High-precision integrated tool detection system and control method thereof

Abstract

The application discloses a high-precision integrated tool detection system and a control method thereof, and deep fusion of 'on-machine detection' and 'automatic compensation processing' is achieved to construct a full-automatic closed-loop manufacturing system from 'workpiece positioning-tool calibration-first processing-deviation analysis-compensation processing', so that deviation in the processing can be automatically identified and corrected without manual intervention, and finally the processing precision and one-time qualified rate of the workpiece are significantly improved.

Description

Technical Field

[0001] This invention relates to the field of CNC machining technology, specifically a high-precision integrated tool setting detection system and its control method. Background Technology

[0002] In the field of precision machining using CNC machine tools, especially in the production of multi-variety, small-batch workpieces, the accurate establishment of the workpiece coordinate system (centering) and the precise setting of tool parameters (tool setting) are the two cornerstones for ensuring final machining accuracy. Traditional methods heavily rely on manual operation by operators, using "centering bars" and "edge finders" for centering and "tool setting instruments" or "trial cutting methods" for tool setting. These methods are not only inefficient but also prone to introducing human error, leading to problems such as inconsistent workpiece coordinate systems and inaccurate tool compensation parameter settings in batch processing, directly affecting the first-piece pass rate and production stability.

[0003] To improve accuracy and efficiency, existing technologies have developed automated solutions using a single measurement method (such as a laser tool setter or a contact probe). However, these solutions still have significant limitations: First, their functions are often isolated and fragmented; the sub-center, tool setting, and in-machine inspection processes are not integrated into a coherent, automated workflow, resulting in data chain breaks. Second, they suffer from low operational efficiency and a high proportion of auxiliary time. Summary of the Invention

[0004] This invention aims to solve the technical problems of low operating efficiency and high auxiliary time ratio in existing tool setting systems. To this end, this invention provides a high-precision integrated tool setting detection system and its control method.

[0005] A control method for a high-precision integrated tool setting detection system according to an embodiment of the present invention includes the following steps: The system performs online inspection on a rectangular workpiece to obtain its initial position. Based on the initial position, the system automatically generates and executes a measurement macro program to control the online inspection module to perform measurements on the first and second reference surfaces of the workpiece, wherein the first reference surface is perpendicular to the second reference surface. Based on the measurement data on the first and second reference surfaces, the rotation angle and origin coordinates of the coordinate system are calculated. Based on the rotation angle and origin coordinates, a target machining coordinate system aligned with the workpiece reference is established, and the center coordinates of the X and Y axes are obtained. Based on the determined X and Y axis center coordinates, the Z axis coordinate origin is determined by measuring the workpiece surface with a probe. The laser tool setter measures the diameter and length of the target tool and automatically sets the corresponding tool compensation parameters to obtain the tool machining parameters. Based on the set coordinate system of X and Y axis center coordinates and tool machining parameters, the workpiece is machined for the first time; The key features of the workpiece are scanned and inspected, and the dimensional data is recorded; The inspection data is analyzed to generate a 3D inspection center map. The 3D inspection center map is compared with the 3D theoretical model of the workpiece, and the processing deviation is visualized in the 3D inspection center map. Based on the aforementioned machining deviation, the automatic computer tool compensation parameters are determined. Based on the compensation parameters, the workpiece is processed a second time to correct the deviation of the first processing.

[0006] The control method of a high-precision integrated tool setting detection system according to an embodiment of the present invention has the following beneficial effects: By deeply integrating "in-machine inspection" with "automatic compensation machining", a fully automated closed-loop manufacturing system is constructed, which covers "workpiece positioning - tool calibration - first machining - deviation analysis - compensation machining". This system can automatically identify and correct deviations in the machining process without human intervention, ultimately significantly improving the machining accuracy and first-pass yield of the workpiece.

[0007] According to some embodiments of the present invention, the online detection module performs measurements on the first and second reference surfaces of the workpiece, specifically: Measure at least two points on the first reference plane and at least two points on the second reference plane.

[0008] According to some embodiments of the present invention, the rotation angle is obtained by calculating the angle between the reference plane and the reference coordinate axis based on the coordinates of a point measured on the first reference plane or the second reference plane; The origin coordinates are obtained by calculating the theoretical intersection point of the two reference planes based on the coordinates of the points measured on the first and second reference planes.

[0009] According to some embodiments of the present invention, after the step of performing secondary processing on the workpiece based on the compensation parameters to correct the deviation of the first processing, the method further includes: After the secondary machining is completed, the system is calibrated using a standard positioning circle. The accuracy of the current sub-center, tool setting, and test results is verified using the standard positioning circle as a reference.

[0010] According to some embodiments of the present invention, after the secondary machining is completed, system calibration is performed using a standard positioning circle. The accuracy of the current sub-center, tool setting, and detection results is verified using the standard positioning circle as a reference, including: Reference identification: The control probe scans the standard positioning circle on the workpiece after the secondary processing to measure the actual center coordinates and diameter of the workpiece; The measured actual center coordinates and diameter are compared with the theoretical design value of the standard positioning circle to obtain the center position deviation and diameter deviation. If the deviation of the center position exceeds the first preset threshold, it is determined that the sub-center system is drifting and a sub-center system calibration alarm is generated. If the diameter deviation exceeds the second preset threshold, it is determined that there is tool wear or error in the tool setting system, and a tool and tool setting system calibration alarm is generated.

[0011] According to some embodiments of the present invention, when generating a tool and tool setting system calibration alarm, the system automatically records the current deviation data, tool number and machining timestamp, and summarizes and generates a device accuracy health status report.

[0012] According to some embodiments of the present invention, the step of calling the laser tool setter to measure the diameter and length of the target tool and automatically setting the corresponding tool compensation parameters to obtain the tool processing parameters includes: synchronously recording the data of the laser tool setter measuring the tool diameter and tool length into the tool management library of the system.

[0013] According to some embodiments of the present invention, the step of calling a laser tool setter to measure the diameter and length of the target tool and automatically setting the corresponding tool compensation parameters to obtain the tool machining parameters includes: Collect and analyze historical wear data of cutting tools during the machining process, and establish a tool wear prediction model; Based on the tool wear prediction model and the current tool's machining parameters, the current tool wear amount is predicted; Based on the predicted tool wear, calculate the corresponding tool length compensation value and tool radius compensation value; The calculated compensation value is updated in real time to the tool compensation table of the CNC system.

[0014] According to some embodiments of the present invention, it further includes: System preparation steps: Obtain the processing requirements input by the user, automatically call the matching control program according to the processing requirements, trigger system initialization, complete the self-check and initialization of hardware modules and software parameters, and confirm that the communication between each module is normal.

[0015] A high-precision integrated tool setting detection system for implementing any of the control methods described above, according to an embodiment of the present invention, includes: Processing station; The online detection module includes multiple types of sensors installed at the processing station, used to scan the reference surface, contour and key features of the workpiece before and after processing to collect the spatial coordinate data of the workpiece. The tool calibration module includes a laser tool setter and a drive unit, wherein the drive unit is used to drive the laser tool setter to move in order to automatically find the target tool; The machining execution module, including a spindle, cutting tools and a multi-axis drive mechanism, is used to perform initial machining and secondary machining based on compensation parameters on the workpiece. The central control module is connected to the online detection module, the tool calibration module, and the machining execution module via signals, respectively; the central control module includes: The data processor is configured to: receive data collected by the online detection module, generate a 3D detection center image of the workpiece, and compare the 3D detection center image with a pre-stored 3D theoretical model of the workpiece to calculate the processing deviation and automatically generate machine tool compensation parameters.

[0016] Other features and advantages of the invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. Attached Figure Description

[0017] The present invention will be further described below with reference to the accompanying drawings and embodiments, wherein: Figure 1 A flowchart of a control method for a high-precision integrated tool setting detection system; Figure 2 This explains the working principle of online detection. Figure 3 For flexible precision online testing process; Figure 4 This is a schematic diagram of the workpiece structure being inspected; Figure 5 For in-machine testing reports; Figure 6 For the user interface; Figure 7 A schematic diagram of the core hardware device structure for the online detection and tool setting sub-center for horizontal machining; Figure 8 This is an operation flowchart; Figure 9 Screenshot of the precise entity export operation page; Figure 10 Save to another folder; Figure 11 Precise Entity Process Introduction Table. Detailed Implementation

[0018] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0019] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, etc., are based on the orientation or positional relationship shown in the drawings and are only for the convenience of describing this invention and simplifying the description, and are not intended to 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 this invention.

[0020] In the description of this invention, "multiple" refers to two or more. The use of "first" and "second" is for distinguishing technical features only and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features or their sequential relationship.

[0021] In the description of this invention, unless otherwise explicitly defined, terms such as "set up," "install," and "connect" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0022] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described below are some embodiments of the present invention, not all embodiments.

[0023] Reference Figure 1 A control method for a high-precision integrated tool setting detection system includes the following steps: Step S100: Perform online inspection on the rectangular workpiece to obtain its initial position. Based on the initial position, the system automatically generates and executes a measurement macro program to control the online inspection module to perform measurements on the first and second reference surfaces of the workpiece, wherein the first reference surface is perpendicular to the second reference surface. Based on the measurement data on the first and second reference surfaces, calculate the rotation angle and origin coordinates of the coordinate system. Based on the rotation angle and origin coordinates, establish a target machining coordinate system aligned with the workpiece reference and obtain the center coordinates of the X and Y axes. Step S200: Based on the determined X and Y axis center coordinates, use a probe to measure the workpiece surface and determine the origin of the Z axis coordinate; Step S300: Call the laser tool setter to measure the diameter and length of the target tool, and automatically set the corresponding tool compensation parameters to obtain the tool machining parameters; Step S400: Based on the set coordinate system of X and Y axis center coordinates and tool machining parameters, perform the first machining of the workpiece; Step S500: Scan and inspect the key features of the workpiece and record the dimensional data; Step S600: Analyze the inspection data, generate a 3D inspection center map, compare the 3D inspection center map with the 3D theoretical model of the workpiece, and visualize the processing deviation in the 3D inspection center map; Step S700: Automatically calculate the machine tool compensation parameters based on the machining deviation; Step S800: Based on the compensation parameters, perform secondary processing on the workpiece to correct the deviation of the first processing.

[0024] By deeply integrating "in-machine inspection" with "automatic compensation machining", a fully automated closed-loop manufacturing system is constructed, which covers "workpiece positioning - tool calibration - first machining - deviation analysis - compensation machining". This system can automatically identify and correct deviations in the machining process without human intervention, ultimately significantly improving the machining accuracy and first-pass yield of the workpiece.

[0025] Before step S100, a system preparation step is also included: obtaining the processing requirements input by the user, automatically calling the matching control program according to the processing requirements, triggering system initialization, completing the self-test and initialization of hardware modules and software parameters, and confirming that the communication between each module is normal.

[0026] Specifically, the parts to be processed are transported to the machine tool's worktable and placed randomly at the processing station. Subsequently, the operator selects the "Aerospace Aluminum Parts - Finishing" processing program on the system's human-machine interface.

[0027] After the system starts, it calls the corresponding control program according to the processing requirements. The control program automatically identifies the task type as "high-precision box-type workpiece" and matches and selects a preset execution process that includes high-precision sub-centering, full-tool laser tool setting, and comprehensive surface inspection.

[0028] After the program is invoked, system initialization is triggered. All modules of the device are powered on and automatically complete self-tests of hardware such as the laser cutting tool measuring instrument, infrared probe, and servo driver, while simultaneously loading software parameters related to "finishing". Once the system confirms that all modules are communicating normally and their status is stable, it enters the automatic execution phase.

[0029] By automatically identifying task types and matching them to selected execution processes, the system standardizes and proceduralizes key steps such as centering, tool setting, and inspection, which previously relied on operator experience. The system executes automatically, avoiding accidental and gross errors caused by manual operation, visual judgment, and manual data input. This ensures extremely high consistency and repeatability of workpieces processed by different batches and operators, making it particularly suitable for large-scale precision production. It integrates traditionally scattered and discontinuous preparation work (centering, tool setting, and inspection) into a seamless automated process, eliminating manual intervention and waiting time between processes. It achieves "one-click" operation, significantly shortening pre-processing preparation time and post-processing inspection time, forming a complete quality closed loop of "processing → in-machine inspection → data analysis → automatic compensation → reprocessing." The system not only detects deviations but also automatically calls algorithms to calculate compensation values ​​and drive secondary processing, proactively correcting deviations. Furthermore, ordinary operators can handle high-precision workpiece processing tasks with simple training, reducing technical fluctuations and quality risks caused by personnel turnover.

[0030] In step S100: Online detection and initial positioning A rectangular workpiece is randomly placed on the worktable of a CNC machine tool. A vision sensor (such as a CCD camera) mounted on the machine tool spindle takes an image of the workpiece for online inspection. An image processing system (such as a host computer running Halcon software) identifies the workpiece's outline and, through coordinate system transformation, calculates the workpiece's initial position in the worktable coordinate system—a rough initial coordinate. This initial coordinate is used to quickly move the machine tool spindle or probe near the workpiece, preparing for subsequent precision measurements.

[0031] Automatically generate and execute measurement macro programs Based on the initial position, the CNC system (CNC controller) automatically generates a measurement macro program. The core of this macro program is to control a contact probe (such as a Renishaw OMP40) to perform measurements on two mutually perpendicular reference planes of the workpiece.

[0032] Specifically, the macro program controls the probe to perform the following actions: Move to the vicinity of the first reference plane (e.g., the long side of the workpiece) and measure two points P1(X1, Y1) and P2(X2, Y2) on that plane.

[0033] Move to the vicinity of the second reference plane (the short side perpendicular to the first reference plane) and measure two points P3(X3, Y3) and P4(X4, Y4) on that plane.

[0034] Calculate positioning parameters After the measurement is completed, the CNC system's macro program variables will automatically record the coordinates of the four trigger points. Subsequently, the system will calculate the positioning parameters required to establish a new coordinate system based on these coordinates.

[0035] Calculate the rotation angle (θ): Calculate the direction vector of the first reference plane based on the coordinates of points P1 and P2. Then, calculate the angle between this vector and the machine tool's X-axis using the arctangent function.

[0036] θ= ATAN2[(Y2 - Y1), (X2 - X1)] Here, ATAN2 is a function that can correctly handle angles in all quadrants.

[0037] Calculate the coordinates of the origin (X0, Y0): The origin is defined as the theoretical intersection of the first and second reference planes. The coordinates of the origin (X0, Y0) can be obtained by fitting points P1 and P2 to a straight line L1 and points P3 and P4 to another straight line L2, and then solving for the coordinates of the intersection of these two lines.

[0038] Establish target machining coordinate system After calculating the rotation angle θ and the origin coordinates (X0, Y0), the system automatically executes the following CNC instructions to establish the target machining coordinate system (e.g., the G54 coordinate system): Perform coordinate system rotation: Invoke the coordinate system rotation command. In the Fanuc system, the command is: G68 Rθ This command rotates the entire workpiece coordinate system around the current origin by an angle θ.

[0039] Set the origin of the coordinate system: Use the coordinate system setting command to translate the origin of the rotated coordinate system to the point (X0, Y0). Example command: G10 L2 P1 X X0 Y Y0 (where P1 represents the G54 coordinate system).

[0040] In step S200, based on the determined X and Y axis center coordinates, the workpiece surface is measured using a probe to determine the origin of the Z axis coordinate.

[0041] In step S300: After the sub-center is completed, the system automatically switches to the tool setting process. The machine tool calls the laser tool measuring instrument, and the tool magazine sequentially replaces the multiple end mills and drills required for this machining process onto the spindle. The laser tool measuring instrument automatically locates the tool tip and diameter of each tool, sequentially completes the tool diameter measurement and tool length measurement, and automatically sets the measurement data as the corresponding tool diameter compensation parameters and length compensation parameters, recording them in the system tool magazine.

[0042] In step S400: Based on the set coordinate system of X and Y axis center coordinates and tool machining parameters, the workpiece is initially processed, and the machine tool controls the spindle to process the workpiece according to the machining path.

[0043] In step S500: After the machining is completed, multiple sensors scan and detect the key features of the workpiece and record the dimensional data.

[0044] In steps S600 and S700: Subsequently, the system's data processing module organizes and analyzes all the dimensional data obtained from the detection, automatically generating a three-dimensional inspection center map. This graphical report intuitively presents the current actual center position of the workpiece, the microscopic deviations between each structural dimension and the theoretical three-dimensional model, and clearly reflects the actual state of the machining datum. Based on the deviations revealed by the three-dimensional inspection center map, the system automatically calls the machine tool compensation algorithm to calculate the compensation parameters used to correct positioning and geometric errors, and transmits these parameters to the CNC system through a general interface.

[0045] In step S800: After the compensation parameters take effect, the system automatically drives the machine tool to perform secondary finishing on the features with deviations, thereby effectively correcting the aforementioned deviations and improving the machining accuracy to the design requirements.

[0046] Following step S800, the process further includes: after secondary machining, system calibration is performed using a standard positioning circle. The accuracy of the current sub-centering, tool setting, and inspection results is verified using this standard positioning circle as a reference. After secondary machining, for final verification and system accuracy maintenance, the operator installs a standard positioning circle on the worktable. The system then drives the probe to measure this positioning circle again. Using the precise center of this standard part as a reference, the accuracy of the entire sub-centering, tool setting, and inspection process is verified in reverse, completing a full accuracy closed-loop control cycle.

[0047] Specifically, after completing the positioning and machining of the inclined workpiece, in order to verify and ensure the long-term accuracy and stability of the entire system, the present invention can also perform the following calibration procedure: Install the standard: The operator installs a standard positioning circle (usually a high-precision ceramic or steel standard part) with known theoretical center coordinates (X_standard, Y_standard) and precise diameter in the blank area of ​​the worktable.

[0048] Perform standard measurements: The system automatically invokes (or is initiated by the operator) a preset measurement program. This program controls the contact probe or vision sensor to perform multi-point measurements on the standard positioning circle in a manner similar to the "corner macro program" in Embodiment 1, and calculates the actual measured circle center coordinates (X_measured, Y_measured) using a circle fitting algorithm.

[0049] Error analysis and calibration: The system calculates the deviation between the actual center and the theoretical center of the circle: ΔX = X_measured - X_standard ΔY = Y_measured - Y_standard Verification and Decision-Making: If the absolute values ​​of ΔX and ΔY are less than a preset tolerance threshold (e.g., 0.005 mm), the system determines that the current machine tool's centering, tool setting, and detection system are in good condition, and the process ends.

[0050] If the deviation exceeds the threshold, the system determines that a systematic error exists. At this point, the system can: a) Issue an alarm to prompt operators to perform maintenance.

[0051] b) Automatic compensation: The calculated deviation value (ΔX, ΔY) is used as a global compensation value and automatically input into the tool compensation table or workpiece coordinate system offset of the CNC system for subsequent machining tasks, so as to achieve automatic recovery of accuracy.

[0052] The closed-loop calibration process added in this embodiment enables the system to have "self-diagnosis" and "self-repair" capabilities. It can detect and compensate for systematic errors caused by factors such as machine tool thermal deformation, lead screw wear, and probe calibration drift, thereby ensuring machining accuracy over a long period of time. This greatly reduces the reliance on external coordinate measuring machines (CMMs) and the frequency of manual intervention, and is a core technological guarantee for realizing "unmanned" intelligent production.

[0053] According to some embodiments of the present invention, when generating a tool and tool setting system calibration alarm, the system automatically records the current deviation data, tool number and machining timestamp, and summarizes and generates a device accuracy health status report.

[0054] According to some embodiments of the present invention, the step of calling the laser tool setter to measure the diameter and length of the target tool and automatically setting the corresponding tool compensation parameters to obtain the tool processing parameters includes: synchronously recording the data of the laser tool setter measuring the tool diameter and tool length into the tool management library of the system.

[0055] According to some embodiments of the present invention, the step of calling a laser tool setter to measure the diameter and length of the target tool and automatically setting the corresponding tool compensation parameters to obtain the tool machining parameters includes: Collect and analyze historical wear data of cutting tools during the machining process, and establish a tool wear prediction model; Based on the tool wear prediction model and the current tool's machining parameters, the current tool wear amount is predicted; Based on the predicted tool wear, calculate the corresponding tool length compensation value and tool radius compensation value; The calculated compensation value is updated in real time to the tool compensation table of the CNC system.

[0056] A high-precision integrated tool setting detection system for implementing any of the control methods described above, according to an embodiment of the present invention, includes: Processing station; The online detection module includes multiple types of sensors installed at the processing station, used to scan the reference surface, contour and key features of the workpiece before and after processing to collect the spatial coordinate data of the workpiece. In some other embodiments, the online detection module also includes an integrated detection unit. The tool calibration module includes a laser tool setter and a drive unit, wherein the drive unit is used to drive the laser tool setter to move in order to automatically find the target tool; The machining execution module, including a spindle, cutting tools and a multi-axis drive mechanism, is used to perform initial machining and secondary machining based on compensation parameters on the workpiece. The central control module is connected to the online detection module, the tool calibration module, and the machining execution module via signals, respectively; the central control module includes: The data processor is configured to: receive data collected by the online detection module, generate a 3D detection center image of the workpiece, and compare the 3D detection center image with a pre-stored 3D theoretical model of the workpiece to calculate the processing deviation and automatically generate machine tool compensation parameters.

[0057] According to some embodiments of the present invention, an interface unit is further included; the interface unit adopts a universal interface design and is configured to achieve seamless data interface and communication with various CNC systems of different models. The interface unit adopts a modular design, and its physical interface is compatible with common protocols such as Ethernet, RS-232, and USB. The interface unit also includes various hardware interfaces, specifically including: a G31 interface for communication with traditional CNC systems; a DNC interface for communication with modern CNC systems, supporting the TCP / IP protocol; a software interface; and a custom interface, supporting users to develop dedicated interfaces as needed.

[0058] At the software level, this unit incorporates a communication protocol conversion module for mainstream CNC systems (such as Siemens, FANUC, and Heidenhain). By configuring different protocol drivers, seamless integration with various CNC machine tools can be achieved, greatly enhancing the universality and ease of deployment of this invention. The system integrates multiple independent functions such as sub-centering, tool setting, detection, and compensation into a unified hardware and software platform, avoiding compatibility issues and coordination difficulties caused by using multiple distributed devices. Simultaneously, the interface unit adopts a universal interface design, enabling seamless integration with mainstream CNC systems on the market, significantly enhancing the system's universality and reducing deployment difficulty and modification costs on different machine tools.

[0059] Example 1: High-precision mold processing Application scenario: Precision mold processing, requiring tool setting accuracy of ±0.002mm and centering accuracy of ±0.005mm.

[0060] System Configuration Integrated detection unit: laser probe + contact probe Data processing unit: FPGA+ARM architecture, 1GHz clock speed Interface unit: Machine tool interface, supporting OPC UA protocol Measurement process Tool mounting: Mount the tool onto the spindle.

[0061] Automatic measurement: The system automatically controls the spindle movement, the laser probe quickly measures the tool length and diameter, and the contact probe accurately measures the tool shape and position.

[0062] Data processing: The sub-center algorithm calculates the tool center position, and adaptive accuracy compensation technology is used for error compensation.

[0063] Output results: The measurement results are transmitted to the CNC system for subsequent processing.

[0064] Measurement results: Tool setting accuracy: ±0.0018mm Centering accuracy: ±0.0045mm Measurement time: 5 seconds per knife Specific implementation method of the testing equipment: The in-machine testing system mainly consists of a probe, a CNC machine tool, a signal receiving device, and a computer. Using the OMP40 probe and applying a measurement cycle program, the CATIA model (igs) of the part is imported into the UG system. Measurement points are selected to generate the testing program, which is then simulated and verified. After successful simulation verification, the computer transmits the testing program to the CNC machine tool via the CNC machine tool communication interface. The CNC machine tool drives the probe to move along the testing path. When the probe contacts the part, it sends a trigger signal, which is received by the receiving device and transmitted to the converter. The converter processes the signal and transmits it to the CNC machine tool control system. The machine tool stops moving, and the actual measurement point coordinates (report) text is stored in system variables.

[0065] (1). Automatic measurement content: The position measurement of the processing parts of the automobile mold is carried out, including plane, vertical plane, compound angle plane, contour plane, cylinder, curved surface, etc. The measurement data is compared with the theoretical data of the three-dimensional design entity to obtain the error value, which is automatically judged according to the mold manufacturing standard, and finally a test report is generated. (2) Automatic identification: Upgrade the CNC system macro program, and automatically identify machine tool accuracy errors through standard gauge calibration, and automatically compensate for machine tool accuracy; (3) Measurement range: Measurements can be taken at any distance within the travel of the flexible line; (4) Practicality: Based on the machining model or solid, and using CATIA programming software as the carrier, the automatic measurement program is generated through secondary development using UG software.

[0066] This technical solution, by employing automated centering and inspection equipment, achieves significant optimization in both efficiency and quality compared to traditional manual operation. Specific benefits are as follows: 1. Significantly improved efficiency: The traditional manual process of rounding, centering, tool setting, and inspection takes about 15 minutes. However, with this equipment, the entire process time is reduced to 3 minutes, increasing the efficiency by 80%. This effectively reduces the time spent on a single process and significantly improves the overall production cycle time.

[0067] 2. Stable and controllable quality: Through automated operation of the equipment, errors caused by manual operation are avoided, and the product quality pass rate can be stably reached 100%, completely eliminating defective products caused by manual tool setting and inspection deviations, reducing production rework costs and material losses.

[0068] Reference Figure 2 , Figure 3 , Figure 4 and Figure 5 The flexible online inspection device uses a three-dimensional trigger-type workpiece inspection probe and optical signal transmission to perform workpiece inspection throughout the entire production line according to the online inspection process.

[0069] Results: Comparative analysis of the accuracy self-inspection reports from the coordinate measuring machine and the flexible line. When the double-set drawing die surface deviation is below 0.03mm in the clamped state, it reaches 90% and the single set reaches 98%. The self-inspection report of the CNC structure surface is deemed to meet the standard, and the manufacturing department can accept the die according to the self-inspection report of the flexible line. The measurement group will conduct regular spot checks.

[0070] The flexible automatic inspection system comprises seven functional modules, as shown in the reference. Figure 6 : 1. Simulation Model 2. Safe knife lifting 3. List of measurement point information 4. Core Functional Modules 5. Expand functional modules 6. Simulation display 7. Post-processing module Reference Figure 7 This is the core hardware structure of the online tool setting and inspection sub-center for horizontal machining. The diagram shows a columnar base supporting a detection platform with multiple mounting holes. The tool setting and inspection unit (including sensor components) on the platform can extend and retract horizontally. The blue line on the left connects to an external control module, responsible for signal transmission and command reception. The green line on the right is connected to a drive module, providing power to the tool setting unit. The red line enables high-speed transmission of tool setting data and multi-module linkage. Through multi-line coordination and precise mechanical structure design, the device ensures the high efficiency and accuracy of online tool setting and inspection.

[0071] Reference Figure 8 The streamlined workflow is divided into three modules: precise solid cutting (Tebis software), inspection program development (UG software + automatic inspection system V2.0), and EACT pre-adjustment station inspection operation. The structure is clear and the steps are well-defined. I. Precise Solid Cutting (Tebis software) Figure 11 ) 1. Data preparation and saving Reference Figure 9 Select the current entity to be inspected, coordinate system, and machining model, and then perform the "Save As" operation.

[0072] 2. Cutting blank generation and data alignment Click the "Cut Blank" layer to automatically generate a cut blank according to the inlay size; if a cut surface is missing, adjust the "Safety Offset" parameter, and after converting the data through the filter, align the entity and processing data to the world coordinate system.

[0073] Perform the following steps in sequence: Surface Offset Creation → Contour Surface Creation → Surface Merging; if merging fails, check and adjust according to the flowchart.

[0074] 3. Data Export Reference Figure 10 Export the trimmed precise entity (automatically including the workpiece coordinate system) in igs / stp format. The export path must be consistent with the drawing number and part number of the inspection task.

[0075] II. Inspection Procedure Development (UG Software + Automatic Inspection System V2.0) Embed the automatic inspection system V2.0 into UG software, import the aforementioned precise entities, and develop an inspection program based on process requirements: 1. Import the precise entity into UG software and call the Automatic Inspection System V2.0 function module.

[0076] 2. Based on the process specifications, complete the programming work such as detection path planning and measurement point setting within the system.

[0077] III. EACT Pre-adjustment Station Inspection Operation (Steel Part Pre-adjustment and In-machine Inspection) Based on the line inspection task, identify the corresponding inspection program, perform in-machine inspection, and generate an accuracy report: 1. Selection of measuring points and setting of coordinate system Open the on-machine inspection system programming point acquisition tool, and select the object to be inspected (including all structural surfaces) in the "Inspection Entity" column.

[0078] Click the "Coordinate System and Reference Point Determination" function, select measurement points on the precise entity (multiple selections are allowed, and you need to click "OK" for each selected point; hold down Shift to select multiple points to be deleted, or select a single point and click the "Delete" button to remove the measurement point).

[0079] 2. Path Simulation and File Generation Perform a simulation, check the collision path, probe and ball display status, and generate a detection file after confirming that there are no errors.

[0080] 3. Report Presentation After the probe contacts the workpiece surface along the measurement point trajectory, the NX drawing report will automatically present the machining accuracy of the insert, and complete the pre-adjustment of the steel part and the output of the in-machine inspection report.

[0081] The processor can be implemented using a general-purpose central processing unit (CPU), microprocessor, application-specific integrated circuit (ASIC), or one or more integrated circuits, and is used to execute relevant programs to implement the technical solutions provided in the embodiments of this application.

[0082] It should be understood that various parts of the present invention can be implemented in hardware, software, firmware, or a combination thereof. In the above embodiments, multiple steps or methods can be implemented in software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented using any one or a combination of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (PGAs), field-programmable gate arrays (FPGAs), etc.

[0083] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "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.

[0084] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A control method for a high-precision integrated tool setting detection system, characterized in that, Includes the following steps: The system performs online inspection on a rectangular workpiece to obtain its initial position. Based on the initial position, the system automatically generates and executes a measurement macro program to control the online inspection module to perform measurements on the first and second reference surfaces of the workpiece, wherein the first reference surface is perpendicular to the second reference surface. Based on the measurement data on the first and second reference surfaces, the rotation angle and origin coordinates of the coordinate system are calculated. Based on the rotation angle and origin coordinates, a target machining coordinate system aligned with the workpiece reference is established, and the center coordinates of the X and Y axes are obtained. Based on the determined X and Y axis center coordinates, the Z axis coordinate origin is determined by measuring the workpiece surface with a probe. The laser tool setter measures the diameter and length of the target tool and automatically sets the corresponding tool compensation parameters to obtain the tool machining parameters. Based on the set coordinate system of X and Y axis center coordinates and tool machining parameters, the workpiece is machined for the first time; The key features of the workpiece are scanned and inspected, and the dimensional data is recorded; The inspection data is analyzed to generate a 3D inspection center map. The 3D inspection center map is compared with the 3D theoretical model of the workpiece, and the processing deviation is visualized in the 3D inspection center map. Based on the aforementioned machining deviation, the automatic computer tool compensation parameters are determined. Based on the compensation parameters, the workpiece is processed a second time to correct the deviation of the first processing. After the secondary machining is completed, the system is calibrated using a standard positioning circle. The accuracy of the current sub-center, tool setting, and detection results is verified using the standard positioning circle as a reference. After the secondary machining is completed, the system is calibrated using a standard positioning circle. The accuracy of the current sub-center, tool setting, and detection results is verified using the standard positioning circle as a reference, including: Reference identification: The control probe scans the standard positioning circle on the workpiece after the secondary processing to measure the actual center coordinates and diameter of the workpiece; The measured actual center coordinates and diameter are compared with the theoretical design value of the standard positioning circle to obtain the center position deviation and diameter deviation. If the deviation of the center position exceeds the first preset threshold, it is determined that the sub-center system is drifting and a sub-center system calibration alarm is generated. If the diameter deviation exceeds the second preset threshold, it is determined that there is tool wear or error in the tool setting system, and a tool and tool setting system calibration alarm is generated.

2. The control method according to claim 1, characterized in that, The online detection module performs measurements on the first and second reference surfaces of the workpiece, specifically as follows: Measure at least two points on the first reference plane and at least two points on the second reference plane.

3. The control method for the high-precision integrated tool setting detection system according to claim 2, characterized in that, The rotation angle is obtained by calculating the angle between the first or second reference plane and the reference coordinate axis based on the coordinates of the point measured on the first or second reference plane. The origin coordinates are obtained by calculating the theoretical intersection of the first and second reference planes based on the coordinates of the points measured on the first and second reference planes.

4. The control method according to claim 1, characterized in that, When generating a tool and tool setting system calibration alarm, the system automatically records the current deviation data, tool number and processing timestamp, and summarizes and generates a device accuracy health status report.

5. The control method according to claim 1, characterized in that, The process of calling a laser tool setter to measure the diameter and length of the target tool and automatically setting the corresponding tool compensation parameters to obtain the tool processing parameters includes: synchronously recording the data of the tool diameter and tool length measured by the laser tool setter to the tool management library of the system.

6. The control method according to claim 1, characterized in that, The process of calling a laser tool setter to measure the diameter and length of the target tool and automatically setting the corresponding tool compensation parameters to obtain the tool machining parameters includes: Collect and analyze historical wear data of cutting tools during the machining process, and establish a tool wear prediction model; Based on the tool wear prediction model and the current tool's machining parameters, the current tool wear amount is predicted; Based on the predicted tool wear, calculate the corresponding tool length compensation value and tool radius compensation value; The calculated compensation value is updated in real time to the tool compensation table of the CNC system.

7. The control method according to claim 1, characterized in that, Also includes: System preparation steps: Obtain the processing requirements input by the user, automatically call the matching control program according to the processing requirements, trigger system initialization, complete the self-check and initialization of hardware modules and software parameters, and confirm that the communication between each module is normal.

8. A high-precision integrated tool setting detection system for implementing the control method as described in any one of claims 1 to 7, characterized in that, include: Processing station; The online detection module includes multiple types of sensors installed at the processing station, used to scan the reference surface, contour and key features of the workpiece before and after processing to collect the spatial coordinate data of the workpiece. The tool calibration module includes a laser tool setter and a drive unit, wherein the drive unit is used to drive the laser tool setter to move in order to automatically find the target tool; The machining execution module, including a spindle, cutting tools, and a multi-axis drive mechanism, is used to perform initial machining and secondary machining based on compensation parameters on the workpiece.

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