A tool position detection system and intelligent adjustment system of a gantry forming grinding machine

Abstract

This invention relates to the field of gantry forming grinding machine technology, specifically to a tool position detection system and intelligent adjustment system for a gantry forming grinding machine. The system includes a data acquisition module with a sensor detection module for synchronously acquiring workpiece sensor data and multi-source sensor data from the gantry forming grinding machine. The position acquisition module determines the workpiece position information based on the sensor data and multi-source sensor data, and then transmits this information to a position comparison module. The position comparison module compares the workpiece position information from the tool position detection system with preset position information and outputs position deviation information. The position adjustment module generates optimization adjustment commands based on the position deviation information and controls the actuator to adjust the tool position based on these commands, thereby improving the accuracy of tool machining operations.

Description

Technical Field

[0001] This invention relates to the field of gantry forming grinding machine technology, and specifically to a tool position detection system and intelligent adjustment system for a gantry forming grinding machine. Background Technology

[0002] During the machining process of a workpiece using a gantry forming grinder, real-time and precise detection and adjustment of the tool position is a core technical aspect to ensure the machining quality of the workpiece, especially the accuracy of hole and complex curved surface contour machining. It directly determines the consistency of machining dimensions, surface quality, and the dynamic response performance of the machine tool.

[0003] Currently, the detection and adjustment of tool position on gantry form grinding machines generally adopts a positioning scheme based on a single laser contour sensor. This involves measuring the workpiece reference point using a laser sensor installed at a fixed position on the machine tool, and directly comparing this measurement with the preset programmed position in the control system to drive the servo actuator to adjust the tool position. However, due to the complex thermal deformation and machining vibrations generated during the actual operation of gantry form grinding machines, these structural deformations and dynamic interferences caused by the coupling of thermal and mechanical forces significantly contaminate the measurement signal of the laser sensor. This results in the acquired workpiece position information deviating significantly from the workpiece's true physical position in the machine tool coordinate system. Consequently, subsequent comparison and adjustment operations are based on a reference with inherent errors, ultimately leading to inaccurate adjustments and an inability to achieve precise workpiece machining operations. Summary of the Invention

[0004] To address the technical problem that existing gantry forming grinders cannot achieve precise workpiece machining operations due to limitations in tool position detection and adjustment, this application provides a tool position detection system and intelligent adjustment system for a gantry forming grinder.

[0005] The tool position detection system and intelligent adjustment system for a gantry forming grinder provided in this application adopt the following technical solution:

[0006] A tool position detection system for a gantry forming grinder includes:

[0007] The data acquisition module is equipped with a sensor detection module. The data acquisition module is used to synchronously collect the sensing data of the workpiece and the multi-source sensing data of the gantry forming grinding machine through the sensor detection module.

[0008] The position acquisition module is used to determine the workpiece position information based on sensor data and multi-source sensor data, and then transmit the workpiece position information to the tool position intelligent adjustment system for tool adjustment.

[0009] Furthermore, the sensor detection module includes a laser profile sensor, an infrared temperature sensor, and a multi-axis vibration sensor, while the data acquisition module is used for:

[0010] When the workpiece is detected to have entered the detection range of the sensor detection module, the sensor detection module is triggered at the same time point. The reference position data of the workpiece is collected by the laser contour sensor, and the global temperature field data and vibration spectrum data of the gantry forming grinder are collected by the infrared temperature sensor and the multi-axis vibration sensor.

[0011] Among them, the reference position data is the position data relative to the machine tool coordinate system, and the multi-source sensor data includes global temperature field data and vibration spectrum data.

[0012] Furthermore, the workpiece types include a first workpiece machined using a stroke machining method, a second workpiece machined using a vertical grinding head, and a third workpiece machined using a horizontal grinding head. The position acquisition module is used for:

[0013] When the workpiece type is the first workpiece, the spindle thermal elongation is calculated based on global temperature field data, and the horizontal plane offset vector is calculated based on vibration spectrum data. Then, the reference position data is superimposed using the spindle thermal elongation and the horizontal plane offset vector to obtain the workpiece position information of the first workpiece; or,

[0014] When the workpiece type is the second workpiece, the triaxial thermal displacement is calculated based on global temperature field data, and the three-dimensional vibration offset is calculated based on vibration spectrum data. Then, the reference position data is superimposed using the triaxial thermal displacement and the three-dimensional vibration offset to obtain the workpiece position information of the second workpiece; or...

[0015] When the workpiece type is the third workpiece, the spindle thermal deformation vector is calculated based on the global temperature field data, and the spindle force deflection vector is calculated based on the vibration spectrum data. Then, the reference position data is vector-superimposed based on the spindle thermal deformation vector and the spindle force deflection vector to obtain the workpiece position information of the third workpiece.

[0016] A tool position intelligent adjustment system for a gantry forming grinder includes:

[0017] The position comparison module is used to compare the workpiece position information input by the tool position detection system with the preset position information and output the position deviation information.

[0018] The position adjustment module is used to generate optimization adjustment instructions based on position deviation information, and control the actuator to adjust the tool position based on the optimization adjustment instructions.

[0019] Furthermore, the intelligent tool position adjustment system also includes an information correction module, which is used for:

[0020] Calculate the thermal vibration composite compensation amount of the workpiece to which the workpiece position information belongs;

[0021] The initial preset position information of the workpiece is corrected based on the thermal vibration composite compensation amount to obtain the preset position information of the workpiece.

[0022] Furthermore, the position adjustment module is used for:

[0023] After generating the initial adjustment command based on the position deviation information, the initial adjustment command is optimized by combining the real-time status data of the actuator to obtain the optimized adjustment command;

[0024] Based on the optimization and adjustment instructions, the control actuator adjusts the position of the tool.

[0025] Furthermore, the workpiece types include a first workpiece machined using a stroke machining method, a second workpiece machined using a vertical grinding head, and a third workpiece machined using a horizontal grinding head. The steps for generating initial adjustment instructions based on position deviation information include:

[0026] When the workpiece type is the first workpiece, the spindle displacement command is calculated based on the axial deviation component in the position deviation information, and the axial compensation amount is calculated based on the multi-source sensor data of the first workpiece. The spindle displacement command and the axial compensation amount are vector-synthesized to obtain the first initial adjustment command for the stroke machining method; or,

[0027] When the workpiece type is the second workpiece, the three-axis linkage command is calculated based on the three-axis linkage deviation component in the position deviation information, and the axial compensation amount is calculated based on the multi-source sensor data of the second workpiece. The three-axis linkage command and the axial compensation amount are then matrix-superimposed to obtain the second initial adjustment command for the vertical grinding head; or,

[0028] When the workpiece type is the third workpiece, the spindle pose command is calculated based on the spindle spatial attitude deviation component in the position deviation information, and the compensation vector is calculated based on the multi-source sensor data of the third workpiece. The spindle pose command and the compensation vector are spatially synthesized to obtain the third initial adjustment command of the horizontal grinding head.

[0029] Furthermore, by combining the real-time status data of the actuator, the initial adjustment command is optimized to obtain the optimized adjustment command. The steps include:

[0030] When the workpiece type is the first workpiece, the first initial adjustment command is optimized by combining the real-time current of the spindle servo motor of the actuator and the feedback data from the horizontal grating ruler, resulting in an optimized adjustment command for the stroke machining method; or,

[0031] When the workpiece type is the second workpiece, the second initial adjustment command is optimized by combining the real-time current of the three-axis servo motor of the actuator and the encoder feedback data to obtain the optimized adjustment command for the vertical grinding head; or,

[0032] When the workpiece type is the third workpiece, the third initial adjustment command is optimized by combining the real-time torque of the spindle servo motor of the actuator, the tilt sensor data and the radial grating ruler feedback data to obtain the optimized adjustment command of the horizontal grinding head.

[0033] Beneficial effects achieved:

[0034] This application provides a tool position detection system for a gantry forming grinder. This tool position detection system is connected to the intelligent tool position adjustment system of the gantry forming grinder. The system includes: a data acquisition module equipped with a sensor detection module, used to synchronously collect workpiece sensor data and multi-source sensor data from the gantry forming grinder; and a position acquisition module, used to determine the workpiece position information based on the sensor data and multi-source sensor data, and then transmit the workpiece position information to the intelligent tool position adjustment system for tool adjustment operations.

[0035] In this application, multi-source sensor data of the workpiece and the gantry forming grinder are simultaneously collected by the sensor detection module. Compared with the traditional single detection method, multi-source sensor data provides more comprehensive workpiece status information. This workpiece status information includes the comprehensive state of the workpiece under the influence of multiple factors such as thermal deformation and vibration interference during the processing. The position acquisition module determines the workpiece position information in the coordinate system of the gantry forming grinder based on the multi-source sensor data. This process effectively removes environmental interference factors through data fusion calculation and restores the true position of the workpiece. Then, the workpiece position information is transmitted to the tool position intelligent adjustment system for tool adjustment operation, so that subsequent adjustment operations can be based on an accurate and reliable workpiece position, thereby improving the accuracy of tool processing operations. Attached Figure Description

[0036] Figure 1 This is a schematic diagram of the system modules of the tool position detection system and intelligent adjustment system of the gantry forming grinder of this application.

[0037] Explanation of icon numbers:

[0038] 10. Data acquisition module; 20. Location acquisition module; 30. Location comparison module; 40. Location adjustment module. Detailed Implementation

[0039] The following is in conjunction with the appendix Figure 1 This application will be described in further detail.

[0040] In the description of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0041] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0042] This application discloses a tool position detection system for a gantry forming grinder.

[0043] Please refer to Figure 1 The tool position detection system for a gantry forming grinder proposed in this embodiment includes:

[0044] The data acquisition module 10 is equipped with a sensor detection module. The data acquisition module 10 is used to synchronously collect the sensing data of the workpiece and the multi-source sensing data of the gantry forming grinder through the sensor detection module. The position acquisition module 20 is used to determine the workpiece position information based on the sensing data and the multi-source sensing data, and then transmit the workpiece position information to the tool position intelligent adjustment system for tool adjustment operation.

[0045] It should be noted that the gantry forming grinding machine in this embodiment includes a tool position detection system and a tool position intelligent adjustment system, and the two systems are connected.

[0046] This embodiment mainly describes the tool position detection system. The data acquisition module 10 of the tool position detection system integrates a sensor detection module to simultaneously collect multi-source sensor data from the workpiece to be processed and the gantry forming grinder, so as to obtain composite information that can comprehensively reflect the actual working conditions of the tool, and provide a reliable data foundation for subsequent accurate positioning.

[0047] The position acquisition module 20 in the tool position detection system calculates and outputs the workpiece position information in the coordinate system of the gantry forming grinder, i.e. the machine tool coordinate system, based on multi-source sensor data. It realizes the fusion processing of multi-source sensor data, effectively separates and compensates for the measurement deviation caused by machine tool factors, thereby restoring the true spatial position of the workpiece on the gantry forming grinder. This ensures that the adjustment operation for the tool is performed based on the accurate workpiece position information, realizes precise control of the tool position, and effectively improves the accuracy of the tool machining operation.

[0048] In one feasible implementation, the sensor detection module includes a laser profile sensor, an infrared temperature sensor, and a multi-axis vibration sensor, and the data acquisition module is used for:

[0049] The system employs a pass-through detection method. When a workpiece is detected entering the detection range of the sensor detection module, the sensor detection module is triggered at the same time point. The system collects the reference position data of the workpiece, as well as the global temperature field data and vibration spectrum data of the gantry forming grinder, through a laser contour sensor, an infrared temperature sensor, and a multi-axis vibration sensor. The reference position data is the position data relative to the machine tool coordinate system, and the multi-source sensor data includes the global temperature field data and vibration spectrum data.

[0050] Specifically, this embodiment integrates a laser contour sensor, an infrared temperature sensor, and a multi-axis vibration sensor into the sensor detection module, so that they work together to achieve multi-data acquisition of the workpiece.

[0051] When the workpiece enters the detection range, the data acquisition module sends a synchronous trigger signal, causing the three sensors in the sensor detection module to simultaneously collect the workpiece's reference position data, as well as the global temperature field data and vibration spectrum data of the gantry forming grinder. Specifically, the laser contour sensor provides the geometric position reference (i.e., reference position data) of the workpiece in the machine tool coordinate system; the infrared temperature sensor establishes the global temperature field by scanning the key structures of the machine tool to obtain temperature distribution data; and the multi-axis vibration sensor obtains the vibration spectrum data by monitoring the vibration acceleration in the XYZ directions (major axis, minor axis, and spindle) and processing it through a fast Fourier transform.

[0052] This multi-sensor synchronous triggering mechanism ensures that all sensor data have the same time reference and spatial correlation. By acquiring spatiotemporally consistent sensor data, it provides a data basis for subsequent position compensation calculations that can accurately reflect the coupling effect of thermal deformation and vibration interference on the workpiece at the same moment. This fundamentally eliminates the compensation error caused by time-division acquisition or data asynchrony, lays a reliable foundation for obtaining real workpiece position information, and avoids errors caused by secondary clamping.

[0053] The laser profile sensor is mounted on the machine tool gantry beam, the infrared temperature sensor is mounted on the machine tool slide, and the multi-axis vibration sensor is mounted on the machine tool spindle bearing seat. They are all fixed with a sturdy mounting bracket to ensure that each sensor has an accurate repeating position and angle relative to the grinding machine and the workpiece. Compared with traditional single-point detection sensors, the laser profile sensor can obtain the workpiece position more comprehensively, thereby ensuring the accuracy of grinding wheel condition adjustment.

[0054] It should be noted that the accuracy requirement of each sensor in this embodiment is greater than 1 / 3 of the measurement error. For example, if the workpiece tolerance is ±10μm, the accuracy of the sensor should be ≤±3μm. The detection speed of the laser contour sensor on the workpiece is not less than the maximum movement speed of the workpiece. Specifically, the detection speed of the laser contour sensor is greater than or equal to the workpiece movement speed / detection point spacing. For example, if the workpiece movement speed is 1m / s and the detection point spacing is 0.1mm, the detection speed of the laser contour sensor should be ≥10kHz.

[0055] It should be noted that the gantry forming grinder in this embodiment is mainly used for processing workpieces of three types: a first workpiece processed by a stroke-based machining method, a second workpiece processed by a vertical grinding head, and a third workpiece processed by a horizontal grinding head. Because the mechanical structures, main external forces and thermal loads, and resulting error forms of different workpiece types are fundamentally different, the acquisition of the corresponding workpiece position information also differs. The specific acquisition process is as follows:

[0056] ① When the workpiece type is the first workpiece, the spindle thermal elongation is calculated based on the global temperature field data, and the horizontal plane offset vector is calculated based on the vibration spectrum data. Then, the reference position data is superimposed according to the spindle thermal elongation and the horizontal plane offset vector to obtain the workpiece position information of the first workpiece.

[0057] It should be noted that the machining tools used in stroke machining primarily address axial thermal expansion and planar vibration. The spindle axis is typically parallel to the minor axis for axial feed motion. Thermal error manifests as linear thermal expansion of the spindle along the minor axis, while vibration error mainly originates from horizontal plane vibration during machining. Therefore, the workpiece position compensation strategy employs coordinate superposition, calculating the spindle thermal expansion and the horizontal plane offset vector separately, then synthesizing them with the reference position to obtain the workpiece position information for the first workpiece. The details are as follows:

[0058] First, global temperature field data collected by an infrared temperature sensor is input into a pre-calibrated mathematical model for spindle thermal expansion. This model is a regression equation obtained by fitting multiple sets of temperature rise experimental data, typically in linear or polynomial form. It establishes a quantitative mapping relationship between the temperature of specific measuring points such as the front and rear bearing housings of the spindle and the axial thermal expansion of the spindle. This allows for the calculation of the spindle thermal elongation under the current thermal state. ,in, The temperature at the front bearing of the main spindle. The temperature at the rear bearing of the main spindle. For constant terms, and As a proportionality coefficient, when A larger value indicates that the change in the front bearing temperature has a significant impact on the thermal elongation of the spindle. When the value is small, it indicates that the change in the bearing temperature has little effect on the thermal elongation of the spindle.

[0059] Simultaneously, vibration spectrum data acquired by multi-axis vibration sensors, which is a time-domain vibration signal, is converted into a frequency-domain signal via Fast Fourier Transform (FFT). This yields the amplitude and phase information of each frequency component. High-frequency noise is then filtered out using a low-pass digital filter, extracting the low-frequency vibration components that affect the accuracy of the horizontal plane. Based on the amplitude and phase of these low-frequency vibration components along the major and minor axes, a composite horizontal plane offset vector is calculated using vector synthesis. ,in, This is the horizontal plane offset vector. The magnitude on the major axis. Phase on the major axis The magnitude on the minor axis. The phase is on the minor axis.

[0060] Next, the reference position data measured by the laser contour sensor is... This is linearly superimposed with the calculated thermal elongation of the main shaft in the main shaft direction, i.e. And it is vector-synthesized with the horizontal plane offset vector in the horizontal plane, that is... The workpiece position information of the first workpiece is obtained through this coordinate superposition operation. This effectively eliminates the combined error caused by spindle thermal expansion and external vibration on the machining accuracy of the first workpiece, and significantly improves the positional accuracy and dimensional consistency of hole machining.

[0061] The horizontal plane refers to the plane between the major and minor axes. The laser profile sensor measures the position data of the first workpiece on its long axis. The laser profile sensor measures the position data of the first workpiece on the minor axis. The laser profile sensor measures the position data of the first workpiece on the spindle. The position data of the first workpiece on the major axis after compensation. The position data of the first workpiece on the short axis after compensation. The position data of the first workpiece on the spindle after compensation.

[0062] ② When the workpiece type is the second workpiece, the triaxial thermal displacement is calculated based on the global temperature field data, and the three-dimensional vibration offset is calculated based on the vibration spectrum data. Then, the reference position data is superimposed according to the triaxial thermal displacement and the three-dimensional vibration offset to obtain the workpiece position information of the second workpiece.

[0063] It should be noted that the vertical grinding head mainly deals with the coupling of three-axis thermal deformation and spatial vibration. It requires the coordinated operation of the long axis, short axis, and spindle to complete the contour machining of complex curved surfaces. The thermal error is caused by the thermal deformation of the machine tool bed, the three-axis lead screw, and the guide rail, which simultaneously affects the three coordinate axes. The vibration error is caused by the mutual coupling of vibrations generated when the three axes move simultaneously. Therefore, the compensation strategy for the second workpiece is to calculate the three-axis thermal displacement and the three-dimensional vibration offset, and then superimpose them with the reference position to obtain the workpiece position information of the second workpiece, as shown below:

[0064] First, based on the global temperature field data collected by the infrared temperature sensor, calculations are performed using a multi-axis thermal error model. This multi-axis thermal error model is a multiple regression model constructed based on the thermodynamic characteristics of the machine tool structure and historical temperature rise experimental data, expressed as follows: ,in, This represents the thermal displacement along the major axis. This is the thermal displacement of the short axis; Main spindle thermal displacement; The coefficients representing the relationship between temperature and deformation along the major axis indicate the degree of influence of the temperature at the corresponding temperature measuring point on the thermal displacement of the major axis. The coefficients representing the relationship between temperature and deformation on the minor axis indicate the degree of influence of the temperature at the corresponding temperature measuring point on the thermal displacement of the minor axis. The coefficient representing the relationship between temperature and deformation on the spindle indicates the degree of influence of the temperature at the corresponding temperature measuring point on the thermal displacement of the spindle. These are the temperature measurement points.

[0065] Using the multi-axis thermal error model described above, the positional offset of each axis due to thermal deformation is output, i.e., the triaxial thermal displacement. ).

[0066] Simultaneously, based on vibration spectrum data collected by multi-axis vibration sensors (which consist of acceleration signals along three axes), Fast Fourier Transform (FFT) is performed on each of these acceleration signals to obtain frequency-amplitude-phase information for each axis. Then, using decoupling algorithms such as Principal Component Analysis (PCA) or Independent Component Analysis (ICA), vibration components caused by machining force and external excitation in the major axis, minor axis, and principal axis directions are separated. Finally, based on the amplitude and phase information of the vibration components in each direction, the three-dimensional vibration offset is calculated using a vector synthesis method. .

[0067] Next, the reference position data measured by the laser contour sensor is... , and the calculated triaxial thermal displacement ( Linear superposition is performed along each coordinate axis, i.e. and with three-dimensional vibration offset Perform spatial vector synthesis, i.e. The compensated workpiece position information, i.e., the workpiece position information of the second workpiece, is obtained through this coordinate superposition operation. It effectively compensates for the spatial error caused by the coupling effect of thermal deformation and vibration during the three-axis linkage process of the gantry forming grinder, and significantly improves the contour accuracy and surface quality when machining complex curved surfaces such as vertical grinding heads.

[0068] in, The laser profile sensor measures the position data of the second workpiece on its long axis. The laser profile sensor measures the position data of the second workpiece on the minor axis. The laser profile sensor measures the position data of the second workpiece on the spindle. The position data of the second workpiece on the major axis after compensation. The position data of the second workpiece on the minor axis after compensation. The position data of the second workpiece on the spindle after compensation.

[0069] ③ When the workpiece type is the third workpiece, the spindle thermal deformation vector is calculated based on the global temperature field data, and the spindle force deflection vector is calculated based on the vibration spectrum data. Then, the reference position data is vector-superimposed based on the spindle thermal deformation vector and the spindle force deflection vector to obtain the workpiece position information of the third workpiece.

[0070] It should be noted that the horizontal grinding head mainly addresses changes in the spatial posture of the spindle. Since the spindle is horizontal with a long overhang, it is prone to flexural deformation under stress. Furthermore, thermal deformation affects its spatial angle. Thermal errors not only cause changes in spindle length but also lead to spindle bending due to temperature differences in different parts. Vibration errors, caused by cutting forces acting on the end of the long overhang, can also cause spindle bending and deflection. Therefore, the compensation strategy for the third workpiece is to use vector superposition. By calculating the thermal deformation vector and the stress-induced deflection vector, and then superimposing them with the reference position, the workpiece position information of the third workpiece is obtained, as shown below:

[0071] First, global temperature field data collected by an infrared temperature sensor is input into a pre-calibrated finite element thermal deformation model of the spindle. This model is a digital simulation model obtained by fitting multiple sets of temperature rise experimental data based on the spindle's geometry, material thermophysical properties (such as coefficient of thermal expansion and thermal conductivity), and boundary constraints. It establishes a quantitative mapping relationship between the temperature distribution of key nodes on the spindle (such as the front bearing housing, rear bearing housing, and characteristic points of the spindle housing) and the three-dimensional thermal deformation displacement vector of the spindle. Output the thermal deformation displacement vector of the principal shaft in three-dimensional space, i.e., the principal shaft thermal deformation vector, where... The main axis thermal deformation vector, For temperature measurement points, The solution process for the heat conduction equation and the thermo-stress coupling equation is shown, where:

[0072] The heat conduction equation is:

[0073]

[0074] Substituting the temperature measurement points into the heat conduction equation as described above, the temperature of each mesh node in the principal axis finite element thermal deformation model is calculated, thereby obtaining the three-dimensional temperature field distribution.

[0075] The thermal-stress coupling equation is:

[0076]

[0077] The three-dimensional temperature field distribution obtained in the previous step is transformed into thermal stress through the thermo-stress coupling equation, so as to calculate the deformation of each mesh node in the principal axis finite element thermal deformation model.

[0078] in, This indicates the heat inflow / outflow at each temperature measuring point inside the spindle. This represents the rate of change of a specific temperature measurement point inside the spindle over time. Indicates thermal stress, Indicates the stiffness properties of a material. Indicates the coefficient of thermal expansion of a material. It represents the change in a temperature measuring point relative to a reference temperature in the temperature field calculated using the heat conduction equation.

[0079] This outputs the thermal deformation displacement vector of the principal axis in three-dimensional space. It should be noted that the thermal deformation displacement vector It is a quantity that has both magnitude and direction, so the offset in the three directions of the major axis, minor axis and spindle in the machine tool coordinate system can be obtained from it.

[0080] Simultaneously, based on the vibration spectrum data collected by the multi-axis vibration sensor, i.e., the time-domain vibration signal, the time-domain vibration signal is converted into a frequency-domain signal via a fast Fourier transform to obtain the amplitude and phase information of each frequency component. Then, combined with the real-time load parameters of the spindle, such as spindle power and current, calculations are performed using a mathematical model of spindle force-deflection. The expression of this mathematical model of spindle force-deflection is as follows:

[0081]

[0082] in, Indicates cutting force. Represents the frequency response function. Indicates amplitude. This represents phase information. After obtaining the cutting force through this model, the spatial deflection vector of the spindle under the coupled action of cutting force and vibration is solved using the deflection formula. The expression for the deflection formula is:

[0083]

[0084] in, Represents the spatial deflection vector. The bending moment generated by vibration is represented by L, and the overhang is represented by L. Indicates the elastic modulus. Represents the moment of inertia of the cross section. Represents the unit vector in the direction of the cutting force. This represents a unit vector in the direction of the bending moment. It should be noted that this is the spatial deflection vector. It is a quantity that has both magnitude and direction, so the deflection deformation in the three directions of the major axis, minor axis and spindle in the machine tool coordinate system can be obtained from it.

[0085] Reference position data measured by laser contour sensor , and the calculated principal shaft thermal deformation vector After spatial superposition, it is then compared with the spatial deflection vector. Perform vector synthesis, that is The compensated workpiece position information, i.e., the workpiece position information of the second workpiece, is obtained through this multi-level vector superposition operation. = It accurately compensates for the spatial orientation error of the second workpiece caused by the combined action of thermal coupling and vibration load under complex working conditions, and significantly improves the spatial orientation accuracy and complex surface forming quality of the horizontal grinding head when performing large overhang machining.

[0086] Reference Figure 1 As shown in the embodiments of this application, an intelligent tool position adjustment system for a gantry forming grinder is also disclosed, including:

[0087] The position comparison module 30 is used to compare the workpiece position information transmitted from the tool position detection system with the preset position information and output the position deviation information; the position adjustment module 40 is used to generate optimization adjustment instructions based on the position deviation information and control the actuator to adjust the tool position based on the optimization adjustment instructions.

[0088] The position comparison module 30 compares the workpiece position information transmitted from the tool position detection system with the preset position information in real time, enabling rapid identification of the deviation between the current actual workpiece position and the theoretical target position, providing a clear direction for subsequent precise adjustment. The position adjustment module 40 generates optimization adjustment instructions based on the position deviation information output by the position comparison module 30, converting the deviation into a control signal that can drive the actuator. Finally, based on the optimization adjustment instructions, the actuator is controlled to adjust the tool position, realizing precise closed-loop position control based on real-time feedback. This effectively eliminates tool pose errors caused by factors such as thermal deformation and vibration during machining, thereby improving the machining accuracy of the tool on the workpiece.

[0089] It should be noted that the intelligent tool position adjustment system also includes an information correction module, which is used to: calculate the thermal vibration composite compensation amount of the workpiece to which the workpiece position information belongs; and correct the initial preset position information of the workpiece based on the thermal vibration composite compensation amount to obtain the preset position information of the workpiece.

[0090] The corresponding compensation model is invoked based on the workpiece type. For the first workpiece machined using a stroke machining method, a spindle thermal elongation and horizontal vibration coupling model is used; for the second workpiece machined using a vertical grinding head, a three-axis thermal-vibration coupling error model is used; and for the third workpiece machined using a horizontal grinding head, a spindle spatial pose error model is used. These models take real-time acquired global temperature field data and vibration spectrum data as input, and use embedded algorithms to calculate in real time the thermal-vibration composite compensation amount, which reflects the combined effect of thermal deformation and vibration interference under the current machining state. Based on this thermal-vibration composite compensation amount, the initial preset position information of the workpiece is dynamically corrected. That is, the initial preset position information and the calculated thermal-vibration composite compensation amount are vector-superimposed to generate preset position information of the workpiece that matches the actual thermal-mechanical state of the current machine tool. This realizes the transformation of the traditional static position comparison benchmark into a dynamic intelligent adjustment benchmark, so that the comparison operation of the position comparison module is always based on the optimal position under the current working conditions. This effectively eliminates systematic errors caused by changes in machine tool thermal state and vibration environment, and significantly improves the adaptability of the position adjustment system and the final machining accuracy.

[0091] Furthermore, the position adjustment module is used to: generate an initial adjustment command based on the position deviation information, optimize the initial adjustment command by combining it with the real-time status data of the actuator, and obtain an optimized adjustment command; and control the actuator to adjust the tool position according to the optimized adjustment command.

[0092] By generating initial adjustment commands based on position deviation information, the aim is to convert the position deviation into control signals that drive the actuator, providing an operational basis for subsequent fine-tuning. The initial adjustment commands are then optimized by incorporating real-time status data from the actuator. Adaptive adjustments are made to the amplitude, rate, and output timing of the control commands based on the actuator's dynamic characteristics. This eliminates control inaccuracies caused by nonlinear characteristics of the actuator or sudden changes in external load. Ultimately, the optimized adjustment commands control the actuator to adjust the tool position, effectively avoiding overshoot, oscillation, or response hysteresis. This ensures rapid and precise tool position adjustment while maintaining system stability.

[0093] In one feasible implementation, the steps for generating initial adjustment instructions and optimized adjustment instructions for different workpiece types are as follows:

[0094] ① When the workpiece type is the first workpiece, the spindle displacement command is calculated based on the axial deviation component in the position deviation information, and the axial compensation amount is calculated based on the multi-source sensor data of the first workpiece. The spindle displacement command and the axial compensation amount are vector-synthesized to obtain the first initial adjustment command of the stroke processing mode. Combined with the real-time current of the spindle servo motor of the actuator and the feedback data of the horizontal grating ruler, the first initial adjustment command is optimized to obtain the optimized adjustment command of the stroke processing mode.

[0095] First, based on the axial deviation component in the position deviation information, the spindle displacement command is calculated using a proportional-integral-derivative control algorithm. Specifically, the axial deviation component is used as input, and the proportional term quickly responds to the deviation, the integral term eliminates steady-state error, and the derivative term suppresses overshoot, outputting a control signal for driving the spindle servo motor, namely the spindle displacement command.

[0096] Simultaneously, based on global temperature field data and vibration spectrum data, the spindle thermal elongation calculated by the spindle thermal elongation mathematical model is compared with the preset spindle thermal elongation in the spindle displacement command to determine the thermal elongation compensation amount. Vibration characteristics are extracted through an adaptive notch filter to generate vibration suppression amount. The two are algebraically added to synthesize the axial compensation amount. Then, the spindle displacement command and the axial compensation amount are vectorized along the spindle axis, i.e., algebraically added, to obtain the first initial adjustment command.

[0097] Then, the real-time current data of the spindle servo motor in the actuator is read, and the motor torque state is determined to be in torque saturation state by multiplying the current by the torque coefficient. At the same time, the feedback data of the horizontal plane grating ruler (i.e., the position of the long axis and the short axis) is obtained, and the plane position is monitored for stability and abnormal vibration by the position loop control algorithm. Finally, the first initial adjustment command is dynamically optimized and adjusted (such as smoothing the command waveform or adjusting the amplitude) by the motor torque state (for overload prevention and amplitude limiting) and the feedback data of the horizontal plane grating ruler (for vibration suppression optimization) to obtain the optimized adjustment command of the stroke machining mode. Specifically, in this embodiment, the grinding wheel of the tool corresponding to the stroke machining mode is adjusted to effectively suppress horizontal vibration interference while ensuring accurate axial position tracking. The status of the actuator is monitored in real time to prevent motor torque saturation and system overshoot, thereby ensuring that the tool corresponding to the stroke machining mode has higher dynamic accuracy and operational stability in hole machining.

[0098] ② When the workpiece type is the second workpiece, the three-axis linkage command is calculated based on the three-axis linkage deviation component in the position deviation information, and the axial compensation amount is calculated based on the multi-source sensor data of the second workpiece. The three-axis linkage command and the axial compensation amount are matrix superimposed to obtain the second initial adjustment command of the vertical grinding head. Combined with the real-time current of the three-axis servo motor of the actuator and the encoder feedback data, the second initial adjustment command is optimized to obtain the optimized adjustment command of the vertical grinding head.

[0099] First, based on the three-axis linkage deviation component in the position deviation information, the three-axis linkage command is calculated using a multi-axis coupled control algorithm. Specifically, the three-axis linkage command is calculated based on an algorithm based on model predictive control (MPC) or cross-coupled control (CCC). This three-axis linkage command generates coordinated position, velocity, and acceleration commands for each axis by solving multi-axis kinematic constraints and dynamic relationships.

[0100] Simultaneously, based on global temperature field data and vibration spectrum data, the triaxial thermal displacement calculated by the multi-axis thermal error model is compared with the preset triaxial thermal displacement in the triaxial linkage command to determine the thermal displacement compensation amount for each axis. Furthermore, vibration characteristics are extracted using an adaptive notch filter to generate vibration suppression amounts, and the thermal displacement compensation amounts for each axis are combined with the vibration compensation amounts to form the axial compensation amount (i.e.,...). After that, the three-axis linkage command and the axial compensation amount are superimposed through a spatial transformation matrix (a Jacobian matrix or its inverse matrix that reflects the coupling relationship between the machine tool geometry and motion) (expressed as...). ), thus obtaining the second initial adjustment instruction.

[0101] Then, the current data of the three-axis servo motors is read in real time, and the torque observer of the current loop is used to determine whether the torque state of each motor is saturated or unbalanced. At the same time, the actual position of each axis is obtained. By comparing the torque state of each motor (for load balancing and overload protection) with the actual position of each axis (for tracking error compensation and synchronization correction), the second initial adjustment command is dynamically optimized (such as adjusting the command amplitude, rate, or adding feedforward compensation) to obtain the optimized adjustment command of the vertical grinding head. Specifically, in this embodiment, the grinding wheel of the vertical grinding head is adjusted to achieve precise linkage control of the three axes while effectively compensating for thermal deformation and vibration coupling errors of each axis. The motion coordination and stability of each axis are ensured by real-time monitoring of the status of the multi-axis actuator, thereby significantly improving the contour accuracy and dynamic performance of the vertical grinding head when performing complex curved surface contouring.

[0102] ③ When the workpiece type is the third workpiece, the spindle pose command is calculated based on the spindle spatial attitude deviation component in the position deviation information, and the compensation vector is calculated based on the multi-source sensor data of the third workpiece. The spindle pose command and the compensation vector are spatially synthesized to obtain the third initial adjustment command of the horizontal grinding head. The third initial adjustment command is optimized by combining the real-time torque of the spindle servo motor of the actuator, the tilt sensor data and the radial grating ruler feedback data to obtain the optimized adjustment command of the horizontal grinding head.

[0103] First, based on the spindle spatial attitude deviation component (including the angular deflection and positional offset of the spindle end in three-dimensional space) in the position deviation information, the spindle pose command (expressed as...) is calculated using a pose description method based on screw theory or Lie group Lie algebras. The spindle pose command converts the spatial pose target into position, velocity and attitude control quantities for each motion axis by solving the inverse kinematics model of the machine tool.

[0104] Simultaneously, based on global temperature field data and vibration spectrum data, the thermal deformation displacement vector calculated by the spindle finite element thermal deformation model is compared with the preset thermal deformation displacement vector in the spindle pose command to obtain the thermal deformation compensation vector. Similarly, the calculated deflection deformation is compared with the preset deflection deformation in the spindle pose command to obtain the deflection compensation vector. Finally, the thermal deformation compensation vector and the deflection compensation vector are combined to form a compensation vector (expressed as...). Next, the spindle pose command and the compensation vector are spatially synthesized using a three-dimensional coordinate transformation matrix (a homogeneous transformation matrix based on the machine tool topology), that is, the spindle pose command and the compensation vector are added together to obtain the third initial adjustment command. .

[0105] Then, the torque data of the spindle servo motor is read in real time, and the load status of the motor is monitored based on the current-torque mapping relationship and the load observer. That is, it is identified whether the motor is overloaded, whether there is torque fluctuation, or whether there is a sudden change in cutting force. At the same time, the tilt sensor data (i.e., the pitch and yaw angles of the spindle housing) and the radial grating ruler feedback data (i.e., the radial displacement of the spindle end) are acquired. The actual spatial attitude of the spindle, including position coordinates and Euler angles, is calculated by Kalman filtering or particle filtering. Finally, the third initial adjustment command is dynamically optimized and adjusted by the load status (for adaptive gain adjustment and cutting force feedforward compensation) and the actual spatial attitude of the spindle (for closed-loop feedback correction) (such as adjusting the amplitude of the pose command, adding a damping term, or reconstructing the trajectory) to obtain the optimized adjustment command of the horizontal grinding head. Specifically, in this embodiment, the grinding wheel of the horizontal grinding head is adjusted to achieve precise control of the spindle spatial attitude while effectively compensating for the spatial error caused by the coupling effect of thermal deformation and cutting force. The stability of the large overhang machining process is ensured by real-time monitoring of the spindle load and spatial attitude, thereby significantly improving the spatial attitude accuracy and anti-interference capability of the horizontal grinding head when performing heavy machining.

[0106] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A tool position detection system for a gantry forming grinder, characterized in that, The tool position detection system establishes a connection with the intelligent tool position adjustment system of the gantry forming grinding machine, including: The data acquisition module is equipped with a sensor detection module. The data acquisition module is used to synchronously acquire the sensing data of the workpiece and the multi-source sensing data of the gantry forming grinding machine through the sensor detection module. The position acquisition module is used to determine the workpiece position information of the workpiece based on the sensing data and the multi-source sensing data, and then transmit the workpiece position information to the tool position intelligent adjustment system to perform tool adjustment operation. The sensor detection module includes a laser profile sensor, an infrared temperature sensor, and a multi-axis vibration sensor. The data acquisition module is used for: When the workpiece is detected to have entered the detection range of the sensor detection module, the sensor detection module is triggered at the same time point. The laser contour sensor collects the reference position data of the workpiece, and the infrared temperature sensor and the multi-axis vibration sensor collect the global temperature field data and vibration spectrum data of the gantry forming grinding machine. The reference position data is position data relative to the machine tool coordinate system, and the multi-source sensing data includes the global temperature field data and the vibration spectrum data. The workpiece types include a first workpiece machined using a stroke machining method, a second workpiece machined using a vertical grinding head, and a third workpiece machined using a horizontal grinding head. The position acquisition module is used for: When the workpiece type is the first workpiece, the spindle thermal elongation is calculated based on the global temperature field data, and the horizontal plane offset vector is calculated based on the vibration spectrum data. Then, the reference position data is superimposed according to the spindle thermal elongation and the horizontal plane offset vector to obtain the workpiece position information of the first workpiece; or, When the workpiece type is the second workpiece, after calculating the triaxial thermal displacement based on the global temperature field data and the three-dimensional vibration offset based on the vibration spectrum data, the reference position data is superimposed according to the triaxial thermal displacement and the three-dimensional vibration offset to obtain the workpiece position information of the second workpiece; or, When the workpiece type is the third workpiece, the spindle thermal deformation vector is calculated based on the global temperature field data, and the spindle force deflection vector is calculated based on the vibration spectrum data. Then, the reference position data is vector-superimposed according to the spindle thermal deformation vector and the spindle force deflection vector to obtain the workpiece position information of the third workpiece.

2. A tool position intelligent adjustment system for a gantry forming grinder, characterized in that, The intelligent tool position adjustment system establishes a connection with the tool position detection system of the gantry forming grinder as described in claim 1, including: The position comparison module is used to compare the workpiece position information input by the tool position detection system with the preset position information and output the position deviation information. The position adjustment module is used to generate optimization adjustment instructions based on the position deviation information, and control the actuator to adjust the tool position based on the optimization adjustment instructions.

3. The intelligent tool position adjustment system for the gantry forming grinder according to claim 2, characterized in that, The intelligent tool position adjustment system also includes an information correction module, which is used for: Calculate the thermal vibration composite compensation amount of the workpiece to which the workpiece position information belongs; The initial preset position information of the workpiece is corrected based on the thermal vibration composite compensation amount to obtain the preset position information of the workpiece.

4. The intelligent tool position adjustment system for the gantry forming grinder according to claim 3, characterized in that, The position adjustment module is used for: After generating an initial adjustment command based on the position deviation information, the initial adjustment command is optimized by combining the real-time status data of the actuator to obtain the optimized adjustment command. According to the optimization adjustment command, the actuator is controlled to adjust the position of the tool.

5. The intelligent tool position adjustment system for the gantry forming grinder according to claim 4, characterized in that, The workpiece types include a first workpiece machined using a stroke machining method, a second workpiece machined using a vertical grinding head, and a third workpiece machined using a horizontal grinding head. The step of generating initial adjustment instructions based on the position deviation information includes: When the workpiece type is the first workpiece, a spindle displacement command is calculated based on the axial deviation component in the position deviation information, and an axial compensation amount is calculated based on the multi-source sensor data of the first workpiece. The spindle displacement command and the axial compensation amount are then vector-synthesized to obtain the first initial adjustment command for the stroke machining method; or... When the workpiece type is the second workpiece, a three-axis linkage command is calculated based on the three-axis linkage deviation component in the position deviation information, and an axial compensation amount is calculated based on the multi-source sensor data of the second workpiece. The three-axis linkage command and the axial compensation amount are then matrix-superimposed to obtain the second initial adjustment command for the vertical grinding head; or, When the workpiece type is the third workpiece, the spindle pose command is calculated based on the spindle spatial attitude deviation component in the position deviation information, and the compensation vector is calculated based on the multi-source sensor data of the third workpiece. The spindle pose command and the compensation vector are spatially synthesized to obtain the third initial adjustment command of the horizontal grinding head.

6. The intelligent tool position adjustment system for the gantry forming grinder according to claim 5, characterized in that, The step of optimizing the initial adjustment command by combining the real-time status data of the actuator to obtain the optimized adjustment command includes: When the workpiece type is the first workpiece, the first initial adjustment command is optimized by combining the real-time current of the spindle servo motor of the actuator and the feedback data from the horizontal grating ruler, resulting in an optimized adjustment command for the stroke processing method; or, When the workpiece type is the second workpiece, the second initial adjustment command is optimized by combining the real-time current of the three-axis servo motor of the actuator and the encoder feedback data to obtain the optimized adjustment command for the vertical grinding head; or, When the workpiece type is the third workpiece, the third initial adjustment command is optimized by combining the real-time torque of the spindle servo motor of the actuator, the tilt sensor data and the radial grating ruler feedback data to obtain the optimized adjustment command of the horizontal grinding head.

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