Profile cutting equipment and method

Abstract

The invention discloses sectional material cutting equipment and method, and relates to the field of sectional material machining, the equipment comprises a rack, and a feeding mechanism is installed on the rack; the clamping mechanisms are arranged on the two sides of the feeding mechanism and used for clamping and fixing the profiles on the feeding mechanism. The vision measurement module comprises an industrial camera and a light source, and the industrial camera is arranged above the rack and used for collecting images of the end of the profile; the force sensing module is integrated in the clamping mechanism and used for monitoring a force signal in the profile clamping process; the laser ranging module comprises a laser displacement sensor and is used for scanning the surface profile of the profile to measure deformation; the cutting executing mechanism comprises a cutting tool and is used for cutting the sectional material; the central control system is in communication connection with the feeding mechanism, the clamping mechanism, the vision measurement module, the force sense sensing module, the laser ranging module and the cutting execution mechanism and used for controlling all the mechanisms to work cooperatively. According to the sectional material cutting equipment and method, high-precision positioning can be achieved, and material defects can be avoided.

Description

Technical Field

[0001] This invention relates to the field of profile processing technology, and in particular to a profile cutting device and method. Background Technology

[0002] Profiles (such as angle steel, channel steel, I-beams, square tubes, and round tubes) are fundamental structural materials in the industrial field, and their cutting and preparation are prerequisites for subsequent welding, assembly, and other processes. Traditional profile cutting mainly relies on manual operation of semi-automatic or fully automatic cutting machines. Manual operation is labor-intensive, inefficient, and the cutting accuracy is heavily dependent on the operator's experience and condition, resulting in poor product quality consistency and failing to meet the needs of modern intelligent manufacturing.

[0003] While existing fully automated profile cutting equipment has improved efficiency to some extent, it still faces numerous technical bottlenecks. Most equipment uses mechanical baffles or simple photoelectric sensors for positioning, which cannot accurately identify the actual end face shape of the profile. Because profiles may bend, deform at the ends, or have burrs during transportation and storage, the positioning method based on the theoretical end face has systematic errors, affecting the final accuracy of the cutting length. Furthermore, the profile surface may have localized defects such as scratches and pits. If these defects happen to be within the effective length range required by the workpiece, traditional equipment will ignore them and cut directly, leading to material waste or defective products.

[0004] Therefore, there is an urgent need to design a profile cutting solution that can achieve high-precision positioning and avoid material defects. Summary of the Invention

[0005] The purpose of this invention is to provide a profile cutting device and method to solve the problems existing in the prior art, achieve high-precision positioning, and avoid material defects.

[0006] To achieve the above objectives, the present invention provides the following solution: This invention provides a profile cutting device, comprising: frame; A feeding mechanism, mounted on the frame, is used to drive the profile to move along its length. A clamping mechanism is provided on both sides of the feeding mechanism for clamping and fixing the profile on the feeding mechanism; The vision measurement module includes at least one industrial camera and a light source. The industrial camera is located above the frame and is used to acquire images of the end of the profile to identify the actual end face position. This invention accurately identifies the actual end face of the profile through machine vision, eliminating positioning errors caused by uneven end faces. A force sensing module, integrated into the clamping mechanism, is used to monitor force signals during the clamping process of the profile; The laser ranging module includes a set of laser displacement sensors for scanning the surface profile of the profile to measure deformation; A cutting actuator, including a cutting tool, for cutting profiles; and The central control system is connected to the feeding mechanism, clamping mechanism, vision measurement module, force sensing module, laser ranging module and cutting execution mechanism. It is used to control the coordinated work of each mechanism. By integrating laser ranging and force sensing data, it constructs a profile deformation model in real time, ensuring that the workpiece with accurate length is cut.

[0007] Preferably, the central control system includes: The data fusion unit is used to fuse the end face image data provided by the vision measurement module, the force signal data provided by the force sensing module, and the profile surface contour data provided by the laser ranging module.

[0008] Preferably, the central control system further includes: The path planning unit is used to calculate the feed distance and generate the motion trajectory of the feed mechanism based on the data collected by the data fusion unit and the preset workpiece length.

[0009] Preferably, the central control system further includes: The parameter adaptive unit is used to adjust the cutting speed of the cutting actuator based on the surface contour data of the profile.

[0010] Preferably, the central control system further includes: The defect identification and avoidance unit is used to analyze the data from the vision measurement module and the laser ranging module to identify defects on the profile surface; when the identified defect is within the effective length range of the current workpiece, it generates instructions to adjust the cutting position to avoid the defect or to issue an alarm signal.

[0011] The present invention also provides a profile cutting method applied to the profile cutting equipment, comprising the following steps: S1: Profile feeding and initial positioning, the profile is transported to the initial station through the feeding mechanism; S2: End face visual precision positioning, which identifies the actual end face of the profile through the visual measurement module and uses it as the length measurement benchmark; S3: Multi-sensor data fusion and deformation modeling. During the profile feeding process, data is collected through force sensing module and laser ranging module, and the central control system fuses the data to establish the deformation model of the profile. S4: The feed mechanism drives the profile to feed at a constant speed; S5: Real-time defect detection and decision-making. During the feeding process, it detects surface defects of the profile and decides whether to adjust the cutting position based on the location of the defects. S6: Cutting. The clamping mechanism clamps and fixes the profile on the feeding mechanism. The feeding mechanism stops, and the cutting execution mechanism performs cutting at the planned position. Since the feeding mechanism uses a conveyor belt or conveyor roller, the profile is placed on the upper part of the feeding mechanism to realize the conveying process. Therefore, in one embodiment, when the clamping mechanism fixes and clamps the profile, the feeding mechanism may not stop. At this time, the upper surface of the feeding mechanism slides and rubs against the lower surface of the profile, which will not affect the fixing of the profile and the movement of the feeding mechanism.

[0012] S7: Complete cutting and unloading.

[0013] Preferably, in step S2, the method for identifying the actual end face includes: acquiring an image of the end face using an industrial camera.

[0014] Preferably, in step S3, the method for establishing the deformation model includes: using a laser ranging module to acquire contour point data of the upper surface of the profile, and generating a model that reflects the actual state of the profile.

[0015] Preferably, the feeding mechanism is a conveyor belt or a conveyor roller.

[0016] Preferably, in step S5, the specific process of determining whether to adjust the cutting position based on the defect location includes: If a defect is detected, determine whether the defect is located within the current workpiece's set length range; If so, then further determine whether the severity of the defect exceeds a preset threshold; If the threshold is not exceeded, the control path planning unit will shift the cutting position to the tail or head of the profile by a preset safe distance to avoid the defect; If the threshold is exceeded, an alarm signal will be sent to the operator and the cutting process will be suspended.

[0017] The beneficial effects of this invention are as follows: This invention utilizes machine vision to accurately identify the actual end face of the profile, eliminating positioning errors caused by uneven end faces. By integrating laser ranging and force sensing data, a profile deformation model is constructed in real time, ensuring the accurate cutting of workpieces. The central control system dynamically optimizes the cutting path and cutting speed parameters based on the real-time status of the profile (deformation, defects), achieving intelligent processing. This invention features defect identification and avoidance capabilities, maximizing the utilization of profiles with local defects, reducing waste, and lowering production costs. Adaptive cutting parameter adjustment avoids cut quality problems or equipment overload caused by improper cutting speed and feed rate parameters, improving the safety and reliability of the processing. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the profile cutting equipment in one or more embodiments of the present invention; Figure 2 This is a schematic diagram of the feeding mechanism and clamping mechanism of the profile cutting equipment in one or more embodiments of the present invention; Figure 3 This is a block diagram of the central control system module of the profile cutting equipment in one or more embodiments of the present invention; In the diagram: 1-Frame; 2-Feeding mechanism; 3-Profile; 4-Vision measurement module; 41-Industrial camera; 42-Light source; 5-Force sensing module; 6-Laser ranging module; 61-Laser displacement sensor; 7-Cutting actuator; 71-Cutting tool; 72-Traveling frame; 73-Cutting rod; 8-Central control system; 81-Data fusion unit; 82-Path planning unit; 83-Parameter adaptive unit; 84-Defect identification and avoidance unit; 9-Clamping mechanism. Detailed Implementation

[0020] 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.

[0021] The purpose of this invention is to provide a profile cutting device and method to solve the problems existing in the prior art, achieve high-precision positioning, and avoid material defects.

[0022] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0023] This invention provides a profile cutting device, such as... Figure 1 , Figure 2 and Figure 3The locking mechanism includes a frame 1, a feeding mechanism 2, a clamping mechanism 9, a vision measurement module 4, a force sensing module 5, a laser ranging module 6, a cutting execution mechanism 7, and a central control system 8. The feeding mechanism 2 is powered by a servo motor-driven ball screw or rack and pinion mechanism. The clamping mechanism 9 is a pneumatically or hydraulically driven clamp. Multiple clamps are symmetrically arranged on the frame 1 on both sides of the feeding mechanism 2, and the clamps are located above the feeding mechanism 2. When they extend horizontally forward, they can clamp or abut against the side wall of the profile 3 on the feeding mechanism 2, thereby fixing the profile 3. The clamps will not contact the feeding mechanism 2. The clamping mechanism 9 integrates a force sensing module 5, which can be an array of thin-film pressure sensors for real-time sensing of the uniformity of the clamping force. In another embodiment, the clamps can be horizontally arranged block clamps or horizontally arranged cylindrical clamps, with the axis of the cylindrical clamp perpendicular to the length direction of the feeding mechanism 2. This embodiment... Figure 2The feeding mechanism 2 employs a block-shaped clamp on one side and a cylindrical clamp on the other, which, when used together, can clamp both sides of the profile 3. The vision measurement module 4 uses a high-resolution CCD camera 41, along with a light source 42, which is an LED surface light source. Both the camera 41 and the light source 42 are mounted above the feeding mechanism 2 via a bracket. In one embodiment, the camera 41 can be mounted on a robotic arm, which can move the camera 41 to ensure clear imaging of the details at the end of the profile 3. The laser ranging module 6 consists of multiple laser displacement sensors 61 arranged linearly. These sensors are mounted above the frame 1 via a connecting bracket, forming a scanning line to continuously acquire the contour height data of the upper surface of the profile 3. The cutting actuator 7 uses a high-precision servo motor-driven circular saw blade as the cutting tool 71. The cutting actuator 7 includes a traveling frame 72 set on one side of the frame 1. The traveling frame 72 is equipped with a slider, and a cylinder or lead screw and nut pair is connected to the bottom of the slider to realize the up and down movement of the slider. A horizontally arranged cutting rod 73 is connected to the slider. The cutting tool 71 and the servo motor are mounted on a tool holder, which is slidably mounted on the cutting rod 73. The cutting rod 73 is equipped with a horizontal drive mechanism, which can drive the cutting tool 71 and the servo motor along the cutting rod. 73 Horizontal movement: Through the above structure, the cutting tool 71 can reciprocate horizontally and move up and down, thereby realizing the cutting and avoidance processes. The output shaft of the servo motor is connected to the rotating shaft of the cutting tool 71, and the servo motor can achieve precise control of the cutting speed. The horizontal drive mechanism can be a horizontally arranged pneumatic or hydraulic cylinder, or the cutting rod 73 can be replaced by a horizontally arranged lead screw with a nut on it. The tool holder is fixed on the nut, and one end of the lead screw is connected to a lead screw motor, thereby realizing the horizontal movement of the tool holder on the lead screw. During the cutting process, the tool holder is moved above the cutting position, the cutting tool 71 is started, and the cutting rod 73 is driven to move downward at a uniform speed, thereby realizing the feeding and cutting of the cutting tool 71. When avoidance is required, the horizontal drive mechanism drives the cutting tool 71 to move to one side of the profile 3, and the slider drives the cutting rod 73 to move above the profile, without interfering with the feeding process of the profile 3.

[0024] The central control system 8 is based on an industrial computer or a high-performance programmable logic controller (PLC) using existing technology, running existing numerical control software. Its internal functional modules include a data fusion unit 81, which receives images from a camera, force signals from an array-type thin-film pressure sensor, and distance data from a laser displacement sensor 61—that is, the detected displacement data. This unit aligns and fuses data from different sources and time sequences to generate a model containing information such as the profile end face position and surface roughness.

[0025] The path planning unit 82 receives the set workpiece length input by the user and calls the profile model generated by the data fusion unit 81. It sends corresponding motion commands to the feed mechanism 2 to ensure that the actual length of the cut workpiece is equal to the set length and that the end face is perpendicular to the tangent direction of the profile end face.

[0026] The parameter adaptive unit 83 has a pre-stored library of optimized cutting parameters for profiles of different materials (such as aluminum and steel) and cross-sectional specifications. Before cutting, it sets the basic parameters according to the profile model. At the moment of cutting, it fine-tunes the cutting speed of the cutting tool 71 or the spindle speed based on the local deformation (such as tiny protrusions) detected in real time by the laser sensor near the cutting point, thus avoiding impact and vibration.

[0027] The defect identification and avoidance unit 84 performs real-time analysis of the visual image and laser profile, identifying defects such as scratches and dents through edge detection and texture analysis. Once a defect is identified, it is compared with the currently planned workpiece position for cutting. If the defect is within acceptable limits, an instruction is sent to the path planning unit 82 to finely adjust the cutting position forward or backward by a safe distance to avoid the defect area, thereby ensuring workpiece quality and preventing damage to the cutting tool 71.

[0028] This invention uses machine vision to accurately identify the actual end face of the profile 3, eliminating positioning errors caused by uneven end faces. By fusing laser ranging and force sensing data, a profile deformation model is constructed in real time, ensuring that workpieces with accurate lengths are cut. The central control system 8 can use existing computers and can dynamically optimize the cutting path and cutting speed parameters based on the real-time status of the profile (deformation, defects), realizing intelligent processing. This invention has defect identification and avoidance functions, which can maximize the use of profiles with local defects, reduce waste, and lower production costs. Adaptive cutting parameter adjustment avoids cut surface quality problems or equipment overload caused by improper cutting speed and feed speed parameters, improving the safety and reliability of the processing.

[0029] The specific steps of the workflow of this invention are as follows: S1: Profile 3 is placed on the guide rail of feeding mechanism 2 by the loading robot. The clamping mechanism 9 is not in contact with profile 3 in the initial state and has no clamping force.

[0030] S2: The feed mechanism 2 delivers the profile 3 to the area below the vision measurement module 4. The industrial camera 41 captures an image of the end face.

[0031] S3: The feed mechanism 2 begins to drive the profile 3 to feed intermittently or continuously towards the cutting execution mechanism 7. The clamping mechanism 9 initially abuts against the side wall of the profile. At this time, the clamping mechanisms 9 on both sides of the profile 3 slide in contact with the profile 3. During this process, if the profile 3 does not deform, the data detected by the force sensing modules 5 in the clamping mechanisms 9 on both sides should remain constant. If the friction force monitored by the force sensors in the clamping mechanisms 9 shows abnormal fluctuations, it indicates that the profile 3 may be deformed. At the same time, the laser ranging module 6 continuously scans to obtain the full contour data of the profile 3. The data fusion unit 81 combines the force data and the laser contour data to accurately calculate the model of the profile 3.

[0032] S4: When the feed mechanism 2 drives the profile 3 to feed at a constant speed to the cutting position corresponding to the cutting tool 71, the feeding process stops.

[0033] S5: During the feeding process, the defect identification and avoidance unit 84 continues to operate. For example, when the system plans to cut at a distance of 2000mm from the end face, it detects a noticeable dent near the cutting position. It immediately makes a decision and adjusts the final cutting position to 2005mm, thereby avoiding the defect and preventing potential damage to the cutting tool 71 caused by the irregular shape of the defect. At the same time, this offset is recorded, and the positioning reference of all subsequent workpieces is automatically adjusted to ensure consistency in the total length of the batch.

[0034] S6: When profile 3 reaches the target position, the feed stops. The parameter adaptive unit 83 drives the cutting tool 71 to perform smooth cutting at the set cutting speed based on the local flatness data fed back in real time by the laser sensor at the cutting position. The cutting execution mechanism 7 completes the cutting according to the instructions.

[0035] S7: After cutting, the clamping mechanism 9 is released, and the finished product is taken away by the unloading robot. The system uses the newly cut end face as the reference for the next workpiece and repeats steps S2 to S6 until the entire profile 3 is processed.

[0036] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A profile cutting apparatus, characterized in that, The application relates to a cutting device for profiled materials, which comprises the following parts: a rack; a feeding mechanism mounted on the rack and used for driving the profiled material to move along the length direction of the profiled material; a clamping mechanism arranged on both sides of the feeding mechanism and used for clamping and fixing the profiled material on the feeding mechanism; a visual measurement module comprising at least one industrial camera and a light source, the industrial camera being arranged above the rack and used for collecting the image of the end of the profiled material to identify the actual end surface position; a force sensing module integrated in the clamping mechanism and used for monitoring the force signal in the process of clamping the profiled material; a laser distance measuring module comprising a laser displacement sensor and used for scanning the surface profile of the profiled material to measure the deformation; a cutting execution mechanism comprising a cutting tool and used for cutting the profiled material; and a central control system in communication connection with the feeding mechanism, the clamping mechanism, the visual measurement module, the force sensing module, the laser distance measuring module and the cutting execution mechanism, and used for controlling the cooperation of the mechanisms.

2. The profile cutting apparatus according to claim 1, characterized in that The central control system comprises: a data fusion unit used for fusing the end surface image data provided by the visual measurement module, the force signal data provided by the force sensing module and the surface profile data of the profiled material provided by the laser distance measuring module.

3. A profile cutting apparatus according to claim 2, characterised in that, The central control system further comprises: a path planning unit used for calculating the feeding distance according to the data collected by the data fusion unit and the preset workpiece length, and generating the movement track of the feeding mechanism.

4. A profile cutting apparatus according to claim 3, characterised in that, The central control system further comprises: a parameter self-adaptive unit used for adjusting the cutting speed of the cutting execution mechanism according to the surface profile data of the profiled material.

5. The profile cutting apparatus according to claim 2, characterized in that The central control system further comprises: a defect identification and avoidance unit used for analyzing the data of the visual measurement module and the laser distance measuring module, identifying the defects on the surface of the profiled material, generating an instruction to adjust the cutting position to avoid the defects or issuing an alarm signal when the identified defects are located in the effective length range of the current workpiece.

6. A profile cutting method applied to the profile cutting apparatus according to any one of claims 1 to 5, characterized by, The application further discloses a cutting method for profiled materials, which comprises the following steps: S1: profiled material loading and initial positioning, the profiled material is conveyed to an initial work station through the feeding mechanism; S2: end surface visual accurate positioning, the actual end surface of the profiled material is identified through the visual measurement module, and the actual end surface is taken as the length measurement reference; S3: multi-sensor data fusion and deformation modeling, data are collected through the force sensing module and the laser distance measuring module in the process of feeding the profiled material, and the data are fused by the central control system to establish the deformation model of the profiled material; S4: the profiled material is fed at a constant speed by the feeding mechanism; S5: real-time defect detection and decision, the defects on the surface of the profiled material are detected in the feeding process, and it is decided whether the cutting position is adjusted according to the defect position; S6: cutting, the profiled material on the feeding mechanism is clamped and fixed by the clamping mechanism, and the cutting execution mechanism cuts at the planned position; S7: cutting is completed and the profiled material is unloaded.

7. The profile cutting method according to claim 6, characterized in that, In the step S2, the method for identifying the actual end surface comprises the following steps: collecting the end surface image through the industrial camera.

8. The profile cutting method according to claim 6, characterized in that, In the step S3, the method for establishing the deformation model comprises the following steps: acquiring the profile point data of the upper surface of the profiled material through the laser distance measuring module, and generating the model reflecting the actual state of the profiled material.

9. The profile cutting method according to claim 8, characterized in that, The feeding mechanism is a conveying belt or a conveying roller.

10. The profile cutting method according to claim 6, characterized in that, In the step S5, the specific process of deciding whether the cutting position is adjusted according to the defect position comprises the following steps: If a defect is identified, it is determined whether the defect is located in a current workpiece set length interval; If yes, it is further determined whether the severity of the defect exceeds a preset threshold value; If the threshold value is not exceeded, the path planning unit is controlled to offset the cutting position by a preset safety distance towards the tail end or head end of the profile to avoid the defect; If the threshold value is exceeded, an alarm signal is sent to the operator and the cutting process is paused.

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