A high-precision numerical control universal grinding machine system and control method

Abstract

The application discloses a high-precision numerical control universal grinding machine system and a control method, and relates to the technical field of precision manufacturing. The system comprises a dynamic balance control module, an intelligent temperature control module, a deformation monitoring module and a control center. In the application, the dynamic balance control module collects spindle vibration and speed fluctuation data in real time, dynamically adjusts spindle transmission torque distribution, and weakens mechanical vibration during high-speed operation. The intelligent temperature control module monitors the temperature of key heat sources in the system, automatically adjusts the flow of cooling liquid according to temperature changes, and suppresses thermal deformation of the mechanical structure. The deformation monitoring module collects force / torque data of the workpiece and key mechanical connection parts, converts the data into workpiece deformation variables and feeds back the variables to the control center. The control center communicates with each module, calculates processing parameter correction instructions through a closed-loop compensation unit, integrates data storage and maintenance prediction functions, realizes collaborative control of each module, and guarantees processing precision and stability.

Description

Technical Field

[0001] This invention relates to the field of precision manufacturing technology, and in particular to a high-precision CNC universal grinding machine system and control method. Background Technology

[0002] A CNC universal grinding machine is a precision machining equipment that integrates CNC technology and universal grinding functions. It can be precisely controlled by a CNC system to achieve grinding of workpieces of various shapes. It can achieve micron-level high-precision machining by means of precise CNC control and multi-module collaboration. It supports automatic program operation to improve production efficiency, adapts to multiple working conditions to reduce equipment switching costs, and can also avoid interference factors through multiple technical means to ensure stable machining process and strong consistency of finished products.

[0003] Currently, high-precision CNC universal grinding machines suffer from insufficient mechanical vibration suppression, resulting in large vibrations and poor machining accuracy during high-speed operation. They also lack thermal deformation control, with lag in the temperature response of key heat sources and large thermal deformation errors. Furthermore, they lack deformation monitoring and compensation, with no real-time acquisition and feedback of workpiece and key component deformation, leading to significant accuracy loss. Additionally, each functional unit operates independently without a unified control center, making it difficult to continuously guarantee machining accuracy and equipment stability, and maintenance relies on manual labor.

[0004] Therefore, a high-precision CNC universal grinding machine system and control method are proposed to solve the above problems. Summary of the Invention

[0005] The main objective of this invention is to provide a high-precision CNC universal grinding machine system and control method to solve the problems mentioned in the background.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: a high-precision CNC universal grinding machine system, the system comprising a dynamic balance control module, an intelligent temperature control module, a deformation monitoring module, and a control center;

[0007] The dynamic balance control module is used to collect spindle vibration data and speed fluctuation data in real time, and reduce mechanical vibration during high-speed operation by dynamically adjusting the spindle transmission torque distribution.

[0008] The intelligent temperature control module is used to monitor the temperature of key heat sources in the system and automatically adjust the coolant flow rate according to temperature changes to suppress thermal deformation of the mechanical structure.

[0009] The deformation monitoring module is used to collect force / torque data of the workpiece and key mechanical connection parts, convert it into workpiece deformation, and feed it back to the control center;

[0010] The control center is connected to the dynamic balance control module, the intelligent temperature control module, and the deformation monitoring module. It calculates the processing parameter correction instructions through the built-in closed-loop compensation unit, and integrates data storage and maintenance prediction functions to achieve coordinated control of each module to ensure processing accuracy and stability.

[0011] Preferably, the dynamic balance control module includes a vibration sensor and a spindle speed adjustment mechanism;

[0012] The vibration sensor is fixed to the outside of the spindle housing and is used to continuously collect the vibration frequency and amplitude data of the spindle, with a measurement range of 0.001-0.5mm.

[0013] The spindle speed adjustment mechanism consists of a photoelectric encoder and an electromagnetic clutch. The photoelectric encoder is coaxially connected to the spindle to detect the spindle speed fluctuation in real time, and its signal output terminal is connected to the control terminal of the electromagnetic clutch.

[0014] Preferably, the vibration sensor has a built-in two-level vibration threshold judgment logic: the first-level warning amplitude threshold is set to 0.05mm, and the second-level adjustment amplitude threshold is set to 0.1mm;

[0015] When the detected spindle amplitude At this time, the dynamic balance control module only records data to the storage unit of the control center and does not trigger other actions;

[0016] When the amplitude is between 0.05 and 0.1 mm, the control center sends a vibration warning message to the operating terminal to remind the operator to pay attention to the processing status.

[0017] When the amplitude Upon activation, the spindle speed adjustment mechanism is immediately triggered, the photoelectric encoder provides real-time speed feedback, and the electromagnetic clutch adjusts the torque distribution in steps of 1-3% of the initial speed until the amplitude drops back to the set value. .

[0018] Preferably, the intelligent temperature control module includes a temperature sensor array, a two-stage linkage flow regulating valve, and a coolant circulation pump;

[0019] The temperature sensor array consists of 3-6 thermocouple temperature sensors or resistance temperature sensors, which are respectively installed on key heat source parts such as the spindle motor housing, grinding wheel flange, and guide rail slider.

[0020] The first-stage valve core of the dual-stage linkage flow regulating valve is used to quickly respond to temperature changes to adjust the coolant flow, and the second-stage valve core is used to maintain a stable flow output.

[0021] The coolant circulation pump is a variable frequency pump, and the signal output terminal of the temperature sensor array is electrically connected to the flow regulating valve control unit to form a temperature-flow closed-loop control.

[0022] Preferably, the target control temperature of the intelligent temperature control module is preset according to the type of material being processed: when processing metal materials, the target temperature is set to 25-35℃; when processing ceramic materials, the target temperature is set to 30-40℃.

[0023] When the temperature sensor array detects the actual temperature With target temperature The difference The flow regulating valve is according to the formula Adjust the coolant flow rate, where This is the initial coolant flow rate. This is the flow adjustment factor;

[0024] when The flow control valve reduces the coolant flow rate to This is to avoid excessive cooling that could cause condensation and condensation on the mechanical structure.

[0025] Preferably, the deformation monitoring module includes at least three six-dimensional force sensors and a data verification unit;

[0026] The six-dimensional force sensor is respectively mounted on the flange connecting the worktable and the spindle, the contact surface between the feed slider and the guide rail, and the bolt connecting the grinding wheel support and the base. The six-dimensional force sensor can be replaced by a strain gauge sensor.

[0027] The data verification unit is used to compare the workpiece deformation converted from any two six-dimensional force sensors. If the two deviate... If the value is 0.02mm, the data is deemed abnormal. On the one hand, a sensor calibration reminder is sent to the control center, and on the other hand, the average deformation value under similar processing conditions in the same period in history is automatically retrieved as temporary data to ensure that the processing is not interrupted.

[0028] Preferably, the data verification unit of the deformation monitoring module also has a sensor fault self-diagnosis function: if the data collected by a certain six-dimensional force sensor exceeds the normal measurement range for three consecutive times, the sensor is determined to be faulty, and the system automatically switches to the backup sensor or uses historical similar working condition data. At the same time, a sensor replacement reminder is sent to the control center to ensure that deformation monitoring is not interrupted.

[0029] Preferably, the control center is equipped with a closed-loop compensation unit, which is based on the workpiece deformation fed back by the deformation monitoring module. Compare with the preset target machining model of the workpiece to calculate the feed rate correction and grinding depth correction;

[0030] The formula for calculating the feed rate correction is as follows: ;

[0031] The formula for calculating the grinding depth correction is: ;

[0032] In the formula, The initial feed rate, This is the initial grinding depth. The preset deformation correction factor has a value range of 0.8-1.2; when At this time, the closed-loop compensation unit does not trigger parameter correction.

[0033] Preferably, the control center includes a data storage unit and a maintenance prediction unit;

[0034] The data storage unit uses an industrial-grade solid-state drive to store vibration / speed data from the dynamic balance control module, temperature / flow data from the intelligent temperature control module, deformation data from the deformation monitoring module, and processing parameter adjustment records. The storage period is ≥3 years, and it supports retrieval by processing task number.

[0035] The maintenance prediction unit establishes the remaining service life of vulnerable components of the equipment based on historical data. The evaluation model calculates the frequency of spindle vibration frequency peaks, the duration of coolant temperature exceeding the threshold, and the variance of workpiece deformation fluctuations by statistically analyzing these factors. ;when At that time, an audible and visual maintenance reminder signal is sent to the operating terminal.

[0036] A control method for a high-precision CNC universal grinding machine system includes the following steps:

[0037] S1: Start the grinding machine. The control center reads the initial parameters corresponding to the current machining task, including the initial spindle speed of 1000-8000 r / min, the initial feed rate of 50-500 mm / min, the initial grinding depth of 0.01-0.1 mm, and the target control temperature, and sends the parameters to each module.

[0038] S2: The dynamic balance control module is activated. The vibration sensor and photoelectric encoder work synchronously to collect the spindle vibration and speed data in real time. The adjustment is triggered according to the threshold logic until the spindle runs stably.

[0039] S3: The intelligent temperature control module starts up, the temperature sensor array monitors the temperature of key heat sources, and controls the two-stage linkage flow regulating valve and coolant circulation pump according to the target temperature and flow adjustment logic to maintain the system temperature stability.

[0040] S4: The deformation monitoring module is activated. The six-dimensional force sensor collects force / torque data of key parts and converts it into deformation. The data verification unit completes the data validity verification and feeds back the valid deformation data to the control center.

[0041] S5: The closed-loop compensation unit in the control center calculates the feed rate and grinding depth correction based on the effective deformation according to the formula, and sends it to the feed servo drive and grinding wheel drive unit to update the machining parameters.

[0042] S6: Repeat S2-S5 until the control center receives the processing task completion signal, stores the processing data of this time to the data storage unit, the maintenance prediction unit updates the remaining service life assessment result of vulnerable parts based on the new data, and the grinding machine is reset to standby state.

[0043] The present invention has the following beneficial effects:

[0044] 1. In this invention, the dynamic balance control module dynamically adjusts the spindle transmission torque distribution by collecting spindle vibration and speed fluctuation data in real time. This not only effectively reduces mechanical vibration during high-speed operation and avoids machining defects such as chatter marks and dimensional deviations caused by vibration, but also creates a low-vibration interference machining environment for the intelligent temperature control module and deformation monitoring module. This lays the foundation for high-precision grinding from the perspective of motion stability and ensures that the grinding machine can maintain consistent machining accuracy under high-speed conditions.

[0045] 2. In this invention, the intelligent temperature control module monitors the temperature of key heat sources in the system in real time and automatically adjusts the flow rate of coolant, which can accurately suppress the thermal deformation of mechanical structures and prevent dimensional and shape errors caused by temperature changes. Especially in long-term continuous processing scenarios, it can effectively avoid the decay of precision. At the same time, in coordination with the dynamic balance control module, it reduces the superimposed interference of vibration-temperature coupling effect on processing precision and ensures the processing reliability of the grinding machine in terms of thermal stability.

[0046] 3. In this invention, the deformation monitoring module collects the deformation of the workpiece and key mechanical connection parts in real time and feeds it back to the control center. The control center calculates the processing parameter correction instructions based on this, forming a closed-loop link of monitoring-calculation-adjustment. This collaboration can not only accurately capture the small deformations caused by force, thermal stress and other factors during the processing, and correct parameters such as feed speed and grinding depth in a timely manner, but also link the dynamic balance and intelligent temperature control modules for fine adjustment. It can achieve micron-level precision control from all dimensions of the processing process, and significantly improve the dimensional consistency and form and position accuracy qualification rate of the finished product. Attached Figure Description

[0047] Figure 1 This is a flowchart of a control method for a high-precision CNC universal grinding machine system according to the present invention;

[0048] Figure 2 This is a framework diagram of a high-precision CNC universal grinding machine system according to the present invention. Detailed Implementation

[0049] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0050] Please see Figure 1 The present invention provides a technical solution: a high-precision CNC universal grinding machine system, the system including a dynamic balance control module, an intelligent temperature control module, a deformation monitoring module and a control center;

[0051] The dynamic balance control module is used to collect spindle vibration data and speed fluctuation data in real time, and to reduce mechanical vibration during high-speed operation by dynamically adjusting the spindle transmission torque distribution;

[0052] The intelligent temperature control module is used to monitor the temperature of key heat sources in the system and automatically adjust the coolant flow rate according to temperature changes to suppress thermal deformation of mechanical structures.

[0053] The deformation monitoring module is used to collect force / torque data of the workpiece and key mechanical connection parts, convert it into workpiece deformation, and feed it back to the control center;

[0054] The control center is connected to the dynamic balance control module, intelligent temperature control module, and deformation monitoring module. It calculates machining parameter correction instructions through the built-in closed-loop compensation unit, and integrates data storage and maintenance prediction functions to achieve coordinated control of each module to ensure machining accuracy and stability.

[0055] The dynamic balance control module includes a vibration sensor and a spindle speed adjustment mechanism;

[0056] The motion sensor is a piezoelectric triaxial vibration sensor, fixed to the outside of the spindle housing, and installed along the three orthogonal directions of the spindle housing: axial, radial (X), and radial (Y). It is used to continuously acquire spindle vibration frequency and amplitude data, with a measurement range of 0.001-0.5 mm and a sampling frequency of 20 kHz. The vibration amplitude synthesis formula is:

[0057] ,

[0058] in The vibration amplitudes are in three directions, respectively. The synthesized amplitude;

[0059] The spindle speed adjustment mechanism consists of a photoelectric encoder and an electromagnetic clutch. The photoelectric encoder is coaxially connected to the spindle to detect the spindle speed in real time. The fluctuation amplitude is calculated using the following formula: Its signal output terminal is connected to the electromagnetic clutch control terminal.

[0060] ,

[0061] when At this time, the electromagnetic clutch triggers torque distribution adjustment: by changing the excitation current (0-3A) to adjust the friction plate pressure, the torque distribution ratio of the main shaft transmission link is adjusted, and the speed is adjusted accordingly. Calculate using the following formula:

[0062] ,

[0063] in The initial adjustment step size is 1%, and subsequent dynamic optimization is performed based on the vibration decay rate (the step size is reduced if the decay is fast, and increased if the decay is slow).

[0064] The electromagnetic clutch can be replaced with a magnetic powder clutch, but the response time will be delayed after the replacement. .

[0065] The vibration sensor has a built-in two-level vibration threshold judgment logic: the first-level warning amplitude threshold is set to... The secondary adjustment amplitude threshold is set to Calibration was performed using a standard test bar: grinding was carried out at a speed of 5000 r / min, and the average vibration amplitude during stable machining was recorded. ,like Then the threshold will be lowered proportionally, and the lowering coefficient will be adjusted accordingly. This ensures that the threshold values ​​match the actual operating conditions of the equipment.

[0066] When the detected spindle amplitude Time: Vibration data is stored in a time-amplitude format in the control center's circular buffer, and a vibration trend curve is generated every minute, with the slope... ,like It only provides advance warning and preparation without triggering other actions;

[0067] when Time: The control center sends a yellow warning to the operating terminal (including the current amplitude, speed, and duration) to remind the operator to pay attention to the processing status. At the same time, it initiates a pre-calculation of speed fine-tuning (predicting the optimal adjustment amount based on historical data). If the warning lasts for more than 5 seconds, the pre-calculated fine-tuning command (adjustment step size) is immediately executed. ).

[0068] when Time: Immediately triggers the spindle speed adjustment mechanism, the photoelectric encoder provides real-time speed feedback, and the adjustment step size is adjusted. Determined dynamically based on the degree of vibration exceeding limits: ( (effective at the time)

[0069] After each adjustment, the speed-amplitude fitting function is used. Based on polynomial fitting:

[0070] Predict amplitude until Stop adjusting.

[0071] The intelligent temperature control module includes a temperature sensor array, a two-stage linkage flow regulating valve, and a coolant circulation pump;

[0072] The temperature sensor array consists of 3-6 thermocouple or resistance temperature sensors, which are installed on key heat source components such as the spindle motor housing, grinding wheel flange, and guide rail slider. After installation, the sensors are calibrated using a constant temperature oil bath (accuracy ±0.05℃), and the deviation values ​​of each sensor at 25℃, 50℃, and 100℃ are recorded. and during data collection through Provide compensation;

[0073] The two-stage linkage flow control valve consists of a first-stage electromagnetic proportional valve (response time ≤0.5s, flow range 0-30L / min) and a second-stage precision servo valve (flow accuracy ±2%, range 10-50L / min). The first-stage valve core is used to quickly respond to sudden temperature changes to adjust the coolant flow, while the second-stage valve core is used to maintain a stable flow output. The coordination logic is as follows:

[0074] When the rate of temperature change (Temperature Sudden Change): Only the first-stage valve actuates, rapidly adjusting the flow rate via a PWM signal (1kHz frequency), resulting in a response delay. ;

[0075] when (Stable temperature change): Two-stage valves work together, with the first-stage valve coarsely adjusted to the target flow rate. Range, second-stage valve fine-tuned to Within this range, ensure stable traffic.

[0076] The coolant circulation pump is a variable frequency pump, specifically a variable frequency centrifugal pump. The signal output terminal of the temperature sensor array is electrically connected to the flow regulating valve control unit, forming a temperature-flow closed loop. Dual closed-loop control is achieved through a pressure sensor and an electromagnetic flow meter.

[0077] Pressure ring: When the outlet pressure deviates At that time, adjust the pump speed. Pressure regulation formula:

[0078] , ;

[0079] Flow loop: After the pressure stabilizes, the speed is finely adjusted through flow feedback to ensure that the actual flow rate deviates from the commanded flow rate. .

[0080] The target temperature of the intelligent temperature control module is preset according to the type of material being processed: 25-35℃ for metal processing and 30-40℃ for ceramic processing, based on the material's thermal conductivity. Preset target temperature :

[0081] Metal materials (aluminum alloy) Titanium alloy ): The better the thermal conductivity, the higher the target temperature can be.

[0082] Ceramic materials (alumina) Zirconium oxide 2): The worse the thermal conductivity, the lower the target temperature needs to be to suppress heat accumulation.

[0083] Temperature control exhibits a lag (lag time) Traffic adjustment needs to be optimized using an advance compensation algorithm:

[0084] When the temperature sensor array detects the actual temperature With target temperature The difference The flow regulating valve is according to the formula Adjust the coolant flow rate, where The initial coolant flow rate is 10 L / min for metal materials and 15 L / min for ceramic materials. For flow adjustment coefficient ( );

[0085] Introducing a delayed compensation term: ( (where the rate of temperature change is...) An additional 10% compensation flow is added to prevent temperature overshoot.

[0086] when (Actual temperature is significantly lower than target temperature):

[0087] The flow regulating valve first reduces the flow rate to Observe the temperature rise trend for 2 seconds.

[0088] If the temperature still does not rise, start the PTC heater (2kW), and adjust the heating power as follows: Adjust the temperature and simultaneously turn on the dehumidifying fan inside the protective cover to prevent condensation caused by low temperature from affecting mechanical precision.

[0089] The deformation monitoring module includes at least three six-dimensional force sensors and a data verification unit;

[0090] The six-dimensional force sensors are respectively mounted on the flange connecting the worktable and spindle, the contact surface between the feed slider and the guide rail, and the bolts connecting the grinding wheel support and the base. The six-dimensional force sensors can be replaced with strain gauge sensors. After replacement, zero-point and range calibration must be performed using a standard force loading device. The correspondence between the strain gauge output signal and the force / torque must be recorded, and a conversion coefficient matrix must be established. During data conversion, the output signal of the strain gauge sensor is calculated using the same multiphysics coupling model as the six-dimensional force sensor to ensure deformation... Data acquisition accuracy deviation Compatibility with the original six-dimensional force sensor data To ensure consistency in deformation data acquisition functionality;

[0091] Three-dimensional force collected by the sensor ) and three-dimensional torque ( The deformation is converted into workpiece deformation through a multiphysics coupling model. :

[0092] ,

[0093] Where E is the elastic modulus of the workpiece material (retrieved from the material database). Let the cross-sectional area be the area subjected to force in each direction. For structural dimensions, This is the torque-force conversion coefficient (based on finite element simulation calibration).

[0094] Deformation of the three sensors Perform three-level verification:

[0095] Level 1 Deviation Verification: Compare the workpiece deformation converted from any two six-dimensional force sensors and calculate the pairwise deviations. ,like Mark an anomaly;

[0096] Secondary trend verification: Calculate the rate of change of deformation. If a certain sensor Deviation from the other two This was determined to be an abnormal trend.

[0097] Level 3 historical verification: Calculates the average deformation value under the same operating conditions in the last 10 instances. If the current value deviates from the mean On the one hand, it sends sensor calibration reminders to the control center, and on the other hand, it automatically retrieves the average deformation values ​​from similar processing conditions in the same historical period. This serves as temporary data to ensure uninterrupted processing.

[0098] The data verification unit of the deformation monitoring module also has a sensor fault self-diagnosis function:

[0099] Measurement range exceeded: If the data collected by a six-dimensional force sensor exceeds the normal measurement range for three consecutive times;

[0100] Data jump: the difference between two adjacent sampled data points (Far exceeding normal deformation fluctuations);

[0101] Communication interruption: No data feedback for 5 consecutive sampling cycles (20ms / cycle);

[0102] If any one of the conditions is met, the sensor is determined to be faulty. At the same time, the machining parameters (rotation speed, feed rate, etc.) at the time of the fault are recorded for subsequent diagnosis.

[0103] Minor fault (only range overrun or data jump): The data verification unit immediately calls the backup sensor (if the system is equipped with one, the response time is [not specified]). The backup sensor and the main sensor adopt a hot backup mode, and the data is updated synchronously.

[0104] Critical Fault (Communication Interruption or Backup Sensor Failure): Automatically activates the historical similar working condition database and simultaneously sends a sensor replacement reminder to the control center to ensure uninterrupted deformation monitoring. It then uses the K-nearest neighbor algorithm (K=5) to retrieve the 5 most similar sets of processing data and calculates the mean deformation value. As temporary data, the feed rate was reduced by 10% to reduce processing risks.

[0105] The control center is equipped with a closed-loop compensation unit, which is based on the workpiece deformation fed back by the deformation monitoring module. First, perform a validity screening:

[0106] Eliminate (The physical meaning is unreasonable) or Data that exceeds the normal processing deformation range;

[0107] Apply a moving average filter to the valid data: This reduces the impact of high-frequency noise.

[0108] Based on the filtered Compared with the preset workpiece target machining model, the feed rate correction and grinding depth correction are calculated:

[0109] Feed rate correction: ;

[0110] Grinding depth correction: ;

[0111] in The initial value is set according to the material hardness, and its range is 0.8-1.2 (1.2 for high-hardness materials, 0.8 for low-hardness materials). At this time, the closed-loop compensation unit does not trigger parameter correction, and the correction amount is transitioned through an exponential smoothing algorithm: This avoids processing shocks caused by sudden parameter changes.

[0112] After machining every 10 workpieces, the deviation between the actual machining accuracy (detected by a coordinate measuring machine) and the target accuracy is compared. ,optimization :

[0113] like (Actual accuracy is lower than expected): ;

[0114] like (Overcorrection): .

[0115] The control center includes a data storage unit and a maintenance and prediction unit;

[0116] The data storage unit uses an industrial-grade solid-state drive to store vibration / speed data from the dynamic balance control module, temperature / flow data from the intelligent temperature control module, deformation data from the deformation monitoring module, and processing parameter adjustment records. The storage period is ≥3 years, and it supports retrieval by processing task number.

[0117] The maintenance prediction unit establishes the remaining service life of vulnerable parts of the equipment based on historical data. The evaluation model calculates the frequency of spindle vibration frequency peaks, the duration of coolant temperature exceeding the threshold, and the variance of workpiece deformation fluctuations by statistically analyzing these factors. :

[0118] Feature extraction: Extracting the number of vibration peaks from historical data Duration of overheating Variation and variance ;

[0119] Initial model: Based on 100 sets of complete grinding wheel life data, established through multiple linear regression:

[0120] ;

[0121] Dynamic update: For every 20 new sets of data, the model coefficients are optimized using gradient descent (0.4, 0.3, 0.3), reducing the prediction error from the initial ±10% to within ±5%.

[0122] when At that time, push notifications will be sent according to the following levels:

[0123] Level 1 Reminder (50h): Sends a text reminder to the operating terminal, including the remaining lifespan and recommended replacement time window;

[0124] Level 2 alert (30h): Sends an audible and visual alarm, along with a grinding wheel wear trend curve (predicted based on historical data).

[0125] Level 3 Reminder (10h): Forcefully pops up the maintenance interface, displays the replacement steps (including torque parameters and installation accuracy requirements), and locks the high-speed grinding mode (maximum speed limited to 50% of the rated value) until maintenance is completed.

[0126] A control method for a high-precision CNC universal grinding machine system includes the following steps:

[0127] S1: Start the grinding machine. The control center reads the initial parameters corresponding to the current machining task, including the initial spindle speed of 1000-8000 r / min, the initial feed rate of 50-500 mm / min, the initial grinding depth of 0.01-0.1 mm, and the target control temperature, and sends the parameters to each module.

[0128] S2: The dynamic balance control module is activated. The vibration sensor and photoelectric encoder work synchronously to collect the spindle vibration and speed data in real time. The adjustment is triggered according to the threshold logic until the spindle runs stably.

[0129] S3: The intelligent temperature control module starts up, the temperature sensor array monitors the temperature of key heat sources, and controls the two-stage linkage flow regulating valve and coolant circulation pump according to the target temperature and flow adjustment logic to maintain the system temperature stability.

[0130] S4: The deformation monitoring module is activated. The six-dimensional force sensor collects force / torque data of key parts and converts it into deformation. The data verification unit completes the data validity verification and feeds back the valid deformation data to the control center.

[0131] S5: The closed-loop compensation unit in the control center calculates the feed rate and grinding depth correction based on the effective deformation according to the formula, and sends it to the feed servo drive and grinding wheel drive unit to update the machining parameters.

[0132] S6: Repeat S2-S5 until the control center receives the processing task completion signal, stores the processing data of this time to the data storage unit, the maintenance prediction unit updates the remaining service life assessment result of vulnerable parts based on the new data, and the grinding machine is reset to standby state.

[0133] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus.

[0134] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-precision numerical control universal grinding machine system, characterized by, The system comprises a dynamic balance control module, an intelligent temperature control module, a deformation monitoring module and a control center; The dynamic balance control module is used for collecting spindle vibration data and rotating speed fluctuation data in real time, weakening mechanical vibration during high-speed operation by dynamically adjusting spindle transmission torque distribution; The intelligent temperature control module is used for monitoring the temperature of key heat sources of the system, automatically adjusting the flow of cooling liquid according to temperature changes, and inhibiting mechanical structure thermal deformation; The deformation monitoring module is used for collecting force / torque data of workpieces and key mechanical connection parts, converting the force / torque data into workpiece deformation variables and feeding back the workpiece deformation variables to the control center; The control center is in communication connection with the dynamic balance control module, the intelligent temperature control module and the deformation monitoring module, calculates processing parameter correction instructions through a built-in closed-loop compensation unit, integrates data storage and maintenance prediction functions, realizes collaborative control of the modules and guarantees processing precision and stability; The control center is configured with a closed-loop compensation unit, which is based on the workpiece deformation variable fed back by the deformation monitoring module In comparison with the preset workpiece target machining model, the feed speed correction amount and the grinding depth correction amount are calculated. The feed speed correction amount calculation formula is: ; The grinding depth correction amount calculation formula is: ; In the formula, is the initial feed speed, is the initial grinding depth, is a preset deformation correction coefficient, and the value range is 0.8-1.2; when , the closed-loop compensation unit does not trigger parameter correction.

2. The high-precision CNC universal grinding machine system according to claim 1, characterized in that: The dynamic balance control module comprises a vibration sensor and a spindle rotating speed adjusting mechanism; The vibration sensor is fixed to the outside of a spindle shell and is used for continuously collecting spindle vibration frequency and amplitude data, with a measurement range of 0.001-0.5mm; The spindle rotating speed adjusting mechanism comprises an optical encoder and an electromagnetic clutch, the optical encoder is coaxially connected with the spindle, detects the rotating speed fluctuation amplitude of the spindle in real time, and a signal output end of the optical encoder is connected with a control end of the electromagnetic clutch.

3. The high-precision CNC universal grinding machine system according to claim 2, characterized in that, The vibration sensor is internally provided with two-stage vibration threshold value judgment logic, a first-stage early warning amplitude threshold value is set to 0.05mm, and a second-stage adjustment amplitude threshold value is set to 0.1mm; When the detected spindle amplitude is less than the threshold value, the dynamic balance control module only records data to the storage unit of the control center, and does not trigger other actions. When the amplitude is between 0.05mm and 0.1mm, the control center sends vibration early warning information to an operation terminal, prompting an operator to pay attention to the processing state; When amplitude , immediately trigger the spindle speed regulation mechanism action, photoelectric encoder feedback real-time speed, electromagnetic clutch according to the initial speed of 1-3% step adjustment torque distribution, until the amplitude back to .

4. The high-precision CNC universal grinding machine system of claim 1, wherein: The intelligent temperature control module comprises a temperature sensor array, a two-stage linkage flow adjusting valve and a cooling liquid circulating pump; The temperature sensor array comprises 3-6 thermocouple temperature sensors or thermistor temperature sensors, which are respectively installed on a spindle motor shell, a grinding wheel flange and a guide rail slider; The first-stage valve core of the two-stage linkage flow adjusting valve is used for quickly responding to temperature mutation to adjust the flow of cooling liquid, and the second-stage valve core is used for maintaining stable flow output; The cooling liquid circulating pump is a variable frequency pump, a signal output end of the temperature sensor array is electrically connected with a flow adjusting valve control unit, and temperature-flow closed-loop control is formed.

5. The high-precision CNC universal grinding machine system according to claim 4, characterized in that, The target control temperature of the intelligent temperature control module is preset according to the type of processing materials, the target temperature is set to 25-35℃ when processing metal materials, and the target temperature is set to 30-40℃ when processing ceramic materials; When the temperature sensor array detects the actual temperature With target temperature The difference The flow regulating valve is according to the formula Adjust the coolant flow rate, where This is the initial coolant flow rate. This is the flow adjustment factor; When The flow regulating valve falls back the coolant flow to Avoid excessive cooling leading to mechanical structure condensation dew.

6. The high-precision CNC universal grinding machine system according to claim 1, characterized in that: The deformation monitoring module comprises at least three six-dimensional force sensors and a data verification unit; The six-dimensional force sensors are respectively arranged at a workbench and spindle connection flange, a feeding slider and guide rail contact surface and a grinding wheel frame support seat and base connection bolt, and the six-dimensional force sensors can be replaced with strain gauge sensors. The data verification unit is used to compare the workpiece deformation converted from any two six-dimensional force sensors. If the two deviate... If the value is 0.02mm, the data is deemed abnormal. On the one hand, a sensor calibration reminder is sent to the control center, and on the other hand, the average deformation value under similar processing conditions in the same period in history is automatically retrieved as temporary data to ensure that the processing is not interrupted.

7. The high-precision CNC universal grinding machine system according to claim 6, characterized in that: The data verification unit of the deformation monitoring module also has a sensor fault self-diagnosis function: if the data collected by a six-dimensional force sensor for three times continuously exceeds the normal measurement range, it is determined that the sensor is faulty, the standby sensor is automatically switched to, or the historical similar working condition data is enabled, and a sensor replacement reminder is sent to the control center, ensuring that the deformation monitoring is not interrupted.

8. The high-precision CNC universal grinding machine system according to claim 1, characterized in that: The control center includes a data storage unit and a maintenance prediction unit; The data storage unit uses an industrial-grade solid-state hard disk to store vibration / rotation speed data of the dynamic balance control module, temperature / flow data of the intelligent temperature control module, deformation data of the deformation monitoring module, and processing parameter adjustment records, with a storage period of ≥3 years and support for retrieval by processing task number; The maintenance prediction unit establishes the remaining service life of the vulnerable components of the equipment based on historical data The evaluation model calculates by counting the occurrence times of the spindle vibration frequency peak value, the duration when the coolant temperature exceeds the threshold value, and the fluctuation variance of the workpiece deformation variable When , an audible and visual maintenance reminder signal is sent to the operation terminal.

9. A control method for a high-precision numerical control universal grinding machine system, using the high-precision numerical control universal grinding machine system of any one of claims 1-8, comprising the following steps: S1: Start the grinding machine, and the control center reads the initial parameters corresponding to the current processing task, including the initial spindle speed 1000-8000 r / min, the initial feed speed 50-500 mm / min, the initial grinding depth 0.01-0.1 mm, and the target control temperature, and sends the parameters to each module; S2: The dynamic balance control module is started, the vibration sensor and the photoelectric encoder work synchronously, the spindle vibration and rotation speed data are collected in real time, and whether the adjustment is triggered is judged according to the threshold value logic until the spindle runs stably; S3: The intelligent temperature control module is started, the temperature sensor array monitors the temperature of the key heat source, and the two-stage linkage flow regulating valve and the cooling liquid circulating pump are controlled according to the target temperature and flow adjustment logic to maintain the stability of the system temperature; S4: The deformation monitoring module is started, the six-dimensional force sensor collects force / torque data of the key parts and converts it into deformation, and the data verification unit completes the data validity verification and feeds back the effective deformation data to the control center; S5: The closed-loop compensation unit of the control center calculates the feed speed and grinding depth correction amount based on the effective deformation according to the formula, and sends it to the feed servo driver and the grinding wheel driving unit to update the processing parameters; S6: Repeat S2-S5 until the control center receives the processing task completion signal, stores the processing data to the data storage unit, and the maintenance prediction unit updates the remaining service life evaluation result of the vulnerable parts based on the new data, and the grinding machine is reset to standby state.

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