid chambers, and the damping regulator independently controls each of the magnetofluid chambers to achieve multi-region dynamic vibration compensation for the adaptive support platform.

[0022] In one embodiment, the chip and oil mist recovery unit further includes a negative pressure device, a liquid collection container, and a chip collection container; the negative pressure end of the negative pressure device is connected to the dust collection hood and the chip removal channel respectively, the discharge end is connected to the feed end of the liquid-solid separation module, the liquid outlet end of the liquid-solid separation module is connected to the liquid collection container, and the solid discharge end is connected to the chip collection container; the negative pressure device is equipped with multiple negative pressure sensors to monitor the negative pressure adsorption working status of the dust collection hood and the chip removal channel, and adjust the suction force in real time according to the negative pressure data fed back by the negative pressure sensors to maintain a constant negative pressure between the dust collection hood and the chip removal channel.

[0023] In one embodiment, the rigid base is equipped with an interface module and a central controller. The interface module includes multiple communication interfaces and is electrically connected to the central controller, the hydraulic control unit, the vibration control unit, and the chip and oil mist recovery unit. The central controller receives data input from the CNC system of the CNC machine tool and controls the operation of the hydraulic control unit, the vibration control unit, and the chip and oil mist recovery unit in conjunction with the machining status, thereby realizing coordinated control, parameter feedback, and dynamic response throughout the machining process.

[0024] A cutting method is also provided, including the following steps: S1, working condition identification: the interface module receives the spindle running status, feed rate and program segment signals of the CNC system and transmits them to the central controller;

[0025] S2, Adaptive Clamping: The central controller controls the hydraulic support unit to enter the contour adjustment mode, and adjusts the support angle and height according to the preset support force threshold, pressure sensor and distance sensor feedback to complete the clamping of the casting;

[0026] S3. Dynamic vibration reduction: During the operation of the spindle of the CNC machine tool, the central controller dispatches the damping regulator to judge the vibration state based on real-time acceleration data, thereby adjusting the viscosity of the magnetorheological fluid and controlling the damping of the vibration reduction unit in real time to achieve multi-zone vibration reduction control.

[0027] S4, Chip Collection Linkage: After the CNC system's cutting start signal is triggered, the negative pressure device starts, and the dust collection hood moves with the spindle and is linked with the chip discharge channel to create negative pressure, thereby completing the capture and collection of chips and cooling oil, liquid dust and oil mist respectively.

[0028] S5. Reset Processing: After machining is completed, the interface module receives the reset signal from the CNC system and feeds it back to the central controller. The central controller controls the hydraulic control unit, the vibration control unit, and the chip and oil mist recovery unit to automatically exit the operating mode and return to the standby state.

[0029] In one embodiment, the liquid-solid separation module is equipped with an oil mist concentration sensor, which monitors the concentration of oil mist particles in the gas entering the liquid-solid separation module in real time; the negative pressure device adaptively adjusts the suction speed according to the pressure difference data fed back by the oil mist concentration sensor and the negative pressure sensor to maintain a stable negative pressure attraction.

[0030] In one embodiment, the central controller is equipped with a collaborative algorithm module, which processes the data from the pressure sensor and the acceleration sensor and outputs joint control commands to synchronize the movement of the hydraulic support unit and the vibration damping unit during the machining process, thereby enhancing the vibration damping effect and improving the posture stability of the casting during the cutting process.

[0031] Compared with the prior art, the multifunctional cutting base provided by the present invention has the following beneficial effects:

[0032] Improving the rigidity and positioning accuracy of casting clamping: This invention sets up multiple hydraulic support units with ball joint universal adjustment capability to connect the ball joint universal plane. The multiple ball joint universal planes form an adaptive and adjustable contour support surface, which can accurately match the bottom contour of large and complex castings, thereby achieving high rigidity, close fit, and multi-point support clamping of castings, significantly improving the clamping stability and clamping efficiency of castings.

[0033] Improving machining vibration control and enhancing machining accuracy: This invention adopts a composite vibration reduction structure filled with magnetorheological fluid and sets up an acceleration sensor and a damping regulator to form a closed-loop control system. It can adjust the damping in real time according to the dynamic vibration during milling or turning, realize active vibration suppression, effectively reduce the contour error and surface roughness caused by machining vibration, and significantly improve the cutting accuracy.

[0034] Optimize the machining environment and chip removal efficiency: The negative pressure dust collection system, which links the dust hood with the machine tool spindle, combined with the negative pressure chip removal channel and liquid-solid separation module inside the base, can effectively capture and collect dust, oil mist and metal chips during the cutting process, and separate coolant for recycling, significantly improving the working environment, reducing manual cleaning, and improving cutting efficiency and equipment cleanliness.

[0035] It has good CNC system compatibility and intelligent control capabilities: Each functional module of the multi-functional cutting base of this invention can be linked and controlled with the CNC system of the CNC machine tool, which has good system integration and can adapt to the needs of automated and intelligent processing, thereby improving the stability, intelligence and industrial adaptability of the overall processing system.

[0036] Therefore, this invention, by integrating a system of contour support, dynamic vibration reduction, dust and chip removal, and a central controller linkage control unit, systematically solves the core problems of unstable clamping, vibration interference, environmental pollution, and low efficiency in the cutting process of large castings, and has significant practical value and prospects for promotion. Attached Figure Description

[0037] To more clearly illustrate the technical solution of the present invention, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0038] Figure 1 This is a side view of the multifunctional cutting base of the present invention.

[0039] Figure 2 This is a schematic diagram of the turning method adapted to the multi-functional cutting base of the present invention.

[0040] The reference numerals in the attached figures are as follows:

[0041] 1. Adaptive support platform; 11. Hydraulic support unit; 111. Hydraulic cylinder; 112. Ball joint universal joint; 113. Pressure sensor; 114. Distance sensor; 12. Ball joint universal plane; 13. Base component;

[0042] 2. Composite damping assembly; 21. Rigid connecting plate; 22. Vibration damping unit; 221. Magnetorheological fluid chamber; 23. Rigid base component; 24. Accelerometer sensor;

[0043] 3. Contouring group;

[0044] 4. Chip and oil mist recovery unit; 41. Dust hood; 42. Chip discharge channel; 43. Negative pressure device; 44. Liquid-solid separation module; 45. Liquid collection container; 46. Chip collection container;

[0045] 5. Interface module;

[0046] 6. Central controller;

[0047] 7. Castings;

[0048] 8. CNC machine tool spindle. Detailed Implementation

[0049] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings.

[0050] The specific implementation provides a multi-functional cutting base and cutting method for large wind turbine castings. The base includes an adaptive support platform, a composite damping component, a vibration control unit, and a chip and oil mist recovery unit. The adaptive support platform conforms to the bottom of the casting through multiple hydraulically adjustable ball joint universal planes with varying angles and heights, forming a contoured support surface to achieve multi-point adaptive clamping. The composite damping component, through a damping unit, works in conjunction with the vibration control unit to dynamically adjust damping according to the processing vibration response, stabilizing the processing posture of the casting. The chip and oil mist recovery unit, through a liquid-solid separation module and a dust suction hood with negative pressure suction and a chip removal channel, is used to simultaneously collect and separate dust, metal chips, and cooling oil generated during the turning process. This effectively improves the clamping stability and processing accuracy of large castings, improves the processing environment, and effectively solves the technical problems of existing large casting processing platforms, such as difficulty in providing high rigidity support and precise positioning for castings, poor vibration control, difficulty in cleaning chips and dust during processing, and low casting clamping efficiency.

[0051] The first implementation of the multi-functional cutting base is as follows: Figure 1As shown, the system includes an adaptive support platform 1, which has multiple hydraulic support units 11 mounted on a base component 13. Each hydraulic support unit 11 has a ball-and-socket universal joint 12 mounted on it. The multiple hydraulic support units 11 are connected to the bottom of the casting 7 to be clamped via the ball-and-socket universal joint 12. The support height and orientation can be adjusted according to the shape of the bottom of the casting 7 to form a contoured support surface that conforms to the bottom surface of the casting 7, achieving multi-point adaptive clamping. The system also includes a composite vibration damping assembly 2, comprising a rigid connecting plate 21 on the upper layer, a vibration damping unit 22 in the middle, and a rigid base component 23 on the lower layer. The vibration damping unit 22 is filled with magnetorheological fluid. The rigid connecting plate 21 is connected to the base component 13 of the adaptive support platform 1, and the rigid base component 23 is connected to the worktable of the CNC machine tool. Finally, a vibration control unit is included, comprising multiple acceleration sensors 24 and... The control valve of the magnetorheological fluid is connected to a damping regulator. An acceleration sensor 24 is mounted on the base component 13 and electrically connected to the damping regulator. The damping regulator dynamically adjusts the flow resistance of the magnetorheological fluid based on the vibration signal fed back by the acceleration sensor 24 to achieve damping adjustment of the vibration damping unit 22. The chip and oil mist recovery unit 4 includes an annular dust collection hood 41 installed outside the CNC machine tool spindle 8 and capable of moving synchronously along the spindle feed direction, a chip removal channel 42 and a liquid-solid separation module 44 set in the adaptive support platform 1. The chip removal channel 42 is arranged in the gap area between the ball joint universal plane 12 of the hydraulic support unit 11 to collect chips and cooling oil generated during the cutting process and separate them through the liquid-solid separation module 44. The dust collection hood 41 maintains a stable suction force to dynamically recover dust and oil mist following the cutting tool.

[0052] The technical advantages of the multi-functional cutting base provided by the present invention are as follows: improving the clamping rigidity and positioning accuracy of the casting 7: the present invention sets up multiple hydraulic support units 11 with ball joint universal adjustment capability to connect ball joint universal plane 12, and the multiple ball joint universal planes 12 form an adaptively adjustable contour support surface, which can accurately match the bottom contour of large and complex castings 7, thereby achieving high rigidity, close fit, multi-point support clamping of castings 7, and significantly improving the clamping stability and clamping efficiency of castings 7;

[0053] Improved machining vibration control and enhanced machining accuracy: This invention adopts a composite vibration reduction structure filled with magnetorheological fluid and sets up an acceleration sensor 24 and a damping regulator to form a closed-loop control system. It can adjust the damping in real time according to the dynamic vibration during milling or turning, realize active vibration suppression, effectively reduce the contour error and surface roughness caused by machining vibration, and significantly improve the cutting accuracy.

[0054] Optimizing the machining environment and chip removal efficiency: A negative pressure dust collection system, with the dust hood 41 linked to the machine tool spindle, combined with the negative pressure system of the chip removal channel 42 inside the base and the liquid-solid separation module 44, effectively captures and collects dust, oil mist, and metal chips during the cutting process. Coolant is separated for recycling, significantly improving the working environment, reducing manual cleaning, and increasing cutting efficiency and equipment cleanliness.

[0055] It has good CNC system compatibility and intelligent control capabilities: Each functional module of the multi-functional cutting base of this invention can be linked and controlled with the CNC system of the CNC machine tool, which has good system integration and can adapt to the needs of automated and intelligent processing, thereby improving the stability, intelligence and industrial adaptability of the overall processing system.

[0056] Therefore, this invention, by integrating a system of contour support, dynamic vibration reduction, dust and chip removal, and a central controller 6 linkage control unit, systematically solves the core problems of unstable clamping, vibration interference, environmental pollution, and low efficiency in the cutting process of large castings 7, and has significant practical value and promotion prospects.

[0057] As one alternative implementation method:

[0058] Regarding the mechanism for controlling the hydraulic support unit 11, the adaptive support platform 1 is also equipped with a hydraulic control unit, which is connected to multiple hydraulic support units 11 for precise control of the extension and support force of the hydraulic support unit 11.

[0059] In application, the hydraulic control unit integrates a proportional valve module, a closed-loop pressure control module, and a main control PLC communication module. The proportional valve module adjusts the oil flow of each hydraulic cylinder 111 in real time according to the control signal sent by the central controller 6, so as to achieve precise adjustment of the support force. The closed-loop pressure control module collects the oil pressure value fed back by each pressure sensor 113 in real time, calculates the error with the set support force, and automatically corrects the output control command, so that the hydraulic support unit 11 maintains a stable clamping force during the clamping of the casting 7, preventing the clamping from loosening due to local unloading or reaction force, and solving the problems of insufficient rigidity and positional deviation of existing clamping supports.

[0060] Regarding the composition of the aforementioned hydraulic support unit 11, the hydraulic support unit 11 includes a hydraulic cylinder 111, a ball joint universal joint 112, a pressure sensor 113, and a distance sensor 114. Both ends of the hydraulic cylinder 111 are connected between the base component 13 and the ball joint universal plane 12 via the ball joint universal joint 112, forming an adjustable hydraulic conformal support. The pressure sensor 113 is installed on the hydraulic cylinder 111, which collects the oil pressure data in the cylinder in real time and transmits the oil pressure data to the hydraulic control unit for precise control of the support force of the hydraulic cylinder 111. The distance sensor 114 is installed on the hydraulic cylinder 111, and the detection direction is towards the extension end of the hydraulic cylinder 111. The detection direction is parallel to the extension path of the hydraulic cylinder 111, which collects the extension length data of the extension end of the hydraulic cylinder 111 in real time and transmits the extension length data to the hydraulic control unit for precise control of the extension length of the hydraulic cylinder 111.

[0061] In application, the ball joint 112 of the hydraulic cylinder 111 has a maximum adjustment angle of ±20°, which can adapt to the angle adjustment of the irregular curved bottom of the large casting 7; the distance sensor 114 adopts laser displacement or LVDT linear detection, with a measurement accuracy better than 0.1mm, ensuring the accuracy of the extension length control of the hydraulic cylinder 111; by combining the dual feedback adjustment of pressure data and length data, the hydraulic control unit can achieve balanced support under the conditions of different mass centers of gravity and non-uniform thickness of the casting 7, thereby improving the conformity and clamping reliability of the contour clamping, and solving the problem of displacement that is easy to occur in the clamping of heavy castings 7 by traditional point support systems.

[0062] Regarding the specific structure of the contouring group 3 composed of the above-mentioned multiple hydraulic support units 11, a contouring group 3 is formed by connecting three hydraulic support units 11 to a ball joint universal plane 12. The multiple contouring groups 3 are distributed in a ring or matrix around the axis of the base member 13, and each contouring group 3 is independently controlled to independently adjust the support angle and height of the ball joint universal plane 12 of each group.

[0063] In application, each contouring group 3 is assigned an independent PID control channel for regional control through the central controller 6. The arrangement of contouring groups 3 can be switched to a ring (suitable for disc-shaped workpieces) or a matrix (suitable for irregularly shaped base workpieces) arrangement according to the bottom shape of the casting 7 to be processed. The ball joint universal plane 12 of each contouring group 3 is hinged to the hydraulic cylinder 111, with a limit and anti-slip structure, which can withstand a point load of not less than 2000kg, effectively improving the adaptive support capability for large and complex shaped castings 7.

[0064] Regarding the structure and function of the vibration damping unit 22, the vibration damping unit 22 is composed of multiple independent magnetofluid chambers 221. The damping regulator independently controls each magnetofluid chamber 221 to achieve multi-region dynamic vibration compensation for the adaptive support platform 1.

[0065] In application, multiple magnetorheological fluid cavities 221 are distributed on the periphery of the vibration damping unit 22 along the critical vibration path between the rigid connector and the rigid base 23 under the adaptive support platform 1, and each cavity corresponds to an independent electromagnetic excitation control channel. During the turning process, the acceleration sensors 24 in different regions transmit real-time vibration signals to the damping regulator, which adjusts the viscosity and flow resistance of the magnetorheological fluid in the corresponding region to construct a multi-zone asynchronous response damping layer. This damping control system can effectively reduce the secondary oscillations caused by local vibration coupling, effectively avoid toolpath drift and cutting ripple generation, and improve the stability of the complex contour machining process of the casting 7.

[0066] Regarding the specific structure and function of the aforementioned chip and oil mist recovery unit 4, the chip and oil mist recovery unit 4 also includes a negative pressure device 43, a liquid collection container 45, and a chip collection container 46; the negative pressure end of the negative pressure device 43 is connected to the dust collection hood 41 and the chip discharge channel 42 respectively, the discharge end is connected to the feed end of the liquid-solid separation module 44, the liquid outlet end of the liquid-solid separation module 44 is connected to the liquid collection container 45, and the solid discharge end is connected to the chip collection container 46; the negative pressure device 43 is equipped with multiple negative pressure sensors to monitor the negative pressure adsorption working status of the dust collection hood 41 and the chip discharge channel 42, and adjust the suction force in real time according to the negative pressure data fed back by the negative pressure sensors to maintain a constant negative pressure in the dust collection hood 41 and the chip discharge channel 42.

[0067] Specifically, the negative pressure device 43 exhausts air, solids, and liquids from the negative pressure end to the discharge end. The liquid-solid separation module 44 filters the feed from the feed end through a cyclone separator and a filter element, respectively discharging the separated solids such as dust and chips to the solid discharge end, and discharging the separated liquids such as cooling oil and oil mist to the liquid discharge end.

[0068] In application, the negative pressure device 43 is equipped with a two-stage wind pressure regulation system. The first stage is controlled by an electronically controlled speed-regulating fan to control the air volume, and the second stage is constructed by a variable channel throttle valve to create a local negative pressure chamber, thereby achieving dynamic negative pressure maintenance between the dust collection hood 41 and the chip removal channel 42. In conjunction with the feedback signals from multiple negative pressure sensors and the liquid-solid separation module 44, a real-time monitoring feedback closed-loop control is formed to ensure constant suction output and adapt to changes in the concentration of chips, cooling oil, dust, and oil mist under different working conditions. The liquid-solid separation module 44 adopts a two-stage combination structure of cyclone separator and filter element, with a solid-liquid separation efficiency of over 98%. The liquid collection container 45 includes an automatic return pump group and a coolant storage tank. The automatic return pump group is connected to the liquid outlet of the liquid-solid separation module 44, and the automatic return pump group is connected to the coolant storage tank to avoid separation failure caused by the accumulation of liquid in the liquid-solid separation module 44 due to untimely storage and extraction of cooling oil.

[0069] Regarding the structure for the coordinated control of the aforementioned hydraulic control unit, vibration control unit, and chip and oil mist recovery unit 4, a rigid base 23 is equipped with an interface module 5 and a central controller 6. The interface module 5 includes multiple communication interfaces and is electrically connected to the central controller 6, hydraulic control unit, vibration control unit, and chip and oil mist recovery unit 4. The central controller 6 receives data input from the CNC system of the CNC machine tool, and controls the operation of the hydraulic control unit, vibration control unit, and chip and oil mist recovery unit 4 in linkage according to the machining status, thereby realizing coordinated control, parameter feedback, and dynamic response throughout the machining process.

[0070] Specifically, the communication interfaces include those with industrial communication protocols such as MODBUS (MODBUS protocol), EtherCAT (EtherCAT control automation technology), or PROFIBUS (Process Field Bus).

[0071] When applied, the collaborative algorithm module of the central controller 6, based on multi-source fusion logic, comprehensively judges the CNC machine tool status information, pressure sensor 113 data, distance sensor 114 data, and acceleration sensor 24 data, and implements dynamic support and dynamic damping coordinated control according to the set processing rhythm; each communication interface of the interface module 5 conforms to the industrial Ethernet communication protocol, supports external host computer control, and has high real-time performance, redundancy protection, and breakpoint resume control functions, thereby improving the industrial adaptability of the system.

[0072] Based on the above embodiments of the multifunctional cutting base, a cutting method is provided, such as... Figure 2 The schematic diagram of the turning method includes the following steps: S1, working condition identification: The interface module receives the spindle running status, feed speed and program segment signals of the CNC system and transmits them to the central controller;

[0073] S2, Adaptive Clamping: The central controller controls the hydraulic support unit to enter the contour adjustment mode, and adjusts the support angle and height according to the preset support force threshold, pressure sensor and distance sensor feedback to complete the clamping of the casting;

[0074] S3. Dynamic vibration reduction: During the operation of the spindle of the CNC machine tool, the central controller dispatches the damping regulator to judge the vibration state based on real-time acceleration data, thereby adjusting the viscosity of the magnetorheological fluid and controlling the damping of the vibration reduction unit in real time to achieve multi-zone vibration reduction control.

[0075] S4, Chip Collection Linkage: After the CNC system's cutting start signal is triggered, the negative pressure device starts, and the dust collection hood moves with the spindle and is linked with the chip discharge channel to create negative pressure, thereby completing the capture and collection of chips and cooling oil, liquid dust and oil mist respectively.

[0076] S5. Reset Processing: After machining is completed, the interface module receives the reset signal from the CNC system and feeds it back to the central controller. The central controller controls the hydraulic control unit, vibration control unit, and chip and oil mist recovery unit to automatically exit the operating mode and return to the standby state.

[0077] When applied, the process is executed sequentially from S1 to S5, and the operation of each sub-module in steps S1 to S5 is synchronized with the CNC system in real time. It also supports visualization of machining process parameters and abnormal prompts. For example, in the dynamic vibration reduction in step S3, if the vibration exceeds the set threshold, the central controller 6 will output a cutting pause command to the CNC system of the CNC machine tool and automatically adjust the damping value to the highest level to prevent further vibration. In the chip suction linkage in step S4, the dust suction hood 41 moves with the spindle to ensure effective coverage of the dust suction range. The entire process can be set to operate through the human-machine interface (HMI), including a complete cycle of "adaptive clamping + machining collaboration + intelligent recovery".

[0078] Regarding the monitoring of the operating status of the aforementioned liquid-solid separation module 44, and the coordination of the negative pressure device 43 to adjust the negative pressure suction force, in order to maintain the collection efficiency of the dust hood 41 and the chip discharge channel 42 for chips, cooling oil, dust and oil mist during the chip and cooling oil collection process, and to maintain the liquid and solid separation efficiency of the liquid-solid separation module 44, the specific operating status monitoring mechanism and setting method of the liquid-solid separation module 44 is as follows: the liquid-solid separation module 44 is equipped with an oil mist concentration sensor, which monitors the concentration of oil mist particles in the gas entering the liquid-solid separation module 44 in real time; the negative pressure device 43 adaptively adjusts the suction speed according to the pressure difference data fed back by the oil mist concentration sensor and the negative pressure sensor, so as to maintain the stability of the negative pressure suction force.

[0079] When applied, the oil mist concentration sensor adopts the light scattering measurement principle with an accuracy better than 5ppm, and can monitor the oil mist saturation level in real time. The negative pressure device 43 receives feedback from the sensor and forms a dynamic suction control closed loop, which automatically adjusts the suction of the dust hood 41 and the chip removal channel 42 to prevent insufficient suction or over-suction from causing local turbulence. This ensures the complete capture of chips, dust and oil mist, effectively improving the processing environment quality and equipment maintenance convenience of the CNC machine tool in the workshop.

[0080] The specific control method for the central controller 6 to control the coordinated movement of the hydraulic support unit 11 and the vibration damping unit 22 during the cutting process of the casting 7, so as to make the posture of the casting 7 more stable during the processing, is as follows: the central controller 6 is equipped with a coordinated algorithm module, which is used to process the data from the pressure sensor 113 and the acceleration sensor 24 and output joint control commands to synchronize the movement of the hydraulic support unit 11 and the vibration damping unit 22 during the processing, enhance the vibration damping effect, and thus improve the posture stability of the casting 7 during the cutting process.

[0081] When applied, the collaborative algorithm module adopts a feedforward + feedback joint control model. After initial clamping, based on the current state data of casting 7, it establishes a center of gravity-support-vibration response model for casting 7, predicts the vibration trend that may occur due to structural deformation during processing, and synchronously sends commands to hydraulic cylinder 111 to adjust the support force distribution and damper to adjust local damping, so as to offset the displacement error caused by stress release or temperature rise deformation, thereby realizing the coupled stability mechanism of "intelligent support + active vibration reduction", which significantly improves the dimensional consistency and surface quality of heavy irregular casting 7 in high-precision cutting.

[0082] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described.

Claims

1. A multifunctional cutting base for large-scale fan castings, characterized in that, it comprises an adaptive support platform provided with a plurality of hydraulic support units mounted on a base member, a spherical hinge universal plane being mounted on each of the hydraulic support units, the plurality of hydraulic support units being connected to the bottom of a to-be-clamped casting through the spherical hinge universal planes, the support height and orientation of each hydraulic support unit being adjustable according to the shape of the bottom of the casting, a profiled support surface being formed to conform to the bottom surface of the casting, and multi-point adaptive clamping being achieved; a composite damping assembly comprising a rigid connecting plate arranged on the upper layer, a damping unit arranged in the middle layer, and a rigid base member arranged on the lower layer, the damping unit being filled with a magneto-rheological fluid, the rigid connecting plate being connected to the base member of the adaptive support platform, and the rigid base member being connected to the worktable surface of a numerical control machine tool; a vibration control unit comprising a plurality of acceleration sensors and a damping adjuster connected to a control valve of the magneto-rheological fluid, the acceleration sensors being mounted on the base member and electrically connected to the damping adjuster, the damping adjuster dynamically adjusting the flow resistance of the magneto-rheological fluid based on the vibration signals fed back by the acceleration sensors, and damping adjustment of the damping unit being achieved; a chip and oil mist recovery unit comprising a ring-shaped dust collection cover mounted on the outside of the spindle of the numerical control machine tool and capable of moving synchronously along the feed direction of the spindle, a chip removal channel arranged in the adaptive support platform, and a liquid-solid separation module, the chip removal channel being arranged in the gap region between the spherical hinge universal planes of the hydraulic support units, and being used to collect the chips and cooling oil generated during the cutting process and separate the chips and cooling oil through the liquid-solid separation module, the dust collection cover maintaining a stable suction force to dynamically recover dust and oil mist following the cutting tool; a hydraulic control unit being further arranged on the adaptive support platform, the hydraulic control unit being connected to the plurality of hydraulic support units for accurately controlling the extension and support force of the hydraulic support units; the hydraulic support unit comprising a hydraulic cylinder, a ball head universal piece, a pressure sensor, and a distance sensor, the two ends of the hydraulic cylinder being connected to the base member and the spherical hinge universal plane through the ball head universal piece, an adjustable hydraulic profiled support being formed, the pressure sensor being mounted on the hydraulic cylinder, real-time oil pressure data in the cylinder being collected, and the data being transmitted to the hydraulic control unit for accurately controlling the support force of the hydraulic cylinder, the distance sensor being mounted on the hydraulic cylinder, the detection direction of the distance sensor being towards the extension end of the hydraulic cylinder, the detection direction being parallel to the extension path of the hydraulic cylinder, real-time extension length data of the extension end of the hydraulic cylinder being collected, and the extension length data being transmitted to the hydraulic control unit for accurately controlling the extension length of the hydraulic cylinder; three hydraulic support units being connected to one spherical hinge universal plane to form a profiled group, a plurality of profiled groups being arranged in a ring shape or a matrix around the axis of the base member, and each profiled group being independently controlled for independently adjusting the support angle and height of the spherical hinge universal plane of each group. 2.A multifunctional cutting base according to claim 1, characterized in that, The damping unit is composed of multiple independent magnetorheological fluid chambers, and the damping adjuster independently controls each of the magnetorheological fluid chambers to achieve dynamic vibration compensation of the adaptive support platform in multiple regions.

3. The multifunctional cutting base according to claim 2, wherein, The chip and oil mist recovery unit further comprises a negative pressure device, a liquid collection container and a chip collection container; The negative pressure end of the negative pressure device is connected to the dust cover and the chip removal channel respectively, the discharge end is connected to the feed end of the liquid-solid separation module, the liquid outlet end of the liquid-solid separation module is connected to the liquid collection container, and the solid discharge end is connected to the chip collection container; A plurality of negative pressure sensors are arranged in the negative pressure device to monitor the negative pressure adsorption working state of the dust cover and the chip removal channel, and the suction force is adjusted in real time according to the negative pressure data fed back by the negative pressure sensors to maintain the negative pressure of the dust cover and the chip removal channel constant.

4. The multifunctional cutting base according to claim 3, wherein, An interface module and a central controller are mounted on the rigid base, the interface module includes a plurality of communication interfaces, and is electrically connected to the central controller, the hydraulic control unit, the vibration control unit and the chip and oil mist recovery unit; The central controller receives data input from the numerical control system of the numerical control machine tool, controls the operation of the hydraulic control unit, the vibration control unit and the chip and oil mist recovery unit according to the machining state, and realizes cooperative control, parameter feedback and dynamic response in the whole machining process.

5. A method of cutting according to claim 4, wherein, The method comprises the following steps: S1, working condition recognition: the interface module receives the spindle running state, feed speed and program segment signals of the numerical control system and transmits them to the central controller; S2, adaptive clamping: the central controller controls the hydraulic support unit to enter the profiling adjustment mode, adjusts the support angle and height according to the preset support force threshold value, pressure sensor and distance sensor feedback, and completes the clamping of the casting; S3, dynamic damping: during the spindle running of the numerical control machine tool, the central controller schedules the damping adjuster to judge the vibration state according to the real-time acceleration data, adjusts the viscosity of the magnetorheological fluid, and realizes multi-region vibration control by real-time control of the damping of the damping unit; S4, chip suction linkage: after the cutting start signal of the numerical control system is triggered, the negative pressure device starts, the dust cover moves with the spindle, and the negative pressure of the dust cover and the chip removal channel is synchronously linked to complete the collection of chips, cooling oil and dust and oil mist respectively; S5, reset processing: after the machining is completed, the interface module receives the reset signal of the numerical control system and feeds it back to the central controller, and the central controller controls the hydraulic control unit, the vibration control unit and the chip and oil mist recovery unit to automatically exit the operation mode and return to the standby state.

6. The cutting method according to claim 5, wherein An oil mist concentration sensor is arranged in the liquid-solid separation module to monitor the oil mist particle concentration in the gas entering the liquid-solid separation module in real time; and the negative pressure device adjusts the air suction speed adaptively according to the differential pressure data fed back by the oil mist concentration sensor and the negative pressure sensor to maintain the negative pressure suction force stable.

7. The cutting method of claim 6, wherein the central controller is configured with a cooperative algorithm module for processing data from the pressure sensor and the acceleration sensor and outputting a joint control instruction to synchronize the movement of the hydraulic support unit and the damping unit during the machining process, thereby enhancing the damping effect and improving the posture stability of the casting during the cutting process. ​

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