Workpiece vibration suppression structure for cutting and balancing adjustment method thereof

Abstract

The application discloses a workpiece vibration suppression structure for cutting machining and a balance adjusting method thereof, and relates to the technical field of cutting machining.The workpiece vibration suppression structure comprises a vibration acquisition module, a rotating speed detection module, a data processing module, a display and early warning module and a communication module; the vibration acquisition module acquires a workpiece vibration signal; the rotating speed detection module detects the rotating speed of a main shaft and calculates a cutting speed; the data processing module analyzes the correlation between the cutting speed and vibration intensity, compares a preset threshold value, and realizes early warning; and the communication module realizes signal transmission with an external execution mechanism.The adjusting method dynamically solves the vibration problem caused by unreasonable cutting speed through initialization setting, real-time data acquisition, data processing analysis, cutting speed adjustment or mechanical balance adjustment.The application can realize real-time monitoring of vibration and cutting speed in the cutting process, accurate positioning of vibration causes, dynamic adjustment of machining balance, improvement of machining quality and efficiency, and prolongation of the service life of equipment.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of cutting machining, more particularly to a workpiece vibration suppression structure for cutting machining and a balance adjustment method thereof. BACKGROUND

[0002] In the process of mechanical cutting machining, cutting speed is one of the key parameters affecting machining quality, efficiency and equipment stability. Reasonable cutting speed can effectively improve material removal rate, ensure workpiece machining precision and reduce tool wear. Unreasonable cutting speed, whether too high or too low, will cause a series of problems, of which workpiece vibration is one of the most prominent problems.

[0003] When the cutting speed is too high, the cutting temperature between the tool and the workpiece will rise sharply, causing the tool material performance to decline and the blade wear to intensify, thereby increasing the cutting force fluctuation and causing severe vibration of the workpiece and the tool. When the cutting speed is too low, the plastic deformation of the cutting layer metal increases, the cutting force increases significantly, and the cutting process is discontinuous, which is prone to chatter, also causing workpiece vibration. Workpiece vibration not only reduces the machining precision and surface quality of the workpiece, producing defects such as corrugation and burr, but also intensifies the wear of the tool and equipment, shortening their service life. In severe cases, it may even cause the machining process to be interrupted and safety accidents to occur.

[0004] In the prior art, the monitoring of cutting machining vibration mostly uses a single vibration sensor for signal acquisition, which can only monitor the vibration amplitude and frequency and cannot correlate and analyze the vibration with the cutting speed, making it difficult to accurately locate the vibration cause as being unreasonable cutting speed. Moreover, the existing vibration adjustment method mostly uses a fixed parameter adjustment method, which lacks real-time and dynamic adaptability and cannot accurately adjust according to the actual vibration situation and cutting speed changes in the cutting process. In addition, some monitoring devices have a single function and can only achieve vibration early warning without active adjustment capability, requiring manual intervention for adjustment, which is low in efficiency and the adjustment effect depends on the experience of the operator, making it difficult to ensure the accuracy and timeliness of the adjustment.

[0005] Therefore, it is necessary to propose a workpiece vibration suppression structure for cutting machining and a balance adjustment method thereof to solve the above problems. SUMMARY

[0006] The purpose of the present application is to solve the technical defects that cutting machining vibration monitoring cannot correlate with cutting speed and accurately locate the vibration cause, and the adjustment method lacks real-time and dynamic adaptability. The present application provides a workpiece vibration monitoring device for cutting machining and a balance adjustment method thereof, aiming to realize real-time and synchronous monitoring of cutting speed and workpiece vibration, accurately analyze the problems caused by unreasonable cutting speed, and provide a workpiece vibration suppression structure for cutting machining and a balance adjustment method thereof.

[0007] The application specifically adopts the following technical solutions to achieve the above-mentioned purpose:

[0008] A workpiece vibration suppression structure for cutting machining and a balance adjustment method thereof, comprising a vibration acquisition module, a rotating speed detection module, a data processing module, a display warning module and a communication module.

[0009] The vibration acquisition module is arranged at a workpiece clamping end of the cutting machining equipment, and is used for acquiring vibration signals in a workpiece cutting process in real time, wherein the vibration signals include vibration amplitude and vibration frequency.

[0010] The rotating speed detection module is connected with a main shaft of the cutting machining equipment, and is used for detecting the rotating speed of the main shaft in real time, and calculating the current cutting speed according to the rotating speed of the main shaft and the diameter of a tool.

[0011] The data processing module is connected with the vibration acquisition module and the rotating speed detection module respectively, and is used for receiving the vibration signals and the cutting speed data, filtering and amplifying the vibration signals, comparing the preset vibration threshold value with the current vibration amplitude, and analyzing the correlation between the cutting speed and the vibration intensity.

[0012] The display warning module is connected with the data processing module, and is used for displaying the real-time cutting speed, the vibration amplitude and the vibration frequency data, and sending a warning signal when the vibration amplitude exceeds the preset threshold value.

[0013] The communication module is connected with the data processing module, and is used for realizing signal transmission between the data processing module and an upper computer.

[0014] Further, the vibration acquisition module adopts a piezoelectric acceleration sensor, the sampling frequency of the piezoelectric acceleration sensor is not less than 1000 Hz, and the measurement range is 0-50g, wherein g is the gravitational acceleration.

[0015] Further, the data processing module is built-in with a cutting speed-vibration database, the database stores the optimal cutting speed range and the corresponding allowed vibration threshold value corresponding to different workpiece materials and tool types, and the data processing module can call the reference data in the database according to the input workpiece material and tool type information.

[0016] Further, a power module is further included, the power module provides stable power supply for the vibration acquisition module, the rotating speed detection module, the data processing module, the display warning module and the communication module, and the power module supports AC 220V input and DC 12V output.

[0017] Further, the communication module adopts RS485, Ethernet or wireless communication mode, and the wireless communication mode includes WiFi, Bluetooth or LoRa communication.

[0018] Further, the display warning module comprises a touch screen, an alarm indicator and a buzzer, the touch screen is used for parameter input and data display, and the alarm indicator and the buzzer cooperate to send an audible and light warning signal.

[0019] The cutting workpiece balance adjustment method comprises the following steps:

[0020] S1: initialization setting, inputting workpiece material type, tool type and size parameters, a data processing module calling a built-in cutting speed-vibration database to determine an initial cutting speed range and a corresponding allowed vibration threshold value;

[0021] S2: starting a cutting machining equipment, a vibration collection module collecting workpiece vibration signals in real time, a speed detection module detecting a main shaft speed in real time and calculating a current cutting speed, and transmitting collected data to the data processing module;

[0022] S3: the data processing module filtering and amplifying the vibration signals, extracting vibration amplitude and vibration frequency, comparing the current cutting speed with the initial cutting speed range, and comparing the current vibration amplitude with the allowed vibration threshold value;

[0023] S4: if the current vibration amplitude does not exceed the allowed vibration threshold value, maintaining the current cutting speed to continue machining; if the current vibration amplitude exceeds the allowed vibration threshold value, the data processing module analyzes the change trend of the cutting speed and the vibration amplitude, and determines that the dominant factor of vibration exceeding the standard is that the cutting speed is unreasonable;

[0024] S5: the data processing module calculates an optimal cutting speed adjustment value based on the cutting speed-vibration database and the current vibration data, and sends a speed adjustment instruction to a main shaft speed control unit of the cutting machining equipment through a communication module by using a PID regulation algorithm;

[0025] S6: repeating steps S2-S5, real-time monitoring vibration signals and cutting speed, dynamically adjusting the cutting speed, until the vibration amplitude is stabilized within the allowed vibration threshold value.

[0026] Further, in step S5, the input of the PID regulation algorithm is a vibration amplitude deviation value, and the output is a cutting speed adjustment value, and the vibration amplitude deviation value is a difference value between the current vibration amplitude and the allowed vibration threshold value.

[0027] Further, the proportional coefficient Kp of the PID regulation algorithm is in a range of 5-15, the integral coefficient Ki is in a range of 0.05-0.2, the differential coefficient Kd is in a range of 0.3-1.0, and the cutting speed adjustment value of the PID regulation algorithm is limited to ±20 m / min.

[0028] Further, the data processing module adopts a low-pass filtering algorithm to process the vibration signal, and the filtering cutoff frequency is 500 Hz, which is used to remove the environmental interference signal.

[0029] The beneficial effects of the present application are as follows:

[0030] 1. The monitoring device realizes real-time synchronous monitoring of cutting speed and workpiece vibration, calculates the cutting speed through the rotation speed detection module, collects the vibration signal through the vibration acquisition module, and analyzes the correlation between the two through the data processing module, which can accurately locate whether the vibration exceeds the standard is caused by unreasonable cutting speed, solving the problem that the existing technology cannot correlate the cutting speed and accurately locate the vibration cause.

[0031] 2. The present application adopts a PID regulation algorithm, combined with a built-in cutting speed-vibration database, which can dynamically adjust the cutting speed according to real-time vibration data and cutting speed, has good real-time and dynamic adaptability, and avoids the defects of fixed parameter adjustment and poor regulation effect in the prior art.

[0032] 3. The present application integrates monitoring, early warning and regulation functions, can display processing data in real time, timely alarm when the vibration exceeds the standard, and actively issue regulation instructions without human intervention, which improves the processing efficiency, reduces the labor intensity of the operator, and at the same time ensures the accuracy and timeliness of the regulation. BRIEF DESCRIPTION OF DRAWINGS

[0033] Figure 1 is a structural schematic diagram of the present application;

[0034] Figure 2 is a step schematic diagram of the present application. DETAILED DESCRIPTION

[0035] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0036] Please refer to FIG. 1-2, a workpiece vibration suppression structure and its balancing regulation method for cutting machining, including a vibration acquisition module, a rotation speed detection module, a data processing module, a display and warning module and a communication module;

[0037] The vibration acquisition module is arranged at the workpiece clamping end or the tool mounting end of the cutting machining equipment, and is used for acquiring vibration signals in a workpiece cutting process in real time. The vibration signals include vibration amplitudes and vibration frequencies. Preferably, the vibration acquisition module adopts a piezoelectric acceleration sensor, the sampling frequency of which is not less than 1000 Hz, and the measurement range is 0-50 g. The piezoelectric acceleration sensor can accurately capture high-frequency and low-frequency vibration signals, and adapt to the monitoring requirements of different cutting conditions.

[0038] The rotation speed detection module is connected with the main shaft of the cutting machining equipment, and is used for detecting the rotation speed of the main shaft in real time, and calculating the current cutting speed according to the rotation speed of the main shaft and the diameter of the tool. The rotation speed detection module can adopt an optical encoder or a Hall sensor, has high measurement accuracy and fast response speed, can feed back the rotation speed change of the main shaft in real time, and ensures the accuracy of the calculation of the cutting speed. The calculation formula of the cutting speed is: v = πdn / 1000, wherein v is the cutting speed (m / min), d is the diameter of the tool (mm), and n is the rotation speed of the main shaft (r / min).

[0039] The data processing module is connected with the vibration acquisition module and the rotation speed detection module respectively, is used for receiving vibration signals and cutting speed data, filtering and amplifying the vibration signals, removing environmental interference signals, and extracting effective vibration characteristic parameters. Meanwhile, the data processing module is provided with a cutting speed-vibration database, the database stores optimal cutting speed ranges and corresponding allowed vibration thresholds corresponding to different workpiece materials and tool types, the data processing module can call the reference data in the database according to the input information of the workpiece material and the tool type, compare the preset vibration threshold with the current vibration amplitude, analyze the correlation between the cutting speed and the vibration intensity, and judge whether the vibration exceeds the standard is caused by unreasonable cutting speed.

[0040] The display and warning module is connected with the data processing module, adopts a touch screen or a liquid crystal display screen, and is used for displaying the current cutting speed, vibration amplitude, vibration frequency data and equipment running state in real time. When the vibration amplitude exceeds the preset threshold, a warning signal is sent through an audible and visual alarm to remind the operator to pay attention to the equipment running state.

[0041] The communication module is connected with the data processing module, can adopt an RS485, Ethernet or wireless communication mode, is used for realizing signal transmission of the data processing module or the upper computer, sending the adjustment instructions of the data processing module to an executing mechanism, and uploading real-time data to the upper computer, so as to facilitate remote monitoring and data tracing.

[0042] The device further includes a power module, which provides stable power supply for the vibration acquisition module, the rotation speed detection module, the data processing module, the display and warning module and the communication module. The power module supports AC 220V input and DC 12V output, has overvoltage and overcurrent protection functions, and ensures stable and reliable operation of the device.

[0043] The communication module adopts RS485, Ethernet or wireless communication mode, and the wireless communication mode includes WiFi, Bluetooth or LoRa communication.

[0044] The display warning module includes a touch screen, an alarm indicator and a buzzer, the touch screen is used for parameter input and data display, and the alarm indicator and the buzzer cooperate to emit a sound and light warning signal.

[0045] The application provides a cutting workpiece balance adjusting method, which comprises the following steps:

[0046] S1: initialization setting, an operator inputs workpiece material type, tool type and size parameter through the display warning module, a data processing module calls a built-in cutting speed-vibration database, determines an initial cutting speed range matched with a current machining condition and a corresponding allowed vibration threshold value, and completes parameter initialization of the device.

[0047] S2: starting a cutting machining equipment, a vibration acquisition module acquires vibration signals in a workpiece cutting process in real time, a speed detection module detects a main shaft speed in real time, and a current cutting speed is calculated according to a tool diameter, and the vibration acquisition module and the speed detection module transmit collected data to the data processing module in real time.

[0048] S3: the data processing module performs filtering, amplification and other pretreatments on the received vibration signals, removes environmental interference in the cutting process, and extracts effective characteristic parameters such as vibration amplitude and vibration frequency; at the same time, the current cutting speed is compared with the initial cutting speed range of the initialization setting, the current vibration amplitude is compared with the allowed vibration threshold value, and whether the cutting speed is in a reasonable range and whether the vibration is over standard is preliminarily judged.

[0049] S4: if the current vibration amplitude does not exceed the allowed vibration threshold value, it is indicated that the current cutting speed is reasonable, the machining state is stable, and the current cutting speed is kept to continue machining; if the current vibration amplitude exceeds the allowed vibration threshold value, the data processing module further analyzes the change trend of the cutting speed and the vibration amplitude, combines the reference data in the cutting speed-vibration database, and determines that the dominant factor of vibration over standard is that the cutting speed is unreasonable.

[0050] S5: the data processing module calculates an optimal cutting speed adjustment value based on the reference data in the cutting speed-vibration database and the current vibration data, and adopts a PID adjusting algorithm. The input of the PID adjusting algorithm is a vibration amplitude deviation value, and the output is a cutting speed adjustment amount. Through proportional, integral and differential adjustment, the cutting speed is accurately adjusted. The data processing module sends a speed adjustment instruction to a main shaft speed control unit of the cutting machining equipment through the communication module, adjusts the main shaft speed, and further changes the cutting speed.

[0051] S6: Repeat steps S2-S5, the vibration acquisition module and the rotational speed detection module continuously collect data, the data processing module analyzes and processes in real time, dynamically adjusts the cutting speed, until the vibration amplitude is stable within the allowable vibration threshold, ensuring the stability of the machining process.

[0052] The proportional coefficient Kp of the PID regulation algorithm is in the range of 5-15, the integral coefficient Ki is in the range of 0.05-0.2, and the differential coefficient Kd is in the range of 0.3-1.0, and the cutting speed adjustment amount of the PID regulation algorithm is limited to ±20 m / min.

[0053] The data processing module uses a low-pass filter algorithm to process the vibration signal, and the filter cutoff frequency is 500 Hz, which is used to remove environmental interference signals

[0054] In step S5, the mathematical model of the PID regulation algorithm is as follows:

[0055] 1. Basic control formula

[0056] The discrete calculation formula of the position type PID control algorithm is as follows: Δv(k)=Kp×e(k)+Ki×∑e(i) (i from 0 to k) +Kd×[e(k)-e(k-1)]

[0057] Δv(k): cutting speed adjustment amount at the kth sampling (unit: m / min);

[0058] e(k): vibration amplitude deviation at the kth sampling (e(k)=current vibration amplitude-allowable vibration threshold, unit: g);

[0059] e(k-1): vibration amplitude deviation at the (k-1)th sampling;

[0060] Kp: proportional coefficient (dimensionless);

[0061] Ki: integral coefficient (dimensionless);

[0062] Kd: differential coefficient (dimensionless).

[0063] 2. Functions and roles of each link

[0064] Proportional link (Kp×e(k)): directly output the adjustment amount according to the current deviation, with the fastest response speed. The larger the deviation, the larger the adjustment amount, which quickly suppresses the vibration amplitude exceeding the threshold, but using it alone may have a steady-state error.

[0065] Integral link (Ki×∑e(i)): accumulates historical deviations and outputs adjustment amount, eliminating the steady-state error left by the proportional link. When there is a small persistent deviation, the integral link gradually increases the adjustment amount to ensure that the vibration amplitude is long-term stable within the threshold.

[0066] Derivative term (Kd x [e(k) - e(k-1)]): Output the adjustment amount according to the rate of change of the deviation, predict the trend of deviation change. Advance to suppress the expansion of the deviation, reduce the overshoot in the adjustment process, and improve the stability of the system.

[0067] III. Algorithm parameter setting and optimization

[0068] 1. Initial parameter value range

[0069] Combined with the characteristics of cutting processing scene, the initial parameter setting needs to match the vibration response speed and the cutting speed adjustment range:

[0070] Proportional coefficient Kp: Value range 5-15, take larger value (10-15) when workpiece hardness is high, and take smaller value (5-10) when soft material;

[0071] Integral coefficient Ki: Value range 0.05-0.2, avoid integral saturation leading to adjustment lag, take smaller value for high-frequency vibration scene (vibration frequency > 100Hz);

[0072] Derivative coefficient Kd: Value range 0.3-1.0, suppress frequent fluctuation of cutting speed, take larger value when tool diameter is larger (> 20mm).

[0073] 2. Parameter self-optimization mechanism

[0074] The data processing module has built-in parameter optimization logic, which dynamically adjusts the PID parameters according to real-time processing data:

[0075] When the overshoot of vibration amplitude > 30% (i.e. the adjusted vibration amplitude exceeds the threshold by more than 30%), decrease Kp and increase Kd;

[0076] When the steady-state deviation duration > 5s, increase Ki;

[0077] When the cutting speed adjustment frequency > 10 times / min, decrease Kp and Kd to avoid system oscillation.

[0078] IV. Algorithm execution process

[0079] Data preprocessing: After the data processing module filters the signal of the vibration acquisition module, the current vibration amplitude is extracted, and the deviation e(k) is calculated;

[0080] Deviation judgment: If e(k) ≤ 0, the PID algorithm outputs Δv = 0, maintaining the current cutting speed;

[0081] Three-link operation: Calculate the output values of the proportional, integral, and derivative links respectively, and superimpose to get the total adjustment amount Δv(k);

[0082] Adjustment amount constraint: limit Δv(k) in a reasonable range (±20 m / min) to avoid sudden cutting speed changes leading to secondary vibration;

[0083] Instruction output: convert Δv(k) into spindle speed adjustment instruction, calculate target speed through the formula n=1000(v+Δv) / (πd), and send it to the spindle control unit through the communication module;

[0084] Iterative update: every sampling period is 10ms-50ms, synchronized with the vibration acquisition module sampling frequency, repeat the above steps, dynamically optimize the adjustment amount. Embodiment

[0085] This embodiment provides a workpiece vibration monitoring device for cutting processing, which includes a vibration acquisition module 1, a speed detection module 2, a data processing module 3, a display and warning module 4, a communication module 5 and a power module 6.

[0086] The vibration acquisition module 1 uses a piezoelectric acceleration sensor with model CA-YD-107, which is set at the workpiece clamping end of the cutting processing equipment. Its sampling frequency is 2000Hz, and the measurement range is 0-50g. It can accurately collect the vibration signals of the workpiece during cutting, including vibration amplitude and vibration frequency, and transmit the collected analog vibration signals to the data processing module 3.

[0087] The speed detection module 2 uses an optical encoder with model E6B2-CWZ6C, which is connected with the spindle of the cutting processing equipment, and can detect the spindle speed in real time. The detection accuracy is 1r / min, and the response time is less than 1ms. The speed detection module 2 transmits the detected spindle speed signal to the data processing module 3. The data processing module 3 calculates the current cutting speed through the formula v=πdn / 1000 according to the preset tool diameter, where the tool diameter can be input by the operator through the display and warning module 4.

[0088] The data processing module 3 uses a microcontroller with model STM32F407, which has a built-in cutting speed-vibration database. The database stores the optimal cutting speed range and the allowed vibration threshold value corresponding to common workpiece materials such as carbon steel, aluminum alloy, copper alloy, and common tool types such as hard alloy knife and high-speed steel knife. After receiving the analog vibration signal transmitted by the vibration acquisition module 1, the data processing module 3 converts it into a digital signal through the built-in A / D converter, and then performs low-pass filtering to remove interference signals with a frequency higher than 500Hz, and extracts the vibration amplitude and vibration frequency. At the same time, the calculated current cutting speed is compared with the optimal cutting speed range in the database, and the extracted vibration amplitude is compared with the allowed vibration threshold value to analyze their correlation.

[0089] The display and early warning module 4 adopts a touch screen with a model of TFT3.5, is connected with the data processing module 3 through an SPI interface, and displays information such as a current cutting speed, a vibration amplitude, a vibration frequency, a workpiece material, a tool type and the like in real time. When the vibration amplitude exceeds an allowable vibration threshold value, an alarm indicator light on the touch screen is turned on, and a buzzer emits an alarm sound with a frequency of 1 kHz, so that sound and light early warning is realized.

[0090] The communication module 5 adopts a communication module with a model of RS485, is connected with the data processing module 3 through a UART interface, and realizes signal transmission of the data processing module 3 and the host computer 8. The data processing module 3 can send an adjustment instruction to a main shaft speed control unit to adjust the main shaft speed, and simultaneously upload real-time monitoring data to the host computer 8, so as to facilitate remote monitoring and data storage.

[0091] The power module 6 adopts a voltage stabilizing module with a model of LM2596, supports AC 220V input, and outputs DC 12V voltage, so as to provide stable power supply for the vibration acquisition module 1, the speed detection module 2, the data processing module 3, the display and early warning module 4 and the communication module 5, and has overvoltage and overcurrent protection functions. When the input voltage exceeds 240V or the output current exceeds 2A, the power module 6 automatically cuts off the power supply, so as to protect the safety of the device.

[0092] The embodiment also provides a cutting workpiece balance adjustment method. The specific steps are as follows:

[0093] S1: initialization setting. An operator inputs, through a touch screen of the display and early warning module 4, that a workpiece material is carbon steel, a tool type is a hard alloy tool, and a tool diameter is 10 mm. The data processing module 3 calls a built-in cutting speed-vibration database to determine that an initial cutting speed range is 100-150 m / min, and an allowable vibration threshold value is 5g.

[0094] S2: starting a cutting machining device. An initial main shaft speed is set to 3820r / min. According to a cutting speed calculation formula v=π×10×3820 / 1000≈120m / min, the initial cutting speed is in the initial cutting speed range. The vibration acquisition module 1 acquires workpiece vibration signals in real time, and the speed detection module 2 detects the main shaft speed in real time. The two modules transmit the collected data to the data processing module 3 in real time.

[0095] S3: The data processing module 3 performs low-pass filtering processing on the vibration signals, extracts a vibration amplitude of 3g and a vibration frequency of 100Hz, compares the current cutting speed 120m / min with the initial cutting speed range 100-150m / min, and determines that the current cutting speed is in a reasonable range. The current vibration amplitude 3g is compared with the allowable vibration threshold value 5g, and it is determined that the current vibration amplitude does not exceed the threshold value, and the current machining state is stable.

[0096] S4: During the machining process, the spindle speed gradually increases to 4775 r / min, and the current cutting speed is calculated to be 150 m / min, reaching the upper limit of the initial cutting speed range; at this time, the vibration amplitude collected by the vibration collection module 1 increases to 6g, exceeding the allowable vibration threshold of 5g. The data processing module 3 analyzes the change trend of the cutting speed and the vibration amplitude, finds that when the cutting speed increases from 120 m / min to 150 m / min, the vibration amplitude increases from 3g to 6g, and the two are positively correlated, and determines that the vibration exceeds the standard is caused by the too high cutting speed.

[0097] S5: The data processing module 3 calculates the cutting speed adjustment value by using the PID adjustment algorithm, the proportional coefficient Kp of the PID adjustment algorithm is 5, the integral coefficient Ki is 0.1, and the differential coefficient Kd is 0.5, the input quantity is the vibration amplitude deviation value 1g (6g-5g), and the cutting speed adjustment value is calculated to be -10 m / min, that is, the target cutting speed is 140 m / min. According to the target cutting speed, the spindle speed n = 1000v / (πd) = 1000x140 / (πx10)≈4456r / min, the data processing module 3 sends the speed adjustment instruction to the spindle speed control unit through the communication module 5, and adjusts the spindle speed to 4456r / min.

[0098] S6: Repeat steps S2-S5, the vibration collection module 1 collects the adjusted vibration amplitude of 4g, which is lower than the allowable vibration threshold of 5g, the cutting speed is 140 m / min, which is in the optimal cutting speed range, the machining state is restored to stable, and the current parameters are continuously maintained for machining.

[0099] It should be noted that in this paper, relationship terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between the entities or operations. Moreover, the terms "include", "contain" or any other variant thereof are intended to cover non-exclusive inclusion, so that the process, method, article or equipment including a series of elements not only includes those elements, but also includes other elements not explicitly listed or inherent to such process, method, article or equipment. Without more limitation, the element defined by the statement "including a…" does not exclude the presence of another identical element in the process, method, article or equipment including the element.

[0100] Although the embodiments of the present application have been shown and described, it will be understood by those of ordinary skill in the art that various changes, modifications, replacements and variations of the embodiments can be made without departing from the principles and spirits of the present application, and the scope of the present application is defined by the appended claims and their equivalents.

Claims

1. A method for balancing a workpiece during machining, characterized in that, Includes the following steps: S1: Initialization settings, input workpiece material type, tool type and size parameters, the data processing module calls the built-in cutting speed-vibration database to determine the initial cutting speed range and the corresponding allowable vibration threshold; S2: Start the cutting equipment. The vibration acquisition module collects the workpiece vibration signal in real time, the speed detection module detects the spindle speed in real time and calculates the current cutting speed, and transmits the collected data to the data processing module. S3: The data processing module filters and amplifies the vibration signal, extracts the vibration amplitude and frequency, compares the current cutting speed with the initial cutting speed range, and compares the current vibration amplitude with the allowable vibration threshold. S4: If the current vibration amplitude does not exceed the allowable vibration threshold, continue machining at the current cutting speed; if the current vibration amplitude exceeds the allowable vibration threshold, the data processing module analyzes the changing trend of cutting speed and vibration amplitude to determine that the main factor causing excessive vibration is an unreasonable cutting speed. S5: The data processing module, based on the cutting speed-vibration database and current vibration data, uses a PID control algorithm to calculate the optimal cutting speed adjustment value. It then sends a speed adjustment command to the spindle speed control unit of the cutting equipment via the communication module. The PID control algorithm flow is as follows: S51. Initial parameter settings: Using a positional PID control algorithm, the discretized calculation formula is as follows: Δv(k) = Kp × e(k) + Ki × ∑e(i) + Kd × [e(k) - e(k-1)] Δv(k): The cutting speed adjustment amount at the kth sampling; e(k): Vibration amplitude deviation at the kth sampling point; e(k-1): Vibration amplitude deviation at the (k-1)th sampling; Kp: Proportional coefficient (dimensionless). Ki: Integral coefficient (dimensionless). Kd: Differential coefficient (dimensionless). The proportionality coefficient Kp ranges from 5 to 15. When the workpiece has high hardness, a larger value of 10 to 15 should be used, and when the material is soft, a smaller value of 5 to 10 should be used. Integral coefficient Ki: The value ranges from 0.05 to 0.2 to avoid integral saturation and subsequent adjustment lag. For high-frequency vibration scenarios with a vibration frequency >100Hz, a smaller value should be used. Differential coefficient Kd: ranges from 0.3 to 1.0, suppresses frequent fluctuations in cutting speed, and takes a larger value when the tool diameter is >20mm; S52: Parameter self-optimization: When the vibration amplitude overshoot is greater than 30%, decrease Kp and increase Kd; When the duration of steady-state deviation is >5s, increase Ki; When the cutting speed adjustment frequency is greater than 10 times / minute, reduce Kp and Kd to avoid system oscillation; S53: Algorithm Execution Data preprocessing: After filtering the signal from the vibration acquisition module, the data processing module extracts the current vibration amplitude and calculates the deviation e(k); Deviation judgment: If e(k)≤0, the PID algorithm outputs Δv=0, and maintains the current cutting speed; Three-stage operation: Calculate the output values ​​of the proportional, integral, and derivative stages separately, and then sum them to obtain the total adjustment Δv(k); Adjustment constraint: Limit Δv(k) within a reasonable range to avoid secondary vibration caused by sudden changes in cutting speed; Command output: Convert Δv(k) into a spindle speed adjustment command, calculate the target speed using the formula n=1000(v+Δv) / (πd), and send it to the spindle control unit via the communication module; Iterative update: Each sampling period is 10ms-50ms, synchronized with the sampling frequency of the vibration acquisition module, repeating the above steps to dynamically optimize the adjustment amount; S6: Repeat steps S2-S5, monitor the vibration signal and cutting speed in real time, and dynamically adjust the cutting speed until the vibration amplitude stabilizes within the allowable vibration threshold.

2. The method for adjusting the balance of a workpiece during machining according to claim 1, characterized in that, In step S5, the input of the PID adjustment algorithm is the vibration amplitude deviation value, and the output is the cutting speed adjustment value. The vibration amplitude deviation value is the difference between the current vibration amplitude and the allowable vibration threshold.

3. The method for adjusting the balance of a workpiece during machining according to claim 1, characterized in that, In step S3, the data processing module uses a low-pass filtering algorithm to process the vibration signal, with a filter cutoff frequency of 500Hz, to remove environmental interference signals.

4. A workpiece vibration suppression structure for machining, used to implement the workpiece balance adjustment method of claim 1, characterized in that: include: Vibration acquisition module, rotational speed detection module, data processing module, display and early warning module, and communication module; The vibration acquisition module is installed at the workpiece clamping end of the cutting equipment and is used to acquire vibration signals during the workpiece cutting process in real time. The vibration signals include vibration amplitude and vibration frequency. The rotational speed detection module is connected to the spindle of the cutting equipment and is used to detect the spindle speed in real time and calculate the current cutting speed based on the spindle speed and the tool diameter. The data processing module is connected to the vibration acquisition module and the rotational speed detection module, respectively. It is used to receive vibration signals and cutting speed data, filter and amplify the vibration signals, compare the preset vibration threshold with the current vibration amplitude, and analyze the correlation between cutting speed and vibration intensity. The data processing module has a built-in cutting speed-vibration database, which stores the optimal cutting speed range and corresponding allowable vibration thresholds for different workpiece materials and tool types. The data processing module can call the reference data in the database according to the input workpiece material and tool type information, compare the preset vibration threshold with the current vibration amplitude, and analyze the correlation between cutting speed and vibration intensity. The display and warning module is connected to the data processing module and is used to display real-time cutting speed, vibration amplitude, and vibration frequency data. When the vibration amplitude exceeds a preset threshold, a warning signal is issued. The communication module is connected to the data processing module and is used to realize signal transmission between the data processing module and the host computer.

5. The workpiece vibration suppression structure according to claim 4, characterized in that: The vibration acquisition module uses a piezoelectric accelerometer with a sampling frequency of not less than 1000Hz and a measurement range of 0-50g, where g is the acceleration due to gravity.

6. The workpiece vibration suppression structure according to claim 4, characterized in that: The data processing module has a built-in cutting speed-vibration database. The database stores the optimal cutting speed range and the corresponding allowable vibration threshold for different workpiece materials and tool types. The data processing module can call the reference data in the database according to the input workpiece material and tool type information.

7. The workpiece vibration suppression structure according to claim 4, characterized in that: It also includes a power supply module, which provides stable power to the vibration acquisition module, speed detection module, data processing module, display and early warning module, and communication module. The power supply module supports AC 220V input and DC 12V output.

8. The workpiece vibration monitoring device according to claim 4, characterized in that, The communication module adopts RS485, Ethernet or wireless communication, including WiFi, Bluetooth or LoRa communication.

9. The workpiece vibration monitoring device according to claim 4, characterized in that, The display and warning module includes a touch screen, an alarm indicator light, and a buzzer. The touch screen is used for parameter input and data display, and the alarm indicator light and buzzer work together to emit audible and visual warning signals.

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