Rubber roller grinding method

Abstract

The invention discloses a rubber roller grinding method which comprises the following steps: acquiring a size parameter of a rubber roller, setting an initial coarse grinding parameter of coarse grinding equipment based on the size parameter, dispersing the contour of the rubber roller into a plurality of control points, performing primary coarse grinding on the rubber roller according to the coarse grinding parameter and a coarse grinding path, acquiring a coarse grinding contour value of the rubber roller, and calculating a first difference value, adjusting the feeding pressure in the coarse grinding process based on the correlation between the grinding data and the first difference value, updating the initial coarse grinding parameter into a final coarse grinding parameter, performing secondary coarse grinding on the rubber roller based on the final coarse grinding parameter, collecting the finish degree of a fine grinding finished product, and comparing the finish degree with a second preset value to obtain a quality judgment result. The precise size parameters of the rubber roller are obtained through the multispectral three-dimensional scanner, the control precision of the surface quality of the rubber roller is improved, the production efficiency of the surface quality control of the rubber roller is improved through the automatic coarse grinding and fine grinding processes, and the grinding consistency of the rubber roller is enhanced through data-based difference calculation and parameter adjustment.

Description

Technical Field

[0001] This invention relates to the field of mechanical polishing technology, and in particular to a rubber roller polishing method. Background Technology

[0002] As the core foil-making equipment in copper foil production, the foil forming machine involves the copper foil being pulled and pressed sequentially by 3 to 5 sets of drive rollers and pressure rollers during the production process, ultimately completing the winding and forming. According to the process specifications, any defects (such as scratches, unevenness, etc.) on the surface of the rollers will cause defects on the surface of the copper foil, resulting in product downgrading.

[0003] While existing methods for controlling the surface quality of rubber rollers can meet basic production needs to some extent, they have significant limitations. First, manual inspection and adjustment cannot provide precise surface geometry parameters, making accurate quality control impossible. Second, simple mechanical inspection equipment cannot adapt to dynamic changes in the surface condition of the rubber rollers and cannot adjust grinding parameters in real time to suit different working conditions. Furthermore, experience-based adjustment methods lack scientific basis, making it difficult to guarantee the stability and reliability of the rubber roller surface quality. Summary of the Invention

[0004] In view of the above situation, it is necessary to provide a rubber roller grinding method to address the issues of stability and reliability of the surface quality of rubber rollers in the prior art.

[0005] A method for grinding rubber rollers includes the following steps:

[0006] S1. Obtain the dimensional parameters of the rubber roller, set the initial rough grinding parameters of the rough grinding equipment based on the dimensional parameters, and discretize the contour of the rubber roller into several control points;

[0007] S2. Based on the aforementioned control points, determine the coarse grinding path of the coarse grinding equipment;

[0008] S3. Perform a rough grinding on the rubber roller according to the rough grinding parameters and the rough grinding path, monitor the grinding data in real time during the rough grinding process, obtain the rough grinding profile value of the rubber roller and calculate the first difference.

[0009] S4. Based on the correlation between the grinding data and the first difference, adjust the feed pressure during the coarse grinding process, update the initial coarse grinding parameters to the final coarse grinding parameters, and perform secondary coarse grinding on the rubber roller based on the final coarse grinding parameters until the first difference is less than the first preset value, so as to obtain a coarse grinding semi-finished product.

[0010] S5. The coarsely ground semi-finished product is finely ground using a fine grinding equipment to obtain the finely ground finished product;

[0011] S6. Collect the surface finish of the finished polished product, and compare the surface finish with a second preset value to obtain a quality judgment result.

[0012] The beneficial effects of this invention are:

[0013] Compared with existing technologies, the beneficial effects of this technical solution are as follows: 1. Improved surface quality control accuracy: By acquiring precise dimensional parameters of the rubber roller through a multispectral 3D scanner and setting the parameters of the rough grinding equipment based on these parameters, accurate measurement and control of the micro-geometric features of the rubber roller surface can be achieved, thereby improving the control accuracy of the rubber roller surface quality. 2. Increased production efficiency: This technical solution reduces the need for manual inspection and adjustment through automated rough grinding and fine grinding processes, significantly improving the production efficiency of rubber roller surface quality control. 3. Enhanced quality consistency: Through data-based difference calculation and parameter adjustment, this technical solution can achieve precise control of the rubber roller surface quality, thereby enhancing the consistency of rubber roller products. 4. Improved reliability: This technical solution uses scientific methods to control the quality of the rubber roller surface, reducing experience-based adjustments and improving the stability and reliability of the rubber roller surface quality. 5. Reduced human error: The automated rough grinding and fine grinding processes reduce human error, ensuring the consistency and accuracy of the rubber roller surface quality. 6. Strong adaptability: This technical solution can adapt to different working conditions, including the usage environment, operating cycle, characteristics of contact materials, degree of rubber oxidation, and temperature and humidity, ensuring the stability of the surface quality of the rubber roller.

[0014] Furthermore, the step of determining the coarse grinding path of the coarse grinding equipment based on the several control points specifically includes:

[0015] For several control points, a two-dimensional plane point set is generated by normal projection mapping, Delaunay triangulation is performed and topological connection relationship is established, and the result is mapped to three-dimensional space to form a surface mesh.

[0016] Based on the aforementioned control points, the curvature gradient ▽κ of each control point is calculated, and ▽κ > 0.05 mm is marked. -2 The region is a high curvature abrupt change region;

[0017] Within the high curvature abrupt change region, the size of the surface mesh is reduced to 30%-50% of that in the conventional region, and the node density of the surface mesh is positively correlated with the curvature gradient;

[0018] Make the angle θ between the expansion direction of the surface mesh and the principal curvature direction ≤ 15°, and advance the leading edge of the surface mesh along the direction of the maximum principal curvature K1;

[0019] The vertices of the optimized surface mesh are connected to form coarse grinding paths, and the spacing of the coarse grinding paths adaptively matches the density of the local surface mesh.

[0020] Furthermore, in the step of reducing the size of the surface mesh to 30%-50% of that in the high curvature abrupt change region, and in which the node density of the surface mesh is positively correlated with the curvature gradient, the mesh node density is positively correlated with the curvature gradient, satisfying:

[0021] d=d0 / (1+λ·∣▽κ∣)

[0022] Where d is the current mesh size, d0 is the baseline mesh size, λ is the scaling factor, and ▽κ is the curvature gradient;

[0023] The value of λ is:

[0024]

[0025] Where λ is the scaling factor, d0 is the reference mesh size, and κ is the scaling factor. ref Characteristic curvature;

[0026] κ ref The value can be:

[0027]

[0028] Among them, R min It is the minimum radius of curvature.

[0029] Further, the step of performing a rough grinding of the rubber roller according to the rough grinding parameters and the rough grinding path, monitoring the grinding data in real time during the rough grinding process, obtaining the contour value of the rubber roller, and calculating the first difference specifically includes:

[0030] Grinding force is monitored in real time by a piezoelectric force sensor, the temperature field of the grinding zone is captured by an infrared thermal imaging unit, vibration signals are collected by a triaxial accelerometer, a time synchronization mechanism is established to align the time of force, temperature and vibration data, and the grinding force, the temperature field and the vibration acceleration are normalized respectively.

[0031] The actual contour point set of the rubber roller is obtained by a laser profilometer, and ICP registration is performed with the target contour point set of the rubber roller to obtain the first difference.

[0032] Furthermore, in the steps of real-time monitoring of grinding force using a piezoelectric force sensor, capturing the temperature field of the grinding zone using an infrared thermal imaging unit, collecting vibration signals using a triaxial accelerometer, establishing a time synchronization mechanism to align the time of force, temperature, and vibration data, and normalizing the grinding force, the temperature field, and the vibration acceleration respectively, the grinding force is normalized as follows:

[0033]

[0034] Among them, F norm F(t) is the normalized grinding force signal, and F(t) is the original grinding force signal measured in real time. max F is the maximum safe grinding force allowed by the system. min The minimum effective grinding force threshold;

[0035] The temperature field is normalized as follows:

[0036]

[0037] Among them, T norm (t) represents the normalized grinding temperature signal, and T(t) represents the real-time maximum temperature in the grinding zone. amb T is the ambient reference temperature. max To ensure the material can withstand the critical temperature;

[0038] The vibration acceleration is normalized to:

[0039]

[0040] Among them, a norm (t) represents the normalized grinding vibration acceleration signal, and a(t) is the vibration characteristic quantity. rated This is the reference value for rated operating conditions;

[0041] In the step of obtaining the actual contour point set of the rubber roller using a laser profilometer and performing ICP registration with the target contour point set of the rubber roller to obtain a first difference, the first difference is:

[0042]

[0043] Where Δ1(t) is the first difference (i.e., the profile deviation), N is the number of valid measurement points, R is the rotation matrix, and P actual Let P be the actual set of contour points, t be the translation vector, and P be the distance from the point of origin. target For the target contour point set.

[0044] Furthermore, before the steps of performing a rough grinding operation on the rubber roller according to the rough grinding parameters and the rough grinding path, monitoring the grinding data during the rough grinding process in real time, obtaining the rough grinding profile value of the rubber roller, and calculating the first difference, the following steps are also included:

[0045] Coolant is sprayed onto the grinding surfaces of the coarse grinding equipment and the rubber roller, and the temperature of the grinding surface is monitored in real time by an infrared temperature controller. The coolant spray flow rate is adjusted according to the cutting temperature using a PID controller, and the coolant spray flow rate is 0.4L / min-0.8L / min, so that the temperature of the grinding surface is controlled at 25℃±2℃.

[0046] Further, coolant is sprayed onto the grinding surfaces of the coarse grinding equipment and the rubber roller, and the temperature of the grinding surface is monitored in real time by an infrared temperature controller. The coolant spray flow rate is adjusted according to the cutting temperature using a PID controller, and the coolant spray flow rate is 0.4L / min-0.8L / min to control the temperature of the grinding surface at 25℃±2℃. After this step, when the coolant spray flow rate is lower than 0.3L / min, a speed reduction mode is triggered. The speed reduction mode includes the following steps:

[0047] When the coolant flow rate is below 0.3 L / min for 3 seconds and the temperature of the grinding surface is controlled at 25℃±2℃, the spindle speed of the lathe and the speed of the rough grinding equipment are both reduced to 80% of the normal speed.

[0048] When the coolant flow rate is below 0.3L / min for 10 seconds and the temperature of the grinding surface is controlled at 25℃±2℃, the spindle speed of the lathe and the speed of the rough grinding equipment are reduced to 50% of the normal speed, and an audible and visual alarm is triggered.

[0049] When the coolant flow rate is below 0.3L / min for 30 seconds and the temperature of the grinding surface is not controlled within 25℃±2℃, the spindle of the lathe and the rough grinding equipment will stop, and the breakpoint coordinates of the rubber roller will be automatically saved.

[0050] Further, the steps of adjusting the feed pressure during the coarse grinding process based on the correlation between the grinding data and the first difference, updating the initial coarse grinding parameters to the final coarse grinding parameters, and performing a second coarse grinding on the rubber roller based on the final coarse grinding parameters until the first difference is less than the first preset value to obtain the coarsely ground semi-finished product are as follows:

[0051] When Δ1 > 0.1mm, a first-level adjustment command is generated, with the feed pressure adjustment amount ΔF = 15N~20N, and the grinding head speed is reduced by 10%~15% simultaneously;

[0052] When 0.05mm < Δ1 ≤ 0.1mm, a second-level adjustment command is generated, with the feed pressure adjustment amount ΔF = 5N ~ 10N, and the grinding head speed is reduced by 5% ~ 8% simultaneously;

[0053] The feed pressure adjustment amount is subjected to pressure clamping.

[0054] Furthermore, the step of associating the grinding data with the first difference specifically includes:

[0055]

[0056] Where Δ1(t) is the first difference (i.e., the profile deviation), α is the grinding force weighting coefficient, β is the temperature exponent term, e is the base of the natural logarithm, λ is the temperature exponent growth rate, and γ is the vibration logarithm term weighting coefficient.

[0057] F norm (t) represents the normalized grinding force signal, T norm (t) represents the normalized grinding temperature signal.

[0058] a norm (t) is the normalized grinding vibration acceleration signal, and c is the reference error;

[0059] The feed pressure adjustment amount is:

[0060]

[0061] Among them, F new For the adjusted new feed pressure, F original ΔF represents the initial feed pressure at the current grinding stage, and ΔF represents the feed pressure adjustment amount.

[0062] The specific steps for performing pressure clamping processing on the feed pressure adjustment amount are as follows:

[0063] F new =min(max(F) new ,F min ),F max );

[0064] Among them, F new For the adjusted new feed pressure, F min For the minimum effective grinding force threshold, F max This is the maximum safe grinding force threshold.

[0065] Furthermore, the step of collecting the surface finish of the finely ground product and comparing the surface finish with a second preset value to obtain a quality judgment result specifically includes:

[0066] The finished polished product is installed on a mobile stage, and the smoothness of the finished polished product is detected using a white light interferometer. The smoothness is compared with a second preset value, and the quality judgment result is saved. Attached Figure Description

[0067] Figure 1 This is a schematic flowchart of the rubber roller grinding method in Embodiment 1 of the present invention. Detailed Implementation

[0068] To facilitate understanding of the present invention, a more complete description will be given below with reference to the accompanying drawings. Embodiments of the invention are shown in the drawings. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete.

[0069] It should be noted that when a component is said to be "fixed to" another component, it can be directly on the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0070] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the specification of this invention is for the purpose of describing particular embodiments only and is not intended to limit the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items. Furthermore, the various embodiments of the invention, the features within those embodiments, and the features of the embodiments may be freely combined without obvious conflict or contradiction.

[0071] Example 1

[0072] Please see Figure 1 A method for grinding rubber rollers, specifically including the following steps:

[0073] S1. Obtain the dimensional parameters of the rubber roller, set the initial rough grinding parameters of the rough grinding equipment based on the dimensional parameters, and discretize the contour of the rubber roller into several control points;

[0074] It should be noted that a high-precision multispectral 3D scanner was used to perform non-contact 3D scanning of the rubber roller to obtain its complete dimensional parameters. The scanning parameters were set as follows: spatial resolution of 0.01 mm, scanning frame rate of 10 frames / second, and scanning range covering the entire outer surface of the rubber roller. Based on the high-precision 3D data obtained from the scan, the surface feature parameters of the rubber roller were extracted, and the rough grinding parameters were set accordingly. After discretizing the rubber roller contour into several key control points using an algorithm, the working parameters of the rough grinding equipment were configured: feed speed set to 100 mm / min, applied pressure of 0.5 MPa, and single grinding depth of 0.1 mm. Finally, the optimal rough grinding path was planned and generated based on the discretized control point data to ensure processing accuracy and efficiency.

[0075] S2. Based on the aforementioned control points, determine the coarse grinding path of the coarse grinding equipment;

[0076] It should be noted that the rough grinding path is planned to ensure that all areas of the rubber roller surface are covered. An improved wavefront propagation method is used to construct a non-uniform processing mesh to adapt to the geometric complexity of the curved surface. Key feature points (such as curvature extrema and boundary points) in the 3D point cloud are extracted as control points, and several control points form a point set. The 3D point cloud is mapped to a 2D plane using normal projection, and then Delaunay triangulation is performed in the 2D domain. The topological relationship of the point set is suggested, and the 2D topology is mapped back to 3D space to form a curved triangular mesh. The point distribution is controlled by curvature adaptive mesh to ensure that the mesh density in high curvature areas (such as the transition surface at the end of the rubber roller) is significantly greater than that in flat areas (such as the middle of the roller body). This allows the generated tool path to be automatically densified where the curvature changes drastically, meeting the requirements for consistent machining allowance. The ratio of mesh cell size to tool step size is controlled within the range of 1:1.2 to 1:1.5 to avoid undermapping or repeated machining.

[0077] Constrained Delaunay triangulation (CDT) is introduced to forcibly preserve boundary edges and feature lines. Point clouds are preprocessed using sliding least squares filtering (MLS), and the generated mesh undergoes curvature adaptive refinement or smoothing iteration. In the 2D Delaunay triangulation stage, the boundary point set after projection is marked to forcibly constrain the triangulation process to not cross the physical boundary of the original point cloud, ensuring that the geometric consistency error between the 3D reconstructed mesh and the actual contour of the workpiece is less than 0.05mm. The sliding least squares filtering (MLS) uses a quadratic basis function, and the filtering radius is set to 2.2-2.5 times the local density of the point cloud. After processing, the high-frequency noise amplitude of the point cloud is reduced by more than 80%, while the position offset of the curvature extremum points is controlled within 0.03mm.

[0078] Based on local quadratic surface fitting, for each vertex Pi, its 1-ring neighborhood triangle is selected, and a quadratic surface is fitted using the least squares method. The formula for calculating the quadratic surface is as follows:

[0079] z = ax 2 +bxy+cy 2 +dx+ey+f;

[0080] Where z is the height of the surface at point (x, y), and a is the height of x. 2 Directional curvature, b is the cross term coefficient, c is the y-coefficient. 2 Directional curvature, d is the slope in the x-direction, e is the slope in the y-direction, and f is the reference height;

[0081] The Gaussian curvature K and mean curvature H of each vertex are calculated based on the quadratic surface. The formula for calculating Gaussian curvature K is:

[0082]

[0083] The formula for calculating the mean curvature H is:

[0084]

[0085] Where z is the height of the surface at point (x, y), and a is the height of x. 2 Directional curvature, b is the cross term coefficient, c is the y-coefficient. 2 Directional curvature, where d is the slope in the x-direction and e is the slope in the y-direction;

[0086] Based on the average curvature H, the curvature gradient ▽κ of each control point is calculated.

[0087]

[0088] Then mark ▽κ>0.05mm -2 The region is a high curvature abrupt change region;

[0089] In regions of high curvature abrupt change, the mesh size is reduced to 30-50% of that in normal regions. The mesh node density is positively correlated with the curvature gradient κ, satisfying the following:

[0090] d=d0 / (1+λ·∣▽κ∣)

[0091] d is the current mesh size, d0 is the reference mesh size, λ is the scaling factor, and ▽κ is the curvature gradient;

[0092] The value of λ is:

[0093]

[0094] Where λ is the scaling factor, d0 is the reference mesh size, and κ is the scaling factor. ref Characteristic curvature;

[0095] κ ref The value can be:

[0096]

[0097] Among them, R min The minimum radius of curvature;

[0098] Seed points are set up in the high curvature region. The principal curvature direction K1 is determined by the eigendecomposition of the Hessian matrix. The angle between the mesh expansion direction and the principal curvature direction is θ≤15°. The mesh front is advanced along the direction of the maximum principal curvature K1. The mesh covers all control points. The boundary fitting error is ∈<0.02mm.

[0099] Sort the mesh vertices according to the principal curvature direction to generate B-spline paths:

[0100]

[0101] Where t is a parameterized variable, n is the total number of control points, and N is the total number of control points. i,p (t) is the p-th order B-spline basis function, Qi is the path control point, p = 3-th order spline, the node vector adopts uniform parameterization, and C(t) is the optimized mesh vertex connection as the processing path;

[0102] Based on the processing path, the local mesh density is dynamically matched by the path spacing δ, where δ = d0 in the normal region and δ = 0.7d in the abrupt change region.

[0103] Where d0 is the baseline spacing and d is the local spacing, so as to achieve adaptive matching of path spacing with local mesh density.

[0104] Specifically, before the steps of performing a coarse grinding on the rubber roller according to the coarse grinding parameters and the coarse grinding path, monitoring the grinding data during the coarse grinding process in real time, obtaining the coarse grinding profile value of the rubber roller, and calculating the first difference, the following steps are also included:

[0105] Coolant is sprayed onto the grinding surfaces of the coarse grinding equipment and the rubber roller, and the temperature of the grinding surface is monitored in real time by an infrared temperature controller. The coolant spray flow rate is adjusted according to the cutting temperature using a PID controller, and the coolant spray flow rate is 0.4L / min-0.8L / min, so that the temperature of the grinding surface is controlled at 25℃±2℃.

[0106] It should be noted that by ensuring a lower limit of 0.4 L / min for the coolant spray flow rate, necessary lubrication and minor cooling can be maintained even when the critical temperature is not reached or is close to the target temperature under high cutting efficiency, thus avoiding localized dry grinding. Setting an upper limit of 0.8 L / min for the coolant spray flow rate can handle most abnormal heat inputs (such as increased grinding contact area, increased feed rate, and initial passivation of the grinding wheel). The infrared temperature controller probe must be precisely positioned to ensure stable and accurate measurement of the actual working area temperature of the grinding surface. 25℃ is an ideal control target, which effectively avoids workpiece thermal deformation, dimensional instability, surface burns (metallographic changes), and increased residual stress caused by overheating in the grinding zone, as well as decreased accuracy or damage to the rubber roller itself due to thermal expansion. A fluctuation range of ±2℃ is acceptable for precision grinding. This ensures the thermal stability of the process, reduces dimensional changes and surface quality differences caused by excessive temperature fluctuations, and helps improve machining consistency and repeatability.

[0107] Specifically, coolant is sprayed onto the grinding surfaces of the coarse grinding equipment and the rubber roller, and the temperature of the grinding surface is monitored in real time by an infrared temperature controller. The coolant spray flow rate is adjusted according to the cutting temperature using a PID controller, and the coolant spray flow rate is 0.4L / min-0.8L / min to control the temperature of the grinding surface at 25℃±2℃. After this step, when the coolant spray flow rate is lower than 0.3L / min, a speed reduction mode is triggered. The speed reduction mode includes the following steps:

[0108] When the coolant flow rate is below 0.3 L / min for 3 seconds and the temperature of the grinding surface is controlled at 25℃±2℃, the spindle speed of the lathe and the speed of the rough grinding equipment are both reduced to 80% of the normal speed.

[0109] When the coolant flow rate is below 0.3L / min for 10 seconds and the temperature of the grinding surface is controlled at 25℃±2℃, the spindle speed of the lathe and the speed of the rough grinding equipment are reduced to 50% of the normal speed, and an audible and visual alarm is triggered.

[0110] When the coolant flow rate is below 0.3L / min for 30 seconds and the temperature of the grinding surface is not controlled within 25℃±2℃, the spindle of the lathe and the rough grinding equipment will stop, and the breakpoint coordinates of the rubber roller will be automatically saved.

[0111] It should be noted that by monitoring the two key parameters of coolant flow rate and grinding surface temperature in real time, the system can intervene in advance when cooling or heat dissipation conditions begin to deteriorate. When the problem is not yet serious (low flow rate but temperature is still within the controllable range), the speed of the spindle and rough grinding equipment is reduced, reducing the generation of frictional heat and mechanical load. This prevents the grinding surface temperature from rapidly and uncontrollably soaring due to insufficient cooling, avoiding overheating damage (such as annealing, burning, deformation) or excessive wear to precision grinding equipment (such as spindle bearings, rough grinding equipment) and the processed rubber roller grinding surface. When the problem persists and the risk intensifies, the speed is further reduced to minimize heat generation. At the same time, audible and visual alarms immediately remind the operator to quickly identify the coolant problem (such as filter blockage, pump failure, insufficient liquid level, etc.) and prevent the problem from deteriorating to an uncontrollable level. When the coolant is severely insufficient for a long time (30 seconds) and has caused the grinding surface temperature to run out of control (exceeding 25℃±2℃), the system determines the fault level to be high and the risk to be extremely high (which may immediately damage expensive workpieces and equipment). At this point, stopping the machine immediately is the safest measure, avoiding catastrophic equipment damage (such as spindle seizing) or complete scrapping of the rubber rollers.

[0112] S3. Perform a rough grinding on the rubber roller according to the rough grinding parameters and the rough grinding path, monitor the grinding data in real time during the rough grinding process, obtain the rough grinding profile value of the rubber roller and calculate the first difference.

[0113] It should be noted that the data acquisition frequency is set to 100Hz. The grinding force is monitored in real time by a Kistler 9257B piezoelectric force sensor located at the front end of the grinding head spindle. An infrared thermal imager (FLIR A655sc) located 50mm from the grinding point captures the temperature field of the grinding zone. A triaxial accelerometer (PCB 356A01) located on the side of the grinding machine table collects vibration signals. A time synchronization mechanism is established to align the time of force, temperature, and vibration data. The grinding force F(t), temperature field T(t), and vibration acceleration a(t) are normalized. The normalized grinding force is:

[0114]

[0115] Among them, F norm F(t) is the normalized grinding force signal, and F(t) is the original grinding force signal measured in real time. max F is the maximum safe grinding force allowed by the system. min The minimum effective grinding force threshold;

[0116] The temperature field is normalized as follows:

[0117]

[0118] Among them, T norm (t) represents the normalized grinding temperature signal, and T(t) represents the real-time maximum temperature in the grinding zone. amb T is the ambient reference temperature. max To ensure the material can withstand the critical temperature;

[0119] The vibration acceleration is normalized to:

[0120]

[0121] Among them, a norm (t) represents the normalized grinding vibration acceleration signal, and a(t) is the vibration characteristic quantity. rated This is the reference value for rated operating conditions;

[0122] The actual profile point set {P} of the rubber roller was obtained using a Keyence LJ-V7080 laser profilometer located 100mm downstream of the grinding zone. actual}, and the target contour point set {P} of the rubber roller target} Perform ICP registration to register the target contour point set {P} of the rubber roller. target To decompose the data into a point cloud, the first difference is obtained, which is:

[0123]

[0124] Where Δ1(t) is the first difference (i.e., the profile deviation), N is the number of valid measurement points, R is the rotation matrix, and P actual Let P be the actual set of contour points, t be the translation vector, and P be the distance from the point of origin. target For the target contour point set

[0125] Perform coarse PCA alignment, then perform Point-to-Plane ICP, ensuring the root mean square variation is <0.001 mm or iterates 50 times.

[0126] S4. Based on the correlation between the grinding data and the first difference, adjust the feed pressure during the coarse grinding process, update the initial coarse grinding parameters to the final coarse grinding parameters, and perform secondary coarse grinding on the rubber roller based on the final coarse grinding parameters until the first difference is less than the first preset value, so as to obtain a coarse grinding semi-finished product.

[0127] It should be noted that the specific steps for associating the grinding data with the first difference are as follows:

[0128]

[0129] Where Δ1(t) is the first difference (i.e., the profile deviation), α is the grinding force weighting coefficient, β is the temperature exponent term, e is the base of the natural logarithm, λ is the temperature exponent growth rate, and γ is the vibration logarithm term weighting coefficient.

[0130] F norm (t) represents the normalized grinding force signal, T norm (t) represents the normalized grinding temperature signal, a norm (t) is the normalized grinding vibration acceleration signal, and c is the reference error;

[0131] The first preset value is 0.05mm. When Δ1 > 0.1mm, the first-level adjustment command is generated, and the feed pressure adjustment amount ΔF = 15N~20N, and the grinding head speed is reduced by 10%~15% simultaneously.

[0132] When 0.05mm < Δ1 ≤ 0.1mm, a second-level adjustment command is generated, with the feed pressure adjustment amount ΔF = 5N ~ 10N, and the grinding head speed is reduced by 5% ~ 8% simultaneously;

[0133] During the adjustment process, the feed pressure adjustment amount is subjected to pressure clamping.

[0134] The feed pressure adjustment amount is dynamically adjusted through the above-mentioned graded response.

[0135] The feed pressure adjustment amount is:

[0136]

[0137] Among them, Fnew For the adjusted new feed pressure, F original ΔF represents the initial feed pressure at the current grinding stage, and ΔF represents the feed pressure adjustment amount.

[0138] The specific steps for performing pressure clamping processing on the feed pressure adjustment amount are as follows:

[0139] F new =min(max(F) new ,F min ),F max );

[0140] Among them, F new For the adjusted new feed pressure, F min For the minimum effective grinding force threshold, F max This is the maximum safe grinding force threshold.

[0141] Specifically, when the actual contour is smaller than the target contour (insufficient material removal), grinding is performed by increasing the feed pressure, with the feed pressure being F. new =F original +ΔF; When the actual profile is larger than the target profile, grinding is performed by reducing the feed pressure, with the feed pressure (risk of overcutting) being: F new =F original -ΔF; Implement pressure clamping:

[0142] F new =min(max(F) new ,F min ),F max ), where the value F min =30N, F max =200N,

[0143] By forcibly limiting the range of values ​​after pressure adjustment (F) min ≤F new ≤F max To avoid the following risks caused by calculation errors or over-adjustment:

[0144] Low pressure (F) new <30N) → Insufficient grinding force, resulting in a sharp drop in material removal efficiency and extended processing time; excessive pressure (F) new >200N)→ Overload of the cutter / roller can cause cutter breakage, surface burns, or equipment damage.

[0145] The comparison data between the dynamic adjustment and fixed parameter methods of this invention are shown in Table 1 below:

[0146] Table 1

[0147] index This invention Fixed parameter method Number of adjustments 2-3 times 5 to 8 times Final accuracy ±0.04mm ±0.10mm Surface burn rate 0％ 15％

[0148] S5. The coarsely ground semi-finished product is finely ground using a fine grinding equipment to obtain the finely ground finished product;

[0149] It should be noted that the feed speed of the fine grinding equipment is set to 50 mm / min, the pressure is set to 0.3 MPa, and the grinding depth is set to 0.05 mm. The fine grinding steps are carried out according to steps S1 to S4, which will not be repeated here.

[0150] S6. Collect the surface finish of the finished polished product, and compare the surface finish with a second preset value to obtain a quality judgment result.

[0151] It should be noted that the rubber roller should be mounted on the moving stage to ensure reliable axial constraint and avoid displacement during the inspection process. The Bruker ContourGT-K white light interferometer should be started, and after warm-up, a reference plane calibration should be performed to ensure sub-nanometer longitudinal resolution. A 20× objective lens should be selected, and the scanning range should cover key areas of the rubber roller surface (such as the contact area). The scanning speed should be adapted to the surface curvature. Five measurement points should be evenly selected along the circumference of the rubber roller, with each measurement point having a scanning area ≥1 mm². 2 The three-dimensional topography data is acquired and the arithmetic mean roughness (i.e., surface finish) is calculated. The surface finish is compared with a second preset value, which is 0.8 μm. If the surface finish is less than 0.8 μm, it is considered qualified; if the surface finish is not less than 0.8 μm twice in a row, it is considered unqualified. The quality judgment result is saved.

[0152] Compared with existing technologies, the beneficial effects of this technical solution are as follows:

[0153] 1. Improve surface quality control accuracy: By acquiring the precise dimensional parameters of the rubber roller through a multispectral 3D scanner and setting the parameters of the rough grinding equipment based on these parameters, it is possible to achieve precise measurement and control of the micro-geometric features of the rubber roller surface, thereby improving the control accuracy of the rubber roller surface quality.

[0154] 2. Improve production efficiency: This technical solution reduces the need for manual inspection and adjustment through automated rough grinding and fine grinding processes, significantly improving the production efficiency of rubber roller surface quality control;

[0155] 3. Enhanced quality consistency: Through data-based difference calculation and parameter adjustment, this technical solution can achieve precise control over the surface quality of rubber rollers, thereby enhancing the consistency of rubber roller products;

[0156] 4. Improved reliability: This technical solution uses scientific methods to control the quality of the rubber roller surface, reducing experience-based adjustments and improving the stability and reliability of the rubber roller surface quality;

[0157] 5. Reduce human error: The automated roughing and fine grinding processes reduce human error, ensuring the consistency and precision of the rubber roller surface quality;

[0158] 6. Strong adaptability: This technical solution can adapt to different working conditions, including the usage environment, operating cycle, characteristics of contact materials, degree of rubber oxidation, and temperature and humidity, ensuring the stability of the surface quality of the rubber roller.

[0159] In this embodiment, the specific implementation of each unit in the above device embodiment is described in the above method embodiment, and will not be repeated here.

[0160] In the description of this specification, references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0161] The embodiments described above are merely illustrative of implementation methods of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of this patent should be determined by the appended claims.

Claims

1. A method for grinding rubber rollers, characterized in that: Includes the following steps: S1. Obtain the dimensional parameters of the rubber roller, set the initial rough grinding parameters of the rough grinding equipment based on the dimensional parameters, and discretize the contour of the rubber roller into several control points; S2. Based on the aforementioned control points, determine the coarse grinding path of the coarse grinding equipment; S3. Perform a rough grinding on the rubber roller according to the rough grinding parameters and the rough grinding path, monitor the grinding data in real time during the rough grinding process, obtain the rough grinding profile value of the rubber roller and calculate the first difference. S4. Based on the correlation between the grinding data and the first difference, adjust the feed pressure during the coarse grinding process, update the initial coarse grinding parameters to the final coarse grinding parameters, and perform secondary coarse grinding on the rubber roller based on the final coarse grinding parameters until the first difference is less than the first preset value, so as to obtain a coarse grinding semi-finished product. S5. The coarsely ground semi-finished product is finely ground using a fine grinding equipment to obtain the finely ground finished product; S6. Collect the surface finish of the finished polished product, and compare the surface finish with a second preset value to obtain a quality judgment result.

2. The rubber roller grinding method according to claim 1, characterized in that: The step of determining the coarse grinding path of the coarse grinding equipment based on the aforementioned control points specifically includes: For several control points, a two-dimensional plane point set is generated by normal projection mapping, Delaunay triangulation is performed and topological connection relationship is established, and the result is mapped to three-dimensional space to form a surface mesh. Based on the aforementioned control points, calculate the curvature gradient of each control point. and mark The region is a high curvature abrupt change region; Within the high curvature abrupt change region, the size of the surface mesh is reduced to 30%-50% of that in the conventional region, and the node density of the surface mesh is positively correlated with the curvature gradient; Make the angle θ between the expansion direction of the surface mesh and the principal curvature direction ≤ 15°, and advance the leading edge of the surface mesh along the direction of the maximum principal curvature K1; The vertices of the optimized surface mesh are connected to form coarse grinding paths, and the spacing of the coarse grinding paths adaptively matches the density of the local surface mesh.

3. The method for grinding rubber rollers according to claim 2, characterized in that: In the step of reducing the size of the surface mesh to 30%-50% of that in the high curvature abrupt change region, and in which the node density of the surface mesh is positively correlated with the curvature gradient, the mesh node density is positively correlated with the curvature gradient, satisfying: Where d is the current mesh size, d0 is the reference mesh size, and λ is the scaling factor. The curvature gradient is λ; the values ​​of λ are: Where λ is the scaling factor, d0 is the reference mesh size, and κ is the scaling factor. ref Characteristic curvature; κ ref The value can be: Among them, R min It is the minimum radius of curvature.

4. The method for grinding rubber rollers according to claim 1, characterized in that: The steps of performing a coarse grinding on the rubber roller according to the coarse grinding parameters and the coarse grinding path, monitoring the grinding data in real time during the coarse grinding process, obtaining the contour value of the rubber roller, and calculating the first difference are as follows: Grinding force is monitored in real time by a piezoelectric force sensor, the temperature field of the grinding zone is captured by an infrared thermal imaging unit, vibration signals are collected by a triaxial accelerometer, a time synchronization mechanism is established to align the time of force, temperature and vibration data, and the grinding force, the temperature field and the vibration acceleration are normalized respectively. The actual contour point set of the rubber roller is obtained by a laser profilometer, and ICP registration is performed with the target contour point set of the rubber roller to obtain the first difference.

5. The method for grinding rubber rollers according to claim 4, characterized in that: In the steps of real-time monitoring of grinding force using a piezoelectric force sensor, capturing the temperature field of the grinding zone using an infrared thermal imaging unit, collecting vibration signals using a triaxial accelerometer, establishing a time synchronization mechanism to align the time of force, temperature, and vibration data, and normalizing the grinding force, the temperature field, and the vibration acceleration respectively, the grinding force is normalized as follows: Among them, F norm F(t) is the normalized grinding force signal, and F(t) is the original grinding force signal measured in real time. max F is the maximum safe grinding force allowed by the system. min The minimum effective grinding force threshold; The temperature field is normalized as follows: Among them, T norm (t) represents the normalized grinding temperature signal, and T(t) represents the real-time highest temperature in the grinding zone. amb T is the ambient reference temperature. max To ensure the material can withstand the critical temperature; The vibration acceleration is normalized to: Among them, a norm (t) represents the normalized grinding vibration acceleration signal, and a(t) is the vibration characteristic quantity. rated This is the reference value for rated operating conditions; In the step of obtaining the actual contour point set of the rubber roller using a laser profilometer and performing ICP registration with the target contour point set of the rubber roller to obtain a first difference, the first difference is: Where Δ1(t) is the first difference (i.e., the profile deviation), N is the number of valid measurement points, R is the rotation matrix, and P actual Let P be the actual set of contour points, t be the translation vector, and P be the translation vector. target For the target contour point set.

6. The method for grinding rubber rollers according to claim 1, characterized in that: Before the steps of performing a coarse grinding of the rubber roller according to the coarse grinding parameters and the coarse grinding path, monitoring the grinding data during the coarse grinding process in real time, obtaining the coarse grinding profile value of the rubber roller, and calculating the first difference, the following steps are also included: Coolant is sprayed onto the grinding surfaces of the coarse grinding equipment and the rubber roller, and the temperature of the grinding surface is monitored in real time by an infrared temperature controller. The coolant spray flow rate is adjusted according to the cutting temperature using a PID controller, and the coolant spray flow rate is 0.4L / min-0.8L / min, so that the temperature of the grinding surface is controlled at 25℃±2℃.

7. The method for grinding rubber rollers according to claim 6, characterized in that: Coolant is sprayed onto the grinding surfaces of the coarse grinding equipment and the rubber roller, and the temperature of the grinding surface is monitored in real time by an infrared temperature controller. The coolant spray flow rate is adjusted according to the cutting temperature using a PID controller, and the coolant spray flow rate is 0.4L / min-0.8L / min to control the temperature of the grinding surface at 25℃±2℃. After this step, when the coolant spray flow rate is lower than 0.3L / min, a speed reduction mode is triggered. The speed reduction mode includes the following steps: When the coolant flow rate is below 0.3 L / min for 3 seconds and the temperature of the grinding surface is controlled at 25℃±2℃, the spindle speed of the lathe and the speed of the rough grinding equipment are both reduced to 80% of the normal speed. When the coolant flow rate is below 0.3L / min for 10 seconds and the temperature of the grinding surface is controlled at 25℃±2℃, the spindle speed of the lathe and the speed of the rough grinding equipment are reduced to 50% of the normal speed, and an audible and visual alarm is triggered. When the coolant flow rate is below 0.3L / min for 30 seconds and the temperature of the grinding surface is not controlled within 25℃±2℃, the spindle of the lathe and the rough grinding equipment will stop, and the breakpoint coordinates of the rubber roller will be automatically saved.

8. The method for grinding rubber rollers according to claim 5, characterized in that: The steps of adjusting the feed pressure during the coarse grinding process based on the correlation between the grinding data and the first difference, updating the initial coarse grinding parameters to the final coarse grinding parameters, and performing a second coarse grinding on the rubber roller based on the final coarse grinding parameters until the first difference is less than the first preset value to obtain the coarsely ground semi-finished product are as follows: When Δ1 > 0.1mm, a first-level adjustment command is generated, with the feed pressure adjustment amount ΔF = 15N~20N, and the grinding head speed is reduced by 10%~15% simultaneously; When 0.05mm < Δ1 ≤ 0.1mm, a second-level adjustment command is generated, with the feed pressure adjustment amount ΔF = 5N ~ 10N, and the grinding head speed is reduced by 5% ~ 8% simultaneously; The feed pressure adjustment amount is subjected to pressure clamping.

9. The method for grinding rubber rollers according to claim 8, characterized in that: The specific steps for associating the grinding data with the first difference are as follows: Where Δ1(t) is the first difference (i.e., the profile deviation), α is the grinding force weighting coefficient, β is the temperature exponent, e is the base of the natural logarithm, λ is the temperature exponent growth rate, γ is the vibration logarithm weighting coefficient, and F norm (t) represents the normalized grinding force signal, T norm (t) represents the normalized grinding temperature signal, a norm (t) is the normalized grinding vibration acceleration signal, and c is the reference error; The feed pressure adjustment amount is: Among them, F new For the adjusted new feed pressure, F original ΔF represents the initial feed pressure at the current grinding stage, and ΔF represents the feed pressure adjustment amount. The specific steps for performing pressure clamping processing on the feed pressure adjustment amount are as follows: F new =min(max(F new ,F min ),F max ); Among them, F new For the adjusted new feed pressure, F min For the minimum effective grinding force threshold, F max This is the maximum safe grinding force threshold.

10. The method for grinding rubber rollers according to claim 1, characterized in that: The step of collecting the surface finish of the finely ground product and comparing the surface finish with a second preset value to obtain a quality judgment result is as follows: The finished polished product is installed on a mobile stage, and the smoothness of the finished polished product is detected using a white light interferometer. The smoothness is compared with a second preset value, and the quality judgment result is saved.

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