Intelligent lead plate flattening and cutting cooperative processing system and method

Abstract

The invention relates to the technical field of lead plate flattening and cutting, in particular to an intelligent lead plate flattening and cutting cooperative processing system and method.The system comprises a data acquisition module, a cooperative control module, an execution module, a state monitoring module and a quality feedback module.According to the scheme, the machining precision is improved through multi-module cooperative operation; the data acquisition module performs high-precision detection on the thickness, deformation and position of the lead plate, the cooperative control module uses a dynamic pressure compensation model to accurately adjust the flattening pressure and plan the optimal cutting path according to the data, and ensures the flatness and higher cutting precision of the lead plate, and in addition, the quality feedback module performs detection and evaluation on the processed lead plate, so that the quality of the lead plate is improved. The thickness uniformity analysis unit and the cutting precision detection unit ensure that the product quality meets the high standard through mean square error calculation and laser contourgraph measurement, and the problem that the product quality is unstable in traditional machining is effectively solved.

Description

Technical Field

[0001] The present invention relates to the technical field of lead plate flattening and cutting, and in particular to an intelligent lead plate flattening and cutting collaborative processing system and method. Background Art

[0002] In the field of lead sheet processing, with the development of industrial technology, the requirements for processing precision and quality of lead sheet are constantly increasing. In the traditional lead sheet processing process, the flattening and cutting steps have gradually shifted from purely manual operations to mechanization and automation. A variety of flattening and cutting equipment have appeared on the market, which has improved production efficiency to a certain extent.

[0003] However, the existing technology still has many problems. In terms of flattening, traditional equipment cannot accurately obtain the thickness and deformation information of the lead plate, making it difficult to achieve precise adjustment of the pressure. For lead plates with uneven thickness, it is impossible to apply appropriate pressure according to the actual situation, resulting in poor flatness of the flattened lead plate and inability to guarantee thickness uniformity. In the cutting process, the path planning is not intelligent enough and cannot be optimized according to the position, posture and surface defects of the lead plate, which can easily cause tool wear and material waste. Therefore, we propose an intelligent lead plate flattening and cutting collaborative processing system and method. Summary of the Invention

[0004] In response to the deficiencies in the prior art, the present invention provides an intelligent lead plate flattening and cutting collaborative processing system and method, thereby solving the technical problems mentioned in the background technology.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solutions:

[0006] An intelligent lead plate flattening and cutting collaborative processing system, comprising a data acquisition module, a collaborative control module, an execution module, a state monitoring module and a quality feedback module;

[0007] The data acquisition module includes a thickness detection unit, a deformation analysis unit and a positioning feedback unit; the thickness detection unit collects data and generates a three-dimensional thickness distribution map; the deformation analysis unit detects the surface undulations and micro cracks of the lead plate and generates a defect report; the positioning feedback unit monitors the position and posture changes of the lead plate in real time;

[0008] The collaborative control module includes a flattening parameter calculation unit, a cutting path planning unit, and a timing synchronization unit; the flattening parameter calculation unit calculates the pressure value of the hydraulic roller press according to the dynamic pressure compensation model; the cutting path planning unit plans the optimal cutting trajectory through the path evaluation function; and the timing synchronization unit coordinates the timing relationship between flattening completion and cutting start through the synchronization constraint equation.

[0009] The execution module includes a flattening control unit, a cutting control unit and a material transmission unit; the flattening control unit is used to straighten the lead plate; the cutting control unit is used to cut the lead plate; the material transmission unit is used to transmit the lead plate;

[0010] The state monitoring module includes a pressure feedback unit and a tool wear detection unit; the pressure feedback unit monitors the pressure fluctuation of the flattening roller; the tool wear detection unit detects the tool wear condition according to the wear judgment formula;

[0011] The quality feedback module includes a thickness uniformity analysis unit and a cutting accuracy detection unit; the thickness uniformity analysis unit is used to evaluate the thickness uniformity of the lead plate; the cutting accuracy detection unit measures the verticality error of the lead plate cut.

[0012] In a possible implementation, the thickness calculation model is h=xcosθ-d, where x represents the laser reflection distance, θ is 45°, and d is the reference compensation value.

[0013] In one possible implementation, the dynamic pressure compensation model is Where K is the pressure coefficient, Δh is the real-time thickness deviation of the lead plate, T is the time constant, and β is the compensation constant.

[0014] In a possible implementation, the path evaluation function is Among them, γ is the distance weight coefficient, (x i ,y i ) and (x i+1 ,y i+1 ) are the coordinates of adjacent path points, N is the number of turns in the path, and the optimal cutting trajectory is generated by minimizing the evaluation function value.

[0015] In a possible implementation, the wear determination formula is: Where A(f) is the amplitude of the acoustic emission signal at different frequencies, S(f) is the characteristic weight coefficient, t1 and t2 are the detection time periods, and when the wear amount approaches or exceeds the threshold, the system issues a tool wear alarm signal.

[0016] In one possible implementation, a method for collaboratively processing intelligent lead plate flattening and cutting includes the following steps:

[0017] Step 1: Synchronous data acquisition. After the system is turned on, the data acquisition module automatically starts. The thickness detection unit collects lead plate thickness data at 100 points per second and generates a three-dimensional thickness distribution map. The deformation analysis unit uses a four-step phase shift method to collect light intensity data to detect surface undulations and microcracks and generate a report. The positioning feedback unit monitors the position and posture changes of the lead plate in real time.

[0018] Step 2: 3D thickness modeling and analysis: the data collected by the thickness detection unit is transmitted to the data processing center, and a 3D thickness model of the lead plate is constructed using 3D modeling software. The overall thickness distribution and thickness deviation information are analyzed and transmitted to the flattening parameter calculation unit.

[0019] Step 3: Dynamic flattening parameter calculation: The flattening parameter calculation unit in the collaborative control module receives the real-time thickness data from the thickness detection unit, compares it with the preset target thickness value to obtain the thickness deviation, combines the current time information of the system, and calculates the required pressure value of the hydraulic roller press according to the dynamic pressure compensation model, and sends the result to the flattening control unit;

[0020] Step 4: Cutting path optimization planning: the cutting path planning unit obtains the current position coordinates of the lead plate and the cutting target contour information, searches for the optimal tool path on the lead plate plane based on the path evaluation function, generates the optimal cutting trajectory data and transmits it to the cutting control unit;

[0021] Step 5: Multi-axis collaborative execution control: The execution module receives instructions from the collaborative control module. The flattening control unit controls the three-level hydraulic system and uses the temperature compensation device to straighten the lead plate. The cutting control unit drives the five-axis linkage servo system, adjusts the tool inclination according to the tool inclination compensation algorithm, and selects the appropriate cutting speed for cutting. The material transfer unit smoothly transfers the lead plate through a double closed-loop control conveyor belt.

[0022] Step 6: Feedback optimization. After the lead plate processing is completed, the quality feedback module works. The thickness uniformity analysis unit calculates the mean square deviation of the lead plate thickness and compares it with the preset threshold. If it does not meet the standard, a flattening quality report is generated; the cutting accuracy detection unit measures the verticality error of the incision. If it exceeds the range, a cutting accuracy report is generated. The operator optimizes the subsequent processing technology based on the report.

[0023] Beneficial effects compared with existing technologies:

[0024] 1. In this solution, processing accuracy is improved through the collaborative operation of multiple modules. The data acquisition module performs high-precision detection of the thickness, deformation, and position of the lead plate. Based on this data, the collaborative control module uses a dynamic pressure compensation model to accurately adjust the flattening pressure and plan the optimal cutting path to ensure the flatness of the lead plate and higher cutting accuracy. In addition, the quality feedback module inspects and evaluates the processed lead plate. The thickness uniformity analysis unit and the cutting accuracy detection unit respectively use mean square error calculation and laser profilometer measurement to ensure that product quality meets high standards, effectively solving the problem of unstable product quality in traditional processing.

[0025] 2. In this solution, by setting up a timing synchronization unit in the collaborative control module and establishing a synchronization constraint equation, the timing relationship between flattening completion and cutting initiation is precisely coordinated to avoid waiting or misoperation caused by time differences. At the same time, the various units in the execution module work closely together. The material transfer unit uses a dual closed-loop control conveyor belt, and the flattening control unit and cutting control unit operate efficiently according to the instructions of the collaborative control module. The entire system realizes full-process collaboration from data acquisition and processing to processing execution, significantly shortening the processing cycle and improving production efficiency.

[0026] 3. In this solution, the status monitoring module monitors the flattening roller pressure and tool wear in real time. The pressure feedback unit monitors pressure fluctuations. The tool wear detection unit uses an acoustic emission sensor and a specific formula to calculate the wear amount and promptly issues an alarm when an abnormality occurs, facilitating equipment maintenance and tool replacement, thereby extending the life of both equipment and tools. The quality feedback module generates reports based on the test results, helping operators optimize the machining process and reduce defective product rates. Through intelligent monitoring and feedback, equipment failures and material waste are effectively avoided, reducing production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The above description is only an overview of the technical solution of the present invention. In order to more clearly understand the technical means of the present invention and implement it according to the contents of the specification, the following is a detailed description of the preferred embodiments of the present invention with reference to the accompanying drawings.

[0028] Figure 1 This is a schematic diagram of the framework of the intelligent lead plate flattening and cutting collaborative processing system of the present invention;

[0029] Figure 2 It is a schematic flow chart of the intelligent lead plate flattening and cutting collaborative processing method of the present invention. DETAILED DESCRIPTION

[0030] Preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. However, the present invention can be implemented in various forms, and therefore the present invention is not limited to the embodiments described below. In addition, in order to more clearly describe the present invention, components that are not related to the present invention will be omitted from the drawings.

[0031] The technical solution in the embodiments of the present application is to solve the problems of the above-mentioned background technology, and the overall idea is as follows:

[0032] Example 1:

[0033] An intelligent lead plate flattening and cutting collaborative processing system includes a data acquisition module, a collaborative control module, an execution module, a status monitoring module and a quality feedback module.

[0034] 1. Data acquisition module

[0035] The data acquisition module includes a thickness detection unit, a deformation analysis unit and a positioning feedback unit. Each unit works together to collect status information of the lead plate from different dimensions.

[0036] 1.1 Thickness detection unit

[0037] The thickness detection unit uses an array of laser triangulation sensors to measure the thickness of the lead sheet. Five sets of sensors are evenly spaced across the width of the sheet, fully covering the entire width and ensuring representative thickness data. The sensors utilize laser triangulation technology, achieving an accuracy of ±0.01mm.

[0038] The thickness calculation model is h = x cos θ - d. Here, x represents the laser reflection distance, measured by the sensor's internal optical and electronic components. θ is set to 45°, an incident angle determined by the principle of laser triangulation and the device's optical design. d is a baseline compensation value, which eliminates measurement deviations caused by device installation location, environmental factors, and other factors. During the device installation and commissioning phase, the value of d is calculated by taking multiple measurements of a standard lead plate of known thickness and averaging the measured data.

[0039] This unit collects data in real time at a high rate of 100 points per second. Using data processing chips and algorithms, it rapidly calculates the thickness of the lead sheet at different locations based on the aforementioned formula. Simultaneously, 3D modeling software integrates this discrete thickness data to generate a 3D thickness distribution map of the lead sheet in real time. This map intuitively displays the overall thickness variation of the lead sheet, providing clear visual feedback to operators.

[0040] 1.2 Deformation analysis unit

[0041] The deformation analysis unit consists of a structured light projector (520nm wavelength) and a high-speed CMOS camera (200fps frame rate). The structured light projector projects a specific pattern onto the lead plate surface, while the high-speed CMOS camera rapidly captures the reflected pattern at a frame rate of 200fps, thereby obtaining surface information.

[0042] The deformation detection formula is In the four-step phase shift method, the structured light projector sequentially projects four structured light patterns with specific phase differences, and the high-speed CMOS camera synchronously captures the light intensity distribution images after the four patterns are reflected. a and I d Respectively represent the light intensity values ​​of two specific images during the four-step phase shift process. By processing and analyzing these light intensity values, the displacement information of the corresponding points can be calculated using the above formula.

[0043] Specifically, when the structured light is projected onto the surface of the lead plate, if there are undulations or defects on the surface of the lead plate, the phase and intensity of the reflected light will change. a and I d It contains these change information. By calculating the D value, combined with the geometric parameters of the camera and projector and the calibration data of the system, the displacement of each point on the lead plate surface can be accurately analyzed, and the surface undulation can be obtained. At the same time, since the detection sensitivity of this unit reaches 0.02mm, it can also effectively identify tiny cracks. Set the abnormal displacement change threshold, which is set according to the cutting requirements and can be set to a minimum of 0.02mm. When an abnormal displacement change is detected and exceeds the threshold, the system will determine that there are tiny cracks in the area.

[0044] Once defects are detected on the lead plate surface, the system will quickly mark the relevant information on the corresponding image area and generate a detailed defect report. The report includes parameters such as the precise location, size, and shape characteristics of the defect. This information can not only intuitively display the quality status of the lead plate surface, but also be transmitted to the quality feedback module and collaborative control module in real time. The quality feedback module evaluates the overall quality of the lead plate based on this, and the collaborative control module can adjust the subsequent processing strategy according to the defect situation. Specifically, the cutting path planning unit can adjust the tool path according to the defect location to avoid the defective area to improve the product qualification rate.

[0045] 1.3 Positioning feedback unit

[0046] The positioning feedback unit is composed of a magnetic scale (resolution 1μm) and a photoelectric encoder. The magnetic scale uses the principle of magnetic signal induction to accurately measure the linear displacement of the lead plate, obtaining information on the plate's position changes in the X and Y directions. The photoelectric encoder is mainly used to measure the plate's rotation angle, i.e., the θ value.

[0047] During the transport and processing of the lead plates, a magnetic scale and photoelectric encoder monitor their position and orientation in real time. The magnetic scale converts the measured displacement signals into electrical signals, which are transmitted via cables to the controller. The photoelectric encoder similarly converts the angular signals and transmits them to the controller. The controller processes and calculates the received signals, providing real-time feedback on the lead plate's position coordinates (X, Y, θ) with an accuracy of ±0.05mm.

[0048] 2. Collaborative control module

[0049] 2.1 Applanation parameter calculation unit

[0050] The flattening parameter calculation unit is based on the dynamic pressure compensation model Calculate the pressure value of the hydraulic roller press. K is the pressure coefficient, which is derived from fitting a large amount of experimental data based on factors such as the hydraulic roller press's equipment characteristics and the properties of the lead sheet material. In this system, K is determined to be 500N / mm for commonly used lead sheet materials after multiple experiments. Δh is the real-time thickness deviation of the lead sheet, obtained by subtracting the real-time thickness data obtained by the thickness detection unit from the target thickness value. T is the time constant, reflecting the system's response speed, and is set to 0.1s based on the system's control requirements and actual operating conditions. β is the compensation constant used to correct pressure deviations caused by factors such as equipment wear and ambient temperature changes. It is determined through regular equipment calibration measurements and is set to 5000N.

[0051] This unit receives the lead plate thickness data from the thickness detection unit in real time, compares it with the pre-set target thickness value, and calculates the thickness deviation Δh. At the same time, it obtains the current time information of the system and substitutes it into the dynamic pressure compensation model to calculate the pressure value F required by the hydraulic roller press. The calculation results will be sent to the flattening control unit in the execution module in real time to accurately control the pressure output of the hydraulic roller press and realize the control of the lead plate flattening process. Specifically, when the thickness detection unit detects that the thickness of a certain area of ​​the lead plate is greater than the target thickness, the flattening parameter calculation unit will calculate the pressure value that needs to be increased according to the model, and send the instruction to the flattening control unit, so that the hydraulic roller press applies greater pressure in this area to achieve the ideal thickness and flatness.

[0052] 2.2 Cutting Path Planning Unit

[0053] The cutting path planning unit optimizes the tool path based on an improved A-algorithm. The A-algorithm is a heuristic search algorithm commonly used for shortest path search. In this system, the traditional A-algorithm is improved by introducing a turning penalty coefficient λ (value λ = 0.2) to better meet the actual needs of the lead sheet cutting process.

[0054] The path evaluation function is Among them, γ is the distance weight coefficient, which is set to 0.8 according to the actual cutting situation to balance the path length and path smoothness; (x i ,y i ) and (x i+1 ,y i+1 ) are the coordinates of adjacent path points; N is the number of turns in the path. This evaluation function comprehensively considers the path length and the number of turns, and generates a collision-free optimal cutting trajectory by minimizing the evaluation function value.

[0055] Before performing the cutting operation, the system obtains the current position coordinates of the lead plate (provided by the positioning feedback unit) and the cutting target contour information (pre-set or imported according to the design drawing). Based on this information, the cutting path planning unit uses the improved A algorithm to search for the optimal tool path on the lead plate plane. During the calculation process, the algorithm continuously tries different path combinations, calculates the score of each path according to the path evaluation function, and finally selects the path with the lowest score as the optimal cutting trajectory. The generated optimal cutting trajectory data is transmitted to the cutting control unit in the execution module to guide the tool for precise cutting. For example, if there is a defect on the lead plate, the position information provided by the positioning feedback unit will enable the cutting path planning unit to avoid the defective area when planning the path, while taking into account the number of tool turns and the path length, to generate an optimal path that both ensures cutting quality and improves processing efficiency.

[0056] 2.3 Timing Synchronization Unit

[0057] The timing synchronization unit coordinates the timing relationship between flattening completion and cutting start through the synchronization constraint equation. Assume that the time required for the flattening control unit to complete the flattening operation is t press , which is related to factors such as the pressure change of the flattening roller and the material properties of the lead plate, and can be expressed as t press =f(P,M), where P is the pressure of the flattening roller and M is the material parameter of the lead sheet. The response time of the cutting control unit from receiving the start signal to the start of cutting is t cut-start , which is related to the response speed of the servo system, the processing time of the controller, etc., and can be expressed as t cut-start =g(V,C), where V is the servo system response speed and C is the controller processing capacity parameter; the transmission time of the lead plate from the flattening area to the cutting area during the transmission process is t transfer , which is related to the conveyor belt speed v and the transmission distance L of the material transmission unit, that is,

[0058] Then the synchronization constraint equation can be expressed as t press +t transfer ≥t cut-start This equation ensures that the cutting control unit is not activated until the lead plate flattening operation is completed and transferred to the cutting position, thus avoiding processing quality problems caused by improper timing.

[0059] During the operation of the system, the timing synchronization unit monitors the status information of the flattening control unit and the cutting control unit in real time, including the current operating stage of the equipment, the action completion signal, etc. At the same time, the transmission speed of the material transmission unit and the position information of the lead plate are obtained. According to the synchronization constraint equation, the calculation and judgment are performed in combination with the actual collected status data. When it is judged that the flattening operation has been completed and the lead plate has been transferred to the appropriate position, and the cutting start conditions are met, the timing synchronization unit sends a start signal to the cutting control unit to ensure that the two key processing steps are closely connected in time, thereby improving production efficiency and processing accuracy. For example, if the flattening control unit takes longer than expected to complete the flattening operation, the timing synchronization unit will adjust the start time of the cutting control unit according to the equation to ensure the smooth progress of the entire processing process.

[0060] 3. Execution module

[0061] The execution module performs actual processing operations on the lead plate according to the instructions of the collaborative control module, converting the control signals into specific processing actions. It includes a flattening control unit, a cutting control unit, and a material transfer unit.

[0062] 3.1 Applanation Control Unit

[0063] The flattening control unit utilizes a three-stage hydraulic system to achieve precise straightening of the lead sheet. The roughing roller, with a pressure range of 0-50 MPa and a response time of 50 ms, is primarily used to quickly reduce significant deformation and initially adjust the flatness of the lead sheet. The finishing roller, with a pressure range of 0-20 MPa and an accuracy of ±0.1 MPa, is responsible for finely flattening the lead sheet to ensure it meets the specified flatness requirements.

[0064] The machine is also equipped with a temperature compensation device, with a heating power range of 0-3kW. During the lead flattening process, the lead sheet's temperature fluctuates due to pressure and frictional heat generation, affecting its material properties and the flattening effect. The temperature compensation device monitors the sheet's temperature in real time via a temperature sensor mounted on or near the sheet's surface. When the temperature falls below the ideal range, the device automatically increases the heating power; when the temperature is too high, the device reduces the heating power or stops heating. This ensures that the sheet remains within the desired temperature range, minimizing the impact of temperature on flattening accuracy.

[0065] The flattening control unit receives pressure commands from the collaborative control module and controls the pressure output of the roughing and finishing rollers in the three-stage hydraulic system. First, the roughing roller applies high pressure and quickly flattens the lead sheet. Then, the finishing roller adjusts the flatness of the sheet according to the precise pressure commands. Throughout the flattening process, the temperature compensation device monitors and adjusts the sheet temperature in real time. This collaborative operation achieves precise straightening of the lead sheet, achieving a flatness of ≤0.1 mm / m, meeting high-quality product requirements.

[0066] 3.2 Cutting control unit

[0067] The cutting control unit is equipped with a five-axis linkage servo system, achieving a repeatable positioning accuracy of ±0.005mm, capable of cutting complex contours. Furthermore, a tool inclination compensation algorithm is employed, which adjusts the tool's inclination in real time based on the actual shape of the lead sheet and the cutting path. This ensures optimal contact between the tool and the lead sheet surface throughout the cutting process, improving cutting quality and tool life.

[0068] Assume that the current position coordinates of the tool are (x0, y0, z0), and the normal vector of a point on the lead plate surface is (n x ,n y ,n z ), the target clipping direction vector is (d x ,d y ,d z ), the tool inclination compensation Δθ is calculated by the following formula: After the cutting control unit receives the optimal cutting trajectory data generated by the cutting path planning unit, it drives the five-axis linkage servo system to move along the trajectory. During the movement, the system calculates and adjusts the tool inclination in real time based on the tool inclination compensation algorithm and the lead plate position and posture information provided by the positioning feedback unit. The system controls the cutting speed within the range of 0.1-5m / min, and makes reasonable selections based on the lead plate material, tool type, and cutting accuracy requirements. Specifically, for harder lead plate materials, the cutting speed is appropriately reduced to ensure cutting quality; for products with higher precision requirements, a lower cutting speed and more accurate tool inclination compensation parameters are selected to complete high-precision cutting of complex contours.

[0069] 3.3 Material transfer unit

[0070] The material transfer unit utilizes a dual closed-loop conveyor belt control system consisting of a speed loop and a tension loop. The speed loop utilizes a PID control algorithm with a sampling period of 10ms. The PID controller precisely controls the conveyor belt speed by adjusting the motor speed based on the set transmission speed and the actual measured conveyor belt speed feedback signal. The tension loop utilizes strain gauges to provide feedback on the tension signal, achieving an accuracy of ±2N. This control adjusts the conveyor belt tension in real time by controlling the motor torque.

[0071] During the lead plate processing process, the material transfer unit is responsible for smoothly transferring the lead plate from the loading position to the processing area, and then transferring the processed lead plate to the unloading position. The speed loop continuously adjusts the conveyor belt motor speed according to the preset transmission speed through the PID control algorithm to ensure that the conveyor belt speed stability reaches ±0.1%. The tension ring monitors the conveyor belt tension in real time. When the tension fluctuates, the motor torque is adjusted in time to ensure that the lead plate does not slip during the transmission process. Specifically, when the lead plate is disturbed by external forces during transmission and the tension increases, the tension ring will automatically reduce the motor torque, reduce the pulling force of the conveyor belt, and prevent the lead plate from being pulled and deformed; when the tension decreases, the motor torque is increased to ensure that the lead plate can be smoothly transmitted and the smooth progress of the entire processing process.

[0072] 4. Status monitoring module

[0073] The status monitoring module is used to monitor the operating status of the system in real time, including a pressure feedback unit and a tool wear detection unit, which monitor the pressure of the flattening roller and tool wear respectively.

[0074] 4.1 Pressure feedback unit

[0075] The pressure feedback unit uses a piezoresistive sensor (range 0-100 MPa, accuracy 0.1% FS) to monitor pressure fluctuations on the flattening roller in real time. Piezoresistive sensors operate based on the piezoresistive effect. When pressure is applied to the flattening roller, the internal resistance of the sensor changes. By measuring this change in resistance, the pressure can be accurately calculated.

[0076] The pressure feedback unit installs piezoresistive sensors at the key stress-bearing parts of the flattening roller to collect pressure signals in real time. The collected signals are amplified, filtered, and processed, then converted into digital signals and transmitted to the control system. The control system analyzes and displays the pressure data in real time, and the operator can visually view the pressure changes of the flattening roller through the monitoring interface. When the pressure fluctuation exceeds the preset normal range, the system immediately issues an alarm signal to remind the operator to make corresponding adjustments. Specifically, if the pressure is too high, it may cause excessive deformation of the lead plate or damage to the equipment; if the pressure is too low, the expected flattening effect cannot be achieved. At this point, the operator can check the equipment operating status according to the alarm information, adjust the flattening parameters or troubleshoot equipment failures to avoid lead plate flattening quality problems due to abnormal pressure.

[0077] 4.2 Tool wear detection unit

[0078] The tool wear detection unit uses an acoustic emission sensor (frequency range 50-400kHz) to detect tool wear. During the cutting process, the tool will generate acoustic emission signals due to friction, cutting force, etc. The acoustic emission sensor can capture these signals. The wear determination formula is: Where A(f) is the amplitude of the acoustic emission signal at different frequencies, S(f) is the characteristic weight coefficient, which reflects the degree to which different frequency signals affect tool wear, and t1 and t2 are the detection time periods. The characteristic weight coefficient S(f) is determined by collecting and analyzing a large number of acoustic emission signals from tools with different degrees of wear, combined with tool wear experimental data.

[0079] During the cutting process, the acoustic emission sensor continuously collects the acoustic emission signal generated by the tool during cutting. After amplification and filtering, the signal is transmitted to the signal processing unit, which calculates the wear W of the tool according to the wear judgment formula. The system compares the wear calculated in real time with the preset wear threshold. The preset wear threshold is determined according to the actual situation. When the wear approaches or exceeds the threshold, the system issues a tool wear alarm signal, prompting the operator to replace the tool in time. This helps to ensure cutting accuracy and processing quality, and avoid problems such as reduced cut quality and dimensional deviation due to excessive tool wear. For example, when the tool wear reaches a certain level, the cut lead plate may have defects such as burrs and unevenness, which will affect the subsequent use of the product. These problems can be effectively avoided by replacing the tool in time.

[0080] 5. Quality feedback module

[0081] The quality feedback module performs quality inspection and evaluation on the processed lead plates, and includes a thickness uniformity analysis unit and a cutting accuracy detection unit.

[0082] 5.1 Thickness Uniformity Analysis Unit

[0083] The thickness uniformity analysis unit evaluates the thickness uniformity of the lead plate by calculating the mean square error. The formula is: where h i Represents the thickness measurement values ​​of the lead plate at different positions. These data are collected by the thickness detection unit after the lead plate is processed. It is the average value of the lead plate thickness, which is calculated by taking the arithmetic mean of the thickness values ​​​​of all measurement points; n is the number of measurement points. The number of measurement points will affect the accuracy of the thickness uniformity assessment.

[0084] In practice, after the lead sheet is flattened, the thickness uniformity analysis unit acquires a large amount of thickness measurement data from the thickness detection unit. This data is then calculated using the aforementioned mean square deviation (MSD) formula. The resulting mean square deviation (σ) reflects the degree of thickness dispersion within the lead sheet. A smaller σ value indicates a more uniform thickness; conversely, a larger σ value indicates greater thickness variation.

[0085] The system will compare the calculated mean square error with the preset threshold (the threshold is set to 0.05mm). If σ>0.05mm, it means that the thickness uniformity of the lead plate does not meet the requirements, and the system will generate a flattening quality report. The report will record in detail the mean square error value, the thickness data of each measurement point, and the deviation from the standard value. Based on this report, the operator can analyze possible problems in the flattening process, such as whether the pressure distribution of the flattening roller is uniform, whether the temperature compensation is appropriate, etc., and adjust the flattening parameters or equipment accordingly to improve the quality of subsequent lead plate flattening.

[0086] 5.2 Cutting accuracy detection unit

[0087] The cutting accuracy detection unit uses a laser profilometer (line scan rate 10kHz) to measure the verticality error of the lead plate cut. After the lead plate is cut, the laser profilometer quickly scans the cut to obtain dense contour data points.

[0088] The system analyzes this data using the Hough transform algorithm. The Hough transform maps lines in image space to parameter space, determining the line parameters by finding peaks in the parameter space. When testing the verticality of a lead cut, the algorithm converts the collected cut contour data points from a Cartesian coordinate system to a polar coordinate system. In a polar coordinate system, a straight line can be represented by the parameters (ρ, θ), where ρ is the perpendicular distance from the origin to the line, and θ is the angle between the line and the positive x-axis.

[0089] The algorithm searches for the corresponding straight line parameter values ​​in parameter space. For an ideal vertical cut, the θ value in the polar coordinate system is 90° or 270°. After using the Hough transform to find the line parameters corresponding to the actual cut contour, the difference between the θ value of the line and 90° or 270° is calculated. This difference is the verticality error of the cut.

[0090] When the angle error is ≤0.1°, the cutting accuracy meets the standard. If it exceeds this range, the system records the data and generates a cutting accuracy report. The report includes information such as the error value and cutting position to help operators identify the problem. Operators can adjust the equipment accordingly, optimize the cutting process, and ensure the cutting accuracy of subsequent products.

[0091] Example 2:

[0092] An intelligent lead plate flattening and cutting collaborative processing method includes the following steps

[0093] 1. Step 1: Synchronous data collection

[0094] Turn on the intelligent lead plate flattening and cutting collaborative processing system, and the system automatically starts the data acquisition module. The laser triangulation ranging sensor array of the thickness detection unit starts working, and 5 groups of probes equidistantly distributed along the width of the lead plate collect data at a speed of 100 points / second. The thickness value of each point on the lead plate is obtained through the thickness calculation model as in Example 1, and a three-dimensional thickness distribution map is generated in real time. At the same time, the structured light projector and high-speed CMOS camera of the deformation analysis unit work together to collect light intensity data using the four-step phase shift method, and calculate the displacement information according to the deformation detection formula as in Example 1, so as to detect the surface undulation and tiny cracks of the lead plate. Once defects are found, they are marked and a report is generated in time. The magnetic scale and photoelectric encoder of the positioning feedback unit also monitor the position and posture changes of the lead plate in real time during the transmission and processing of the lead plate, and accurately obtain the position of the lead plate in the X and Y directions and the rotation angle θ information.

[0095] 2. Step 2: 3D Thickness Modeling Analysis

[0096] The data collected by the thickness detection unit is automatically transmitted to the system's data processing center. Here, 3D modeling software is used to integrate and process this thickness data to construct a 3D thickness model of the lead sheet. The system then conducts in-depth analysis of this model to obtain key information such as the overall thickness distribution and thickness deviation of the lead sheet. This information is not only displayed to the operator in an intuitive 3D graphic format, allowing them to quickly understand the thickness status of the lead sheet, but also transmits the thickness deviation data in real time to the flattening parameter calculation unit in the collaborative control module, providing an important basis for the subsequent calculation of the flattening pressure.

[0097] 3. Step 3: Dynamic applanation parameter calculation

[0098] The flattening parameter calculation unit in the collaborative control module receives the real-time thickness data of the lead sheet from the thickness detection unit and compares it with the preset target thickness value to determine the thickness deviation. Simultaneously, this unit obtains the system's current time information and calculates the required pressure value for the hydraulic roller press based on the dynamic pressure compensation model described in Example 1. Once the calculation is complete, the flattening parameter calculation unit immediately transmits the resulting pressure value in real time to the flattening control unit in the execution module, thereby controlling the pressure during the lead sheet flattening process.

[0099] 4. Step 4: Cutting path optimization planning

[0100] The cutting path planning unit obtains the current position coordinates of the lead plate from the positioning feedback unit and receives the cutting target contour information, either pre-set or imported from a design drawing. Subsequently, based on the path evaluation function described in Example 1, the unit searches for the optimal tool path on the lead plate plane. After calculation and analysis, the cutting path planning unit generates the optimal cutting trajectory data and transmits it to the cutting control unit in the execution module, ensuring the subsequent cutting process is efficient and accurate, avoiding tool collisions and improving processing quality.

[0101] 5. Step 5: Multi-axis collaborative execution control

[0102] After the execution module receives the instruction from the collaborative control module, each unit starts to work together. The flattening control unit controls the three-level hydraulic system according to the pressure instruction from the flattening parameter calculation unit. The rough pressing roller first quickly reduces the large deformation of the lead plate with a pressure of 0-50MPa and a response time of 50ms; then the fine pressing roller flattens it with a pressure of 0-20MPa and an accuracy of ±0.1MPa. During this process, the temperature compensation device automatically adjusts the heating power of 0-3kW according to the lead plate temperature monitored by the temperature sensor to ensure that the lead plate is within the appropriate temperature range, and finally achieves precise straightening of the lead plate to make its flatness ≤0.1mm / m

[0103] The cutting control unit drives the five-axis servo system based on the optimal cutting trajectory data generated by the cutting path planning unit. During this process, the system adjusts the tool inclination in real time using the tool inclination compensation algorithm described in Example 1, combined with the position and posture information of the lead sheet. Furthermore, the system selects a reasonable cutting speed within the range of 0.1-5 m / min, depending on the lead sheet material, tool type, and cutting accuracy requirements, to achieve high-precision cutting of complex contours.

[0104] The material transfer unit utilizes dual closed-loop control of the conveyor belt via speed and tension loops. The speed loop utilizes PID control, adjusting the motor speed based on the preset transfer speed with a 10ms sampling cycle. The tension loop utilizes strain gauge feedback to adjust the motor torque in real time, ensuring no slippage during lead sheet transfer and smooth transfer from the loading station to the processing area and then to the unloading station.

[0105] 6. Step 6: Feedback Optimization

[0106] After the lead sheet processing is complete, the quality feedback module begins operation. The thickness uniformity analysis unit obtains the measured thickness data of the flattened lead sheet from the thickness detection unit and calculates the mean square error (MSE) using the same formula as in Example 1. The calculated result is compared with a preset threshold. If the MSE exceeds the threshold, the system automatically generates a flattening quality report. The operator can use the report to analyze any problems encountered during the flattening process and adjust flattening parameters or perform equipment inspection and maintenance to optimize subsequent flattening processes.

[0107] The cutting accuracy detection unit uses a laser profilometer to scan the cut edge of the lead sheet after cutting. The system analyzes this data using the Hough transform algorithm described in Example 1 to calculate the cut's perpendicularity error. If the angle error is significant, the system records the relevant data and generates a cutting accuracy report. Based on this report, the operator adjusts the equipment and optimizes the cutting process, thereby improving the cutting accuracy of subsequent products.

[0108] Finally, it should be noted that the above embodiments are merely examples for the purpose of illustrating the present invention and are not intended to limit the embodiments. Those skilled in the art will readily appreciate that other variations or modifications based on the above description are possible. It is not necessary and impossible to provide an exhaustive list of all embodiments. However, obvious variations or modifications arising therefrom remain within the scope of protection of the present invention.

Claims

1. An intelligent lead plate flattening and cutting collaborative processing system, characterized in that: It includes data acquisition module, collaborative control module, execution module, status monitoring module and quality feedback module; The data acquisition module includes a thickness detection unit, a deformation analysis unit and a positioning feedback unit; the thickness detection unit collects data and generates a three-dimensional thickness distribution map; the deformation analysis unit detects the surface undulations and micro cracks of the lead plate and generates a defect report; the positioning feedback unit monitors the position and posture changes of the lead plate in real time; The collaborative control module includes a flattening parameter calculation unit, a cutting path planning unit, and a timing synchronization unit; the flattening parameter calculation unit calculates the pressure value of the hydraulic roller press according to the dynamic pressure compensation model; the cutting path planning unit plans the optimal cutting trajectory through the path evaluation function; and the timing synchronization unit coordinates the timing relationship between flattening completion and cutting start through the synchronization constraint equation. The execution module includes a flattening control unit, a cutting control unit and a material transmission unit; the flattening control unit is used to straighten the lead plate; the cutting control unit is used to cut the lead plate; the material transmission unit is used to transmit the lead plate; The state monitoring module includes a pressure feedback unit and a tool wear detection unit; the pressure feedback unit monitors the pressure fluctuation of the flattening roller; the tool wear detection unit detects the tool wear condition according to the wear judgment formula; The quality feedback module includes a thickness uniformity analysis unit and a cutting accuracy detection unit; the thickness uniformity analysis unit is used to evaluate the thickness uniformity of the lead plate; the cutting accuracy detection unit measures the verticality error of the lead plate cut.

2. The intelligent lead plate flattening and cutting collaborative processing system according to claim 1, characterized in that: The thickness calculation model is h=xcosθ-d, where x represents the laser reflection distance, θ is 45°, and d is the reference compensation value.

3. The intelligent lead plate flattening and cutting collaborative processing system according to claim 1, characterized in that: The dynamic pressure compensation model is Where K is the pressure coefficient, Δh is the real-time thickness deviation of the lead plate, T is the time constant, and β is the compensation constant.

4. The intelligent lead plate flattening and cutting collaborative processing system according to claim 1, characterized in that: The path evaluation function is: Among them, γ is the distance weight coefficient, (x i ,y i ) and (x i+1 ,y i+1 ) are the coordinates of adjacent path points, N is the number of turns in the path, and the optimal cutting trajectory is generated by minimizing the evaluation function value.

5. The intelligent lead plate flattening and cutting collaborative processing system according to claim 1, characterized in that: The wear judgment formula is: Where A(f) is the amplitude of the acoustic emission signal at different frequencies, S(f) is the characteristic weight coefficient, t1 and t2 are the detection time periods, and when the wear amount approaches or exceeds the threshold, the system issues a tool wear alarm signal.

6. An intelligent lead plate flattening and cutting collaborative processing method applied to an intelligent lead plate flattening and cutting collaborative processing system according to claims 1 to 5, characterized in that: The following steps are involved: Step 1: Synchronous data acquisition. After the system is turned on, the data acquisition module automatically starts. The thickness detection unit collects lead plate thickness data at 100 points per second and generates a three-dimensional thickness distribution map. The deformation analysis unit uses a four-step phase shift method to collect light intensity data to detect surface undulations and microcracks and generate a report. The positioning feedback unit monitors the position and posture changes of the lead plate in real time. Step 2: 3D thickness modeling and analysis: the data collected by the thickness detection unit is transmitted to the data processing center, and a 3D thickness model of the lead plate is constructed using 3D modeling software. The overall thickness distribution and thickness deviation information are analyzed and transmitted to the flattening parameter calculation unit. Step 3: Dynamic flattening parameter calculation: The flattening parameter calculation unit in the collaborative control module receives the real-time thickness data from the thickness detection unit, compares it with the preset target thickness value to obtain the thickness deviation, combines the current time information of the system, and calculates the required pressure value of the hydraulic roller press according to the dynamic pressure compensation model, and sends the result to the flattening control unit; Step 4: Cutting path optimization planning: the cutting path planning unit obtains the current position coordinates of the lead plate and the cutting target contour information, searches for the optimal tool path on the lead plate plane based on the path evaluation function, generates the optimal cutting trajectory data and transmits it to the cutting control unit; Step 5: Multi-axis collaborative execution control: The execution module receives instructions from the collaborative control module. The flattening control unit controls the three-level hydraulic system and uses the temperature compensation device to straighten the lead plate. The cutting control unit drives the five-axis linkage servo system, adjusts the tool inclination according to the tool inclination compensation algorithm, and selects the appropriate cutting speed for cutting. The material transfer unit smoothly transfers the lead plate through a double closed-loop control conveyor belt. Step 6: Feedback optimization. After the lead plate processing is completed, the quality feedback module works. The thickness uniformity analysis unit calculates the mean square deviation of the lead plate thickness and compares it with the preset threshold. If it does not meet the standard, a flattening quality report is generated; the cutting accuracy detection unit measures the verticality error of the incision. If it exceeds the range, a cutting accuracy report is generated. The operator optimizes the subsequent processing technology based on the report.

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