A laser cutting device and method for aluminum casting machining

Abstract

The application discloses a laser cutting device and method for aluminum casting processing, and belongs to the technical field of laser cutting and precision automation support, which comprises a cutting system, a posture calibration system and a collaborative support unit with a force sensor; the calibration system scans the casting and is aligned with a digital twin model; a controller simulates cutting, identifies a critical separation point, calculates the theoretical weight of a separated part, and obtains the minimum stable detection threshold of the force sensor; cutting is paused before the critical point, and a flexible support head performs adaptive support: if the weight is greater than the threshold, the support is performed until the force value reaches the threshold; if the weight is less than the threshold, the support is performed until the force signal first jumps; after the support is completed, the critical point is cut, and the support unit is used to grab the part. The independent fixed collaborative support base is adopted, mechanical vibration generated by a five-axis motion gantry during high-speed movement is blocked from being transmitted to the collaborative support unit, and the support precision and stability are effectively improved.

Description

Technical Field

[0001] This invention relates to the field of laser cutting and precision automated support, specifically to a laser cutting device and method for processing aluminum castings. Background Technology

[0002] With the rapid development of high-end manufacturing, higher requirements are being placed on the precision and efficiency of three-dimensional laser cutting of complex workpieces such as aluminum castings. During the three-dimensional laser cutting process, when the workpiece is cut, the separated components, such as gates, risers, or scrap, are prone to falling, deforming, or colliding with the workpiece / equipment due to gravity. This is one of the main obstacles affecting cutting quality and equipment operational stability. However, existing technologies have the following limitations in solving this problem:

[0003] Traditional 3D laser cutting solutions fail to identify and predict the precise moment of component separation. This results in the inability to take timely support measures before separation occurs, forcing reliance on manual cleaning or crude receiving mechanisms afterward, leading to low cutting efficiency and high safety risks.

[0004] Existing support technologies lack precise perception of the actual posture of the workpiece; when aluminum castings are placed on the cutting table, their actual position and posture usually have slight deviations; traditional solutions fail to perform high-precision calibration of such deviations, resulting in a mismatch between the cutting path and support position and the workpiece entity, poor support accuracy, and even the possibility of the component warping or undergoing secondary deformation due to the support force being applied to the wrong position.

[0005] Existing support systems typically cannot avoid high-frequency mechanical vibrations from the cutting system; laser cutting systems generate vibrations during high-speed five-axis motion, which are transmitted to the support unit, interfering with the movement accuracy of the support unit and causing signal interference to the precision force sensors used for contact detection, making it impossible for the system to reliably detect minute contact or support forces.

[0006] Existing support methods cannot adaptively adjust to the physical characteristics of the separated components, such as weight and geometry. For heavier components, insufficient support may cause them to fall, while for thinner components, excessive support may cause the components to warp or the thin-walled structure to deform. Existing technologies fail to provide a strategy that can distinguish support strategies based on the theoretical weight of the component and the minimum stable detection threshold of the sensor, resulting in poor robustness of support actions.

[0007] In summary, existing technologies lack an effective method to combine high-precision attitude calibration, digital twin model topology analysis, and adaptive collaborative support for physical isolation to solve the problems of falling, deforming, or colliding of separated parts in the laser cutting of 3D aluminum castings. A new technical solution is urgently needed.

[0008] The information disclosed in the background section above is only intended to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0009] The purpose of this invention is to provide a laser cutting device and method for processing aluminum castings, so as to solve the problems mentioned in the background art. Specifically, the technical solution of this invention is as follows:

[0010] A laser cutting method for machining aluminum castings includes:

[0011] S1. Set up a cutting system, a cutting worktable, a collaborative support unit, and an attitude calibration system. The collaborative support unit is set on a collaborative support base that is physically isolated from the cutting worktable. The collaborative support unit includes a flexible support head with a built-in force sensor. Activate the structured light camera of the attitude calibration system to scan the aluminum casting, obtain an actual point cloud model, and align it with a standard digital twin model.

[0012] S2. Simulate the cutting path in the controller, perform topology analysis to identify critical separation points; calculate the theoretical weight of the separated components, and obtain the minimum stable detection threshold of the force sensor;

[0013] S3. The controller drives the cutting system to pause before reaching the critical separation point, and drives the flexible support head of the cooperative support unit to move to the support position, performing adaptive support based on the comparison result between the theoretical weight and the minimum stable detection threshold.

[0014] If the theoretical weight is greater than the minimum stable detection threshold, the flexible support head moves upward until the force sensor monitoring value reaches the threshold.

[0015] If the theoretical weight is less than the minimum stable detection threshold, the flexible support head moves upward until the force sensor detects the first signal jump.

[0016] S4. After the adaptive support is completed, the cutting system is instructed to cut at the critical separation point, and the collaborative support unit grabs the separated component.

[0017] Preferably, in step S1, the alignment with the standard digital twin model includes:

[0018] Calculate the rotation and translation deviation matrix between the actual point cloud model and the standard digital twin model, and use the deviation matrix to correct the cutting G-code and the support coordinate system.

[0019] Preferably, step S1 is followed by:

[0020] S1.1 Instruct the cooperative support unit to move so that its flexible support head contacts the calibration reference point of the aluminum casting. When the force sensor reading changes from zero to a positive value, record the Z-axis coordinate at this moment to complete the calibration of the support coordinate system and the casting entity coordinate system.

[0021] Preferably, in step S2, performing topological analysis to identify critical breakaway points includes:

[0022] The cutting path is simulated, and real-time topological cutting is performed on the digital twin model. The cutting G code is parsed line by line to determine whether the model splits from a single connected component into multiple independent connected components. The line number of the cutting G code that causes the split is defined as the critical separation point.

[0023] Preferably, step S2 is followed by:

[0024] S2.1 After identifying the critical separation point, calculate the center of mass of the newly separated component and analyze its mechanical stability under gravity to determine whether the component has fallen.

[0025] A laser cutting device for processing aluminum castings includes:

[0026] Main frame;

[0027] A cutting worktable, fixed to the main frame, is used to support aluminum castings;

[0028] The cutting system includes a laser cutting head mounted on a five-axis motion gantry, which straddles the main frame;

[0029] The collaborative support base is fixed independently of the main frame;

[0030] A collaborative support unit is disposed on the collaborative support base. The collaborative support unit includes a three-axis linear platform and a flexible support head disposed at its end. The flexible support head has a built-in force sensor.

[0031] An attitude calibration system, including a structured light camera, is used to scan the aluminum casting;

[0032] The controller is connected to the cutting system, the collaborative support unit, and the attitude calibration system, respectively.

[0033] Preferably, the laser cutting head is fixed to the A / C axis swing mechanism at the Z-axis end of the five-axis motion gantry, which is composed of an X-axis crossbeam, a Y-axis guide rail, and a Z-axis lifting mechanism.

[0034] Preferably, the cutting worktable includes multiple retractable positioning pins, which are driven by a built-in micro cylinder to achieve retraction and extension, and are used to insert into the process hole of the aluminum casting to achieve initial posture calibration.

[0035] Preferably, the flexible support head is a flat plate covered with a high-temperature resistant elastic silicone pad on top, and the force sensor is connected to the bottom of the flat plate.

[0036] Preferably, the controller is installed in an electrical control cabinet that is independent of the main frame and the cooperating support base.

[0037] This invention provides an improved laser cutting apparatus and method for processing aluminum castings, which, compared with the prior art, has the following improvements and advantages:

[0038] 1. This solution uses an independent and fixed collaborative support base, which blocks the mechanical vibration generated by the five-axis motion gantry during high-speed movement from being transmitted to the collaborative support unit, effectively improving the support accuracy and stability, and avoiding the interference of high-frequency vibration of the cutting system on the support accuracy;

[0039] 2. This solution calculates the rotation and translation deviation matrix and uses this matrix to correct the cutting G-code and support coordinate system, achieving high-precision six-degree-of-freedom correction of the actual workpiece's spatial posture. This corrects the positional deviation caused by workpiece placement, achieving high-precision calibration and ensuring the accuracy of subsequent cutting and support actions.

[0040] 3. This solution performs real-time topology cutting on the digital twin model to determine whether the model has split from a single connected component into multiple independent connected components. This allows for the pre-identification of the precise cutting command that will lead to component separation, enabling accurate prediction of the specific command location before physical cutting occurs. The solution implements adaptive support based on the component's theoretical weight: for heavier components (theoretical weight exceeding a threshold), the flexible support head moves until the force sensor detects a value exceeding the threshold, providing a precise support force; for thinner components (theoretical weight less than the threshold), the flexible support head stops moving when the force sensor detects the first signal jump, confirming contact but avoiding excessive force. This effectively prevents components from falling and avoids warping and deformation of thin-walled components due to excessive force.

[0041] 4. This solution adds a physical contact calibration step. By contacting the calibration reference point of the aluminum casting with the flexible support head, and using the precise physical contact signal of the jump from zero to positive value of the force sensor signal, a secondary calibration of the Z-axis reference is achieved. This compensates for the slight height error that may exist in pure optical scanning and provides a more accurate starting reference for the height control of the subsequent adaptive support. Attached Figure Description

[0042] The present invention will be further explained below with reference to the accompanying drawings and embodiments:

[0043] Figure 1 This is a schematic diagram of the overall structure of the device;

[0044] Figure 2 This is a schematic diagram of the cutting system;

[0045] Figure 3 This is a structural diagram of the cutting worktable and the attitude calibration system;

[0046] Figure 4 This is a schematic diagram of the structure of the collaborative support base;

[0047] Figure 5 This is a schematic diagram of the process flow of the method of the present invention.

[0048] In the diagram: 100, Cutting system; 110, Laser cutting head; 120, Five-axis motion gantry; 200, Cutting worktable; 210, Table body; 220, Positioning pin; 300, Collaborative support unit; 310, Collaborative support base; 320, Three-axis linear platform; 330, Flexible support head; 340, Force sensor; 400, Attitude calibration system; 410, Structured light camera; 500, Controller. Detailed Implementation

[0049] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0050] Example 1:

[0051] Please see Figure 1-5 This invention provides a laser cutting method for processing aluminum castings, comprising:

[0052] S1. Set up a cutting system 100, a cutting worktable 200, a collaborative support unit 300, and an attitude calibration system 400. The collaborative support unit 300 is set on a collaborative support base 310 that is physically isolated from the cutting worktable 200. The collaborative support unit 300 includes a flexible support head 330 with a built-in force sensor 340. Start the structured light camera 410 of the attitude calibration system 400 to scan the aluminum casting, obtain the actual point cloud model, and align it with the standard digital twin model.

[0053] S2. Simulate the cutting path in the controller 500, perform topology analysis to identify critical separation points; calculate the theoretical weight of the separated parts, and obtain the minimum stable detection threshold of the force sensor 340;

[0054] S3, the controller 500 drives the cutting system 100 to pause before cutting to the critical separation point, and drives the flexible support head 330 of the cooperative support unit 300 to move to the support position, performing adaptive support based on the comparison result between the theoretical weight and the minimum stable detection threshold:

[0055] If the theoretical weight is greater than the minimum stable detection threshold, the flexible support head 330 moves upward until the force sensor 340 detects the threshold value.

[0056] If the theoretical weight is less than the minimum stable detection threshold, the flexible support head 330 moves upward until the force sensor 340 detects the first signal jump.

[0057] S4. After the adaptive support is completed, the instruction cutting system 100 performs the cutting at the critical separation point, and the collaborative support unit 300 grabs the separated parts.

[0058] In this embodiment, a laser cutting collaborative support method for aluminum casting processing aims to solve the problem of separating components, such as gates, risers, or scrap, impacting the workpiece or equipment due to gravity during the three-dimensional cutting process of aluminum castings. This method utilizes the collaborative operation of a cutting system 100, a cutting table 200, a collaborative support unit 300, and an attitude calibration system 400. The collaborative support unit 300 is mounted on a physically isolated collaborative support base 310. This structure is used to avoid interference from the high-frequency vibration of the cutting system 100 on the support accuracy. The controller 500 sends a command to activate the structured light camera 410 of the attitude calibration system 400 to scan the aluminum casting. The purpose of this step is to obtain the actual three-dimensional contour of the workpiece, i.e., the actual point cloud model, and align it with a standard digital twin model to correct positional deviations caused by workpiece placement. The controller 500 simulates the cutting path and performs topology analysis. The purpose of this analysis is to identify the accurate cutting command that will cause component separation in advance through the digital model without actual cutting, i.e., to identify the critical separation point.

[0059] The purpose of the standard digital twin model is to serve as the original benchmark for cutting and support commands and to accurately predict component separation behavior in a virtual environment. Logical structure and data flow: The model logically receives rotation and translation deviation matrices as input for real-time correction and attitude calibration; it also receives cutting G-code as input to perform topological cutting and simulate Boolean operations. Physical relationships represented: The model comprehensively represents the complete geometry and material density distribution of the aluminum casting, used to accurately calculate the volume, center of mass, and mechanical stability of the separated component under gravity, simulating the destructive impact of the cutting path on the workpiece structure, thereby achieving accurate prediction of the critical separation point.

[0060] At the same time, the controller 500 calculates the theoretical weight of the separated component and obtains the minimum stable detection threshold of the force sensor 340 built into the flexible support head 330. This threshold provides a basis for judgment of subsequent support strategies.

[0061] Specifically, the logic for obtaining the minimum stable detection threshold can be as follows: During device initialization, the controller 500 collects a series of background noise signal readings from the force sensor 340 under no-load conditions and calculates the standard deviation of these readings. Here, the standard deviation is often statistically expressed as... This is used to characterize the fluctuation amplitude of the background noise signal; assuming the force sensor 340 collects data under no-load conditions... The background noise sampling points are: The standard deviation of the background noise is... Calculated using the following formula:

[0062]

[0063] in, The arithmetic mean of the background noise; the controller will set the minimum stable detection threshold. Set as To ensure the signal-to-noise ratio of the detected signal. satisfy The reliability requirements; the controller 500 will apply a preset multiple, such as 3 times, to this standard deviation. And this calculation result, i.e., 3 The minimum stable detection threshold is calibrated. This is to ensure that the threshold is higher than normal noise fluctuations, allowing the system to stably identify force signal jumps caused by actual physical contact. During actual cutting, the controller 500 drives the cutting system 100 to pause before reaching the critical separation point and drives the flexible support head 330 of the cooperative support unit 300 to move to the support position. At this time, the controller 500 controls the cooperative support unit 300 to perform adaptive support based on the comparison between the theoretical weight and the minimum stable detection threshold. This adaptive support is divided into two cases: for heavier components with a theoretical weight greater than the minimum stable detection threshold, the flexible support head 330 moves upward until the force sensor 340 detects the threshold value, thus providing accurate support force; for thin components with a theoretical weight less than the minimum stable detection threshold, the flexible support head 330 moves upward until the force sensor 340 detects the first signal jump and then stops. This is to confirm contact with the component surface but avoid applying excessive force that could cause the thin-walled component to warp and deform. After the adaptive support is completed, the controller 500 generates a control signal to instruct the cutting system 100 to perform cutting at the critical separation point. At this time, the component is stably supported, and the cooperative support unit 300 then grabs the separated component. This method effectively prevents the component from falling off through pre-analysis and the cooperative action of the adaptive support, ensuring the continuity of the cutting operation and the integrity of the workpiece.

[0064] In step S1, alignment with the standard digital twin model includes:

[0065] Calculate the rotation and translation deviation matrix between the actual point cloud model and the standard digital twin model, and use the deviation matrix to correct the cut G-code and support coordinate system.

[0066] The input to this computational logic flow is the actual point cloud model data from the structured light camera 410 of the attitude calibration system 400 and the standard digital twin model data pre-stored in the controller 500. The logical steps are as follows: Step 1: The controller 500 performs a rough initial alignment of the two models, for example, based on feature points on the workpiece or the position of the initial positioning pin 220; Step 2: The controller 500 executes a high-precision iterative nearest-neighbor algorithm or a variant thereof to minimize the distance from each point on the actual point cloud model to the surface of the standard digital twin model; Step 3: The ICP algorithm calculates an optimal rotation and translation transformation matrix in each iteration; The final output of the flow is the optimal rotation and translation deviation matrix, which is subsequently used to correct the cutting G-code and the support coordinate system.

[0067] In this embodiment, the step of aligning with the standard digital twin model provides specific computational logic for achieving high-precision calibration in S1. After the controller 500 acquires the actual point cloud model, it performs a three-dimensional matching with the stored standard digital twin model. This matching process involves the controller 500 calculating the rotation and translation deviation matrix between the actual point cloud model and the standard digital twin model. This deviation matrix describes the six-degree-of-freedom attitude difference of the actual workpiece relative to the theoretical model in space. After calculating this deviation matrix, the controller 500 uses the deviation matrix to correct subsequent motion commands, specifically by correcting the cutting G-code and the support coordinate system. The purpose of correcting the cutting G-code is to ensure that the laser cutting head 110 can accurately follow the contour of the actual workpiece for cutting. The purpose of correcting the support coordinate system is to ensure that the flexible support head 330 of the cooperative support unit 300 can move to the correct support point on the actual workpiece. Through this dual correction, the accuracy of subsequent cutting and support actions is ensured.

[0068] Step S1 is followed by:

[0069] S1.1 Instruct the coordinated support unit 300 to move so that its flexible support head 330 contacts the calibration reference point of the aluminum casting. When the reading of the force sensor 340 changes from zero to a positive value, record the Z-axis coordinate at this moment to complete the calibration of the support coordinate system and the casting entity coordinate system.

[0070] In this embodiment, to further improve the Z-axis height accuracy of the support, step S1.1 is added after step S1. This step involves the controller 500 instructing the coordinated support unit 300 to move, causing its flexible support head 330 to undergo a physical contact calibration. The flexible support head 330 slowly rises to contact the preset calibration reference point on the aluminum casting. During this process, the controller 500 monitors the signal of the force sensor 340 at high frequency; when the reading of the force sensor 340 changes from zero to a positive value, this signal change indicates that the flexible support head 330 has indeed contacted the surface of the casting. Upon receiving this signal, the controller 500 immediately records the Z-axis coordinate of the coordinated support unit 300 at that moment. The significance of this step is that a precise Z-axis reference is obtained through physical contact to complete the calibration of the support coordinate system and the casting coordinate system. This calibration method compensates for the slight height error that may exist in pure optical scanning, providing a more accurate starting reference for the height control of adaptive support in S3.

[0071] In step S2, performing topological analysis to identify critical breakaway points includes:

[0072] Simulate the execution of the cutting path, perform real-time topology cutting on the digital twin model, parse the cutting G code line by line, determine whether the model splits from a single connected component into multiple independent connected components, and define the line number of the cutting G code that causes the split as the critical separation point.

[0073] In this embodiment, the step of performing topology analysis to identify critical separation points details the derivation process of predicting the separation time in S2. After aligning the model in S1, the controller 500 begins to simulate and execute the cutting path. This simulation is not a simple path playback, but a real-time topology cutting operation on the digital twin model, which can be understood as a Boolean operation. The controller 500 parses the cutting G code line by line. For each line of cutting G code represented by the simulated cutting micro-segment, its algorithm performs a connectivity check on the topology of the digital twin model. The logic of this check is to determine whether the model has split from a single connected component into multiple independent connected components.

[0074] The input to this processing flow is the geometric data of the digital twin model and the cutting G-code. The logical steps are as follows: Step 1: Controller 500 simulates the cutting operation starting from the first line of cutting G-code, i.e., performing Boolean difference operations on the digital twin model. Step 2: After simulating the execution of one line of cutting G-code, the algorithm immediately performs a connectivity check on the model's topology. This check uses graph traversal algorithms such as breadth-first search or depth-first search to confirm whether all geometric faces of the model still belong to a single, connected volume. Step 3: If the check result indicates that the model has split from a single connected volume into one or more independent connected volumes, then a split is determined to have occurred. Step 4: The line number of the previous line of cutting G-code that caused the split is defined as the critical separation point; the final output of the flow is the line number of the cutting G-code at the critical separation point, which is subsequently used to trigger the cutting pause and support action in step S3.

[0075] The algorithm continues this process until it finds a line of code that cuts G. After simulating the execution of that line of code, the model's topology splits. The controller 500 then defines the line number of the cutting G code that caused the split as the critical separation point. This process allows the system to accurately predict the specific instruction location where the separation will occur before the physical cutting happens.

[0076] The steps following S2 include:

[0077] S2.1 After identifying the critical separation point, calculate the center of mass of the newly separated component and analyze its mechanical stability under gravity to determine whether the component has fallen off.

[0078] In this embodiment, in S2.1, after the controller 500 identifies the critical separation point through topology analysis, the method further includes a stability analysis step. Based on a digital twin model, the controller 500 automatically calculates the volume of the newly formed separation component and, combined with material density parameters, further calculates its center of mass. After obtaining the center of mass position, the controller 500 analyzes its mechanical stability under gravity. This analysis logic includes determining whether the gravity projection point of the center of mass falls outside its remaining support area. If the projection point exceeds the support area, or if the component's only connection point is the critical separation point that is about to be severed, the controller 500 determines whether the component has fallen. The purpose of this step is to confirm that the separation component does indeed have a risk of falling, thereby providing the necessary decision-making basis for activating the collaborative support unit 300 in S3.

[0079] Example 2:

[0080] Please see Figure 1-4 A laser cutting device for processing aluminum castings, comprising:

[0081] Main frame;

[0082] The cutting worktable 200 is fixed to the main frame and is used to support aluminum castings; the cutting worktable 200 includes a table body 210.

[0083] The cutting system 100 includes a laser cutting head 110 mounted on a five-axis motion gantry 120, which spans the main frame.

[0084] The collaborative support base 310 is fixed independently of the main frame;

[0085] The collaborative support unit 300 is disposed on the collaborative support base 310. The collaborative support unit 300 includes a three-axis linear platform 320 and a flexible support head 330 disposed at its end. The flexible support head 330 has a built-in force sensor 340.

[0086] Attitude calibration system 400 includes structured light camera 410 for scanning aluminum castings;

[0087] The controller 500 is connected to the cutting system 100, the collaborative support unit 300, and the attitude calibration system 400, respectively.

[0088] In this embodiment, an apparatus provides a physical carrier for performing the above-described method. The apparatus includes a main frame as its base structure. A cutting table 200 is fixed to the main frame to support the aluminum casting; a cutting system 100 performs cutting and includes a laser cutting head 110 mounted on a five-axis motion gantry 120 spanning the main frame to cover the entire working area; a key structure is a co-support base 310, which is fixed independently of the main frame, designed to physically isolate mechanical vibrations; a co-support unit 300 is mounted on the co-support base 310 to maintain high stability; the co-support unit 300 includes a three-axis linear platform 320 to provide precise X, Y, and Z-direction motion to a flexible support head 330 at its end; the flexible support head 330 incorporates a force sensor 340 for sensing support forces in S3; and an attitude calibration system 400 includes a structured light camera 410 for scanning the aluminum casting in S1 to obtain three-dimensional data. The controller 500, such as an industrial computer, is connected to the cutting system 100, the collaborative support unit 300, and the attitude calibration system 400 respectively. It acts as the command center to coordinate the actions of all units and execute the entire process from S1 to S4.

[0089] The laser cutting head 110 is fixed on the A / C axis swing mechanism at the Z-axis end of the five-axis motion gantry 120. The five-axis motion gantry 120 consists of an X-axis crossbeam, a Y-axis guide rail, and a Z-axis lifting mechanism.

[0090] In this embodiment, to achieve flexible cutting of three-dimensional aluminum castings, the laser cutting head 110 is fixed to the A / C axis swing mechanism at the Z-axis end of the five-axis motion gantry 120. The five-axis motion gantry 120 consists of an X-axis beam, a Y-axis guide rail, and a Z-axis lifting mechanism, which provide basic X, Y, and Z-axis linear motion. The Z-axis lifting mechanism can be specifically a ball screw slide driven by a servo motor. The A / C axis swing mechanism, for example, is driven by a servo motor in conjunction with a harmonic reducer, providing two rotational degrees of freedom for the laser cutting head 110. The linkage of these five axes, X, Y, Z, A, and C, enables the laser cutting head 110 to approach the complex curved surface of the workpiece in any posture and execute a three-dimensional cutting path.

[0091] The cutting table 200 includes multiple retractable positioning pins 220, which are driven by built-in micro cylinders to achieve retraction and extension, and are used to insert into the process holes of the aluminum casting to achieve initial posture calibration.

[0092] In this embodiment, the structure of the cutting worktable 200 is further described. The cutting worktable 200 includes a plurality of retractable positioning pins 220; these positioning pins 220 are driven by built-in micro cylinders to achieve retraction and extension, where the micro cylinder is a specific implementation of the power mechanism; the function of this structure is to be inserted into the process holes reserved in the aluminum casting;

[0093] Process holes are specific holes reserved during the casting process of aluminum castings for positioning, clamping or cutting; initial posture calibration is to roughly fix the position and posture of the aluminum casting within a known range by inserting the positioning pin 220 into the corresponding process hole, so as to provide an accurate initial posture for subsequent scanning and high-precision alignment by the structured light camera 410.

[0094] When the casting is placed on the cutting table 200, these positioning pins 220 extend and insert into the process holes to achieve the initial orientation calibration of the workpiece; this calibration method provides a roughly accurate initial position for the subsequent scanning by the structured light camera 410 in S1.

[0095] The flexible support head 330 is a flat plate with a high-temperature resistant elastic silicone pad on top, and the force sensor 340 is connected to the bottom of the flat plate.

[0096] In this embodiment, the specific structure of the flexible support head 330 is explained. The main body of the flexible support head 330 can be a flat plate, the top of which is covered with a high-temperature resistant elastic silicone pad. The force sensor 340, such as an ATII Industrial Automation Mini40 sensor, is connected below the flat plate; this structural design has a dual purpose: the high-temperature resistant elastic silicone pad provides a flexible contact surface that will not damage the surface of the aluminum casting when in contact with it in S3; on the other hand, it can also isolate the radiant heat generated during laser cutting; the force sensor 340 is protected below the flat plate, while being able to sensitively detect minute pressure signals transmitted through the silicone pad and the flat plate to achieve adaptive support in S3.

[0097] The top of the flexible support head 330 can also be integrated with a micro suction cup or a low-pressure vacuum generator, which is used to stably grasp and remove the separated parts by negative pressure adsorption after cutting, so as to realize the grasping action in step S4.

[0098] The controller 500 is installed in an electrical control cabinet that is independent of the main frame and the cooperating support base 310.

[0099] In this embodiment, the installation method of the controller 500 is specified. The controller 500 is installed in an electrical control cabinet, which is independent of the main frame and the cooperative support base 310. The purpose of this layout is to physically separate the controller 500 from the mechanical structure that generates vibration, such as the five-axis motion gantry 120. In this way, mechanical vibration is avoided from interfering with the precision electronic components inside the controller 500, such as the central processing unit and hard disk, thereby improving the stability and reliability of the controller 500's operation and ensuring that the entire cooperative support method can be executed stably.

[0100] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A laser cutting method for processing aluminum castings, characterized in that, include: S1. Set up a cutting system (100), a cutting worktable (200), a collaborative support unit (300), and an attitude calibration system (400), wherein the collaborative support unit (300) is set on a collaborative support base (310) that is physically isolated from the cutting worktable (200), and the collaborative support unit (300) includes a flexible support head (330) with a built-in force sensor (340); start the structured light camera (410) of the attitude calibration system (400) to scan the aluminum casting, obtain the actual point cloud model and align it with the standard digital twin model; S2. Simulate the cutting path in the controller (500), perform topology analysis to identify critical separation points; calculate the theoretical weight of the separated parts, and obtain the minimum stable detection threshold of the force sensor (340); S3. The controller (500) drives the cutting system (100) to pause before cutting to the critical separation point, and drives the flexible support head (330) of the cooperative support unit (300) to move to the support position, and performs adaptive support based on the comparison result between the theoretical weight and the minimum stable detection threshold. If the theoretical weight is greater than the minimum stable detection threshold, the flexible support head (330) moves upward until the force sensor (340) detects that the value reaches the threshold. If the theoretical weight is less than the minimum stable detection threshold, the flexible support head (330) moves upward until the force sensor (340) detects the first signal jump; S4. After the adaptive support is completed, the cutting system (100) is instructed to cut the critical separation point, and the collaborative support unit (300) grabs the separated part.

2. The laser cutting method for processing aluminum castings according to claim 1, characterized in that, In step S1, the alignment with the standard digital twin model includes: Calculate the rotation and translation deviation matrix between the actual point cloud model and the standard digital twin model, and use the deviation matrix to correct the cutting G-code and the support coordinate system.

3. The laser cutting method for processing aluminum castings according to claim 2, characterized in that, Step S1 is followed by: S1.1 Instruct the cooperative support unit (300) to move so that its flexible support head (330) contacts the calibration reference point of the aluminum casting. When the reading of the force sensor (340) changes from zero to a positive value, record the Z-axis coordinate at this moment to complete the calibration of the support coordinate system and the casting entity coordinate system.

4. The laser cutting method for processing aluminum castings according to claim 1, characterized in that, In step S2, performing topological analysis to identify critical breakaway points includes: The cutting path is simulated, and real-time topological cutting is performed on the digital twin model. The cutting G code is parsed line by line to determine whether the model splits from a single connected component into multiple independent connected components. The line number of the cutting G code that causes the split is defined as the critical separation point.

5. A laser cutting method for processing aluminum castings according to claim 4, characterized in that, Step S2 is followed by: S2.1 After identifying the critical separation point, calculate the center of mass of the newly separated component and analyze its mechanical stability under gravity to determine whether the component has fallen.

6. The laser cutting method for processing aluminum castings according to claim 1, characterized in that, A laser cutting device for processing aluminum castings is used, the device comprising: Main frame; A cutting worktable (200) is fixed to the main frame and is used to support aluminum castings; The cutting system (100) includes a laser cutting head (110) mounted on a five-axis motion gantry (120), which spans the main frame; The collaborative support base (310) is fixed independently of the main frame; A collaborative support unit (300) is disposed on the collaborative support base (310). The collaborative support unit (300) includes a three-axis linear platform (320) and a flexible support head (330) disposed at its end. The flexible support head (330) has a built-in force sensor (340). An attitude calibration system (400) includes a structured light camera (410) for scanning the aluminum casting; The controller (500) is connected to the cutting system (100), the collaborative support unit (300) and the attitude calibration system (400), respectively.

7. The laser cutting method for processing aluminum castings according to claim 6, characterized in that, The laser cutting head (110) is fixed on the A / C axis swing mechanism at the Z-axis end of the five-axis motion gantry (120). The five-axis motion gantry (120) is composed of an X-axis beam, a Y-axis guide rail and a Z-axis lifting mechanism.

8. A laser cutting method for processing aluminum castings according to claim 6, characterized in that, The cutting worktable (200) includes multiple retractable positioning pins (220), which are driven by built-in micro cylinders to achieve retraction and extension, and are used to insert into the process holes of the aluminum casting to achieve initial posture calibration.

9. A laser cutting method for processing aluminum castings according to claim 6, characterized in that, The flexible support head (330) is a flat plate covered with a high-temperature resistant elastic silicone pad on top, and the force sensor (340) is connected to the bottom of the flat plate.

10. A laser cutting method for processing aluminum castings according to claim 6, characterized in that, The controller (500) is installed in an electrical control cabinet that is independent of the main frame and the cooperating support base (310).

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