Automatic copper bar conveying treatment device and method thereof

Abstract

The invention relates to an automatic copper bar conveying and processing device and method, and belongs to the technical field of copper bar conveying and processing. The automatic copper bar conveying and processing device comprises a gas-magnetic mixed suspension track and a processing station arranged at a preset processing point of the gas-magnetic mixed suspension track; wherein the gas-magnetic hybrid suspension track is integrated with an electromagnetic system and an airflow system, and the airflow system is connected to a low-pressure air blower; a sound pressure self-centering module is installed on the lower portion of the machining station in an embedded mode. The electromagnetic system is used for generating a traveling wave magnetic field and auxiliary suspension force for propelling a copper bar, the airflow system is used for generating a main suspension air film, and the sound pressure self-centering module is an ultrasonic array and is used for generating a sound pressure standing trough; the copper bar is placed at the starting point of the gas-magnetic mixed suspension track, and non-contact mixed suspension conveying in the whole process from the starting point to a machining station is achieved; as the copper bar does not roll or make grabbing contact with any mechanical structure in the whole process, the technical pain points of surface damage and pollution are avoided.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of copper bar conveying processing, in particular to an automatic copper bar conveying processing device and method thereof. BACKGROUND

[0002] In the field of electrical switch cabinet manufacturing, heavy current copper bars are the core conductive components. Their automated processing is the key to improving production efficiency; the existing automation scheme usually adopts a combination of heavy-duty roller conveying line + multi-joint robot / gantry truss + servo precision clamp; this scheme has the following technical pain points: Surface damage and contamination: the surface finish of the copper bar is highly sensitive to its electrical conductivity. In the mainstream scheme, the rolling contact of the roller and the grabbing contact of the robot gripper will inevitably cause scratches, indentations or oil stains on the surface of the copper bar. Metal debris generated during processing is also easy to adhere, affecting the final electrical connection reliability.

[0003] Positioning and handover bottleneck: when heavy long-size copper bars are switched from conveying state to processing state, such as entering the stamping die, the mechanical hand or servo clamp is used for grabbing-releasing-repositioning. This process is not only slow, with a single handover taking more than 10 seconds, but also requires precise alignment to within sub-millimeters under heavy load, which has the problems of large cumulative error and complex debugging.

[0004] Flexibility: when the production line switches different specifications of copper bars in terms of width, thickness and length, the mechanical gripper of the robot, the baffle of the roller line and the positioning clamp on the work station must be replaced or adjusted. This mechanical changeover takes a long time and seriously affects the production efficiency of small batch and multi-specification orders.

[0005] Therefore, there is an urgent need in the industry for a new type of non-contact, high-precision and flexible heavy copper bar conveying processing scheme.

[0006] The above information disclosed in the background section is only used to enhance the understanding of the background of the present disclosure, and therefore it can include information that does not constitute prior art known to those of ordinary skill in the art. SUMMARY

[0007] The purpose of the present application is to provide an automatic copper bar conveying processing device and method thereof to solve the problems raised in the background.

[0008] The technical scheme of the present application includes: S1, set up a gas-magnetic hybrid suspension track integrated with an electromagnetic system and an airflow system, and set up a processing station with a lower embedded sound pressure self-centering module at a predetermined processing point, the array surface of the sound pressure self-centering module is covered with a micro-porous sound transmission-airflow deflector, lateral pulse jet nozzle arrays are arranged on both sides of the track, the airflow system is connected with a low-pressure blower to generate a main suspension air film, the electromagnetic system is used to generate a traveling wave magnetic field and an auxiliary suspension force, and the sound pressure self-centering module is used to generate a sound pressure standing wave trough; S2, place the copper bar at the starting point of the gas-magnetic hybrid suspension track; S3, start the low-pressure blower and the electromagnetic system, provide 80% suspension force by the airflow system and 20% suspension force by the electromagnetic system, and stably suspend the copper bar at a target height of 5 10mm, and drive the copper bar to be non-contact transported at a speed of 0.5 2m / s by generating a traveling wave magnetic field by the electromagnetic system; S4, after the copper bar is decelerated and stopped at the processing station, the lateral displacement of the copper bar is monitored in real time by using lateral position detection sensors arranged on both sides of the track, the lateral pulse jet is triggered to achieve rough positioning within ±3mm, the sound pressure self-centering module is activated to generate a sound pressure standing wave trough in the X-Y plane, and the copper bar is passively locked from the rough positioning position to the center point of the sound pressure trough by using sound radiation force to achieve precise positioning within ±0.1mm; S5, start the processing equipment of the processing station to perform processing on the precisely positioned copper bar.

[0009] Preferably, in the step of S3, the step of stably suspending at the target height comprises: A Z-axis height sensor is arranged along the gas-magnetic hybrid suspension track to monitor the vertical distance between the bottom surface of the copper bar and the surface of the gas-magnetic hybrid suspension track in real time; A hybrid suspension controller is arranged to set and control the constant speed of the low-pressure blower to generate a constant airflow to provide 80% suspension force according to the nominal weight and bottom area of the copper bar; The Z-axis height sensor detects the vertical distance in real time and compares it with the target height to generate a height deviation signal; The hybrid suspension controller dynamically adjusts the current amplitude applied to the electromagnetic system at a high speed according to the height deviation signal and its change rate to compensate for the height deviation, so that the vertical distance is always stable at the target height.

[0010] Preferably, the step of S4 includes a flexible conversion step: When switching copper bars of different specifications, the nominal weight and bottom area of the copper bar are selected in the hybrid suspension controller; The hybrid suspension controller automatically converts and sets the basic speed of the low-pressure blower according to the nominal weight and bottom area to provide the basic pressure value of the air film corresponding to 80% suspension force; The hybrid suspension controller automatically adjusts the reference current of the electromagnetic system to provide a reference force corresponding to 20% suspension force, while the closed-loop feedback logic of the target height remains unchanged.

[0011] Preferably, in the step S4, the working frequency of the ultrasonic array of the acoustic pressure self-centering module is 40 kHz.

[0012] Preferably, in the step S4, the nozzle array of the lateral pulsed jet is arranged on both sides of the gas-magnetic hybrid suspension track, and the gas source thereof is connected to the air flow system or independently arranged. The pulsed air flow is ejected by opening the electromagnetic valve for milliseconds to push the copper bar back to the center line.

[0013] Preferably, after the step S5, the method further comprises: transporting the copper bar to a downstream station and using the Coanda effect wall-attached nozzle arranged at the station to blow off the processing debris on the surface of the copper bar in line.

[0014] Preferably, the Z-axis height sensor is a laser height sensor or an eddy current sensor.

[0015] An automatic copper bar conveying and processing device, comprising: a gas-magnetic hybrid suspension track for the main conveying path of the copper bar; the bottom support seat of the gas-magnetic hybrid suspension track is configured with an active leveling mechanism for keeping the track levelness within ±0.1 mm; a processing station arranged at a predetermined processing point of the gas-magnetic hybrid suspension track; wherein the gas-magnetic hybrid suspension track is composed of a plurality of stator units connected in series, and the stator unit integrally integrates: an electromagnetic system including a linear motor winding for propelling the copper bar and an electromagnetic suspension coil for auxiliary suspension; an air flow system including a composite air duct for main suspension, and the air flow system is connected to an external low-pressure blower; a sound pressure self-centering module is embeddedly installed at the lower part of the processing station, and the array surface of the sound pressure self-centering module is covered with a micro-porous sound transmission-air flow deflector. The sound pressure self-centering module is an ultrasonic array for generating a sound pressure standing wave valley in the X-Y plane of the suspended copper bar to passively and precisely position the copper bar; The device further comprises: a lateral position detection sensor for detecting the lateral position of the copper bar; a Z-axis height sensor installed along the gas-magnetic hybrid suspension track for real-time monitoring of the vertical distance between the bottom surface of the copper bar and the surface of the gas-magnetic hybrid suspension track; a lateral pulsed jet nozzle array installed on both sides of the gas-magnetic hybrid suspension track for pushing the copper bar back to the center line during conveying; A hybrid suspension controller is electrically connected to the low-pressure blower, the electromagnetic system, and the Z-axis height sensor. The hybrid suspension controller is configured to perform the automated copper bar conveying process.

[0016] The present application provides an automated copper bar conveying device and method, which has the following improvements and advantages compared to the prior art: 1. The present application proposes a gas-magnetic hybrid suspension track. The main suspension air film generated by the air flow system bears the main part of the weight of the copper bar. At the same time, the electromagnetic system provides the remaining 20% of the auxiliary suspension force and the high-speed dynamic adjustment force. This synergistic effect enables the heavy copper bar to be stably suspended at a target height of 5-10 mm, achieving non-contact hybrid suspension conveying from the starting point to the processing station. Since the copper bar does not roll or grab contact with any mechanical structure throughout the conveying process, the technical pain points of surface damage and contamination are avoided. 2. The present application adopts an innovative two-stage positioning strategy. When conveying to the processing station, an initial boundary is provided for precise positioning. This passive locking does not rely on any X-Y plane visual or laser servo feedback, but automatically completes using the physical effect of the sound field. The speed is extremely fast, and it is completely immune to dust and vibration interference on site, achieving high positioning robustness. 3. The present application introduces a flexible changeover step. When switching different specifications of copper bars, the operator only needs to select the nominal weight and base area of the new copper bar in the hybrid suspension controller. The hybrid suspension controller will automatically convert and set the base speed of the low-pressure blower according to the new parameters to match the air film base pressure value required for 80% of the suspension force of the new workpiece. It will also automatically adjust the reference current of the electromagnetic system to match the remaining 20% of the reference force. This process is a pure instantaneous switching of electrical and fluid parameters, without any mechanical adjustment, achieving zero-time changeover and greatly improving the production efficiency of small batches and multiple varieties of orders. 4. The Z-axis height sensor of the present application works in cooperation with the hybrid suspension controller. By monitoring the vertical distance in real time and comparing it with the target height, the height deviation signal generated is obtained by the hybrid suspension controller. The hybrid suspension controller only adjusts the current amplitude applied to the electromagnetic system at high speed and dynamically to compensate for the slight fluctuations of the air film. This active closed-loop feedback ensures the absolute stability of the Z-axis height, which is a prerequisite for subsequent X-Y plane precise sound field positioning. BRIEF DESCRIPTION OF DRAWINGS

[0017] The present application will be further explained in conjunction with the accompanying drawings and examples: Figure 1 is a schematic diagram of the overall structure of the device; Figure 2 is a schematic diagram of the processing station and its connection structure; Figure 3 is a schematic diagram of a gas-magnetic hybrid suspension track and its connection structure; Figure 4 is a schematic diagram of the process flow structure of the method.

[0018] In the figure: 100, gas-magnetic hybrid suspension track, 110, stator unit, 200, processing station, 210, acoustic pressure self-centering module, 300, electromagnetic system, 310, linear motor winding, 320, electromagnetic suspension coil, 400, gas flow system, 410, composite air duct, 420, low-pressure blower, 500, Z-axis height sensor, 600, hybrid suspension controller, 700, lateral pulsed jet nozzle array. DETAILED DESCRIPTION

[0019] In order to make the purpose, technical scheme and advantages of the present application clearer, the present application will be further described in detail below in combination with specific examples.

[0020] Example 1: Please refer to Figures 1-4 The present application provides an automatic copper bar conveying and processing method, comprising: S1, setting a gas-magnetic hybrid suspension track integrated with an electromagnetic system 300 and a gas flow system 400, and setting a processing station 200 with a lower embedded acoustic pressure self-centering module 210 at a predetermined processing point, the array surface of the acoustic pressure self-centering module 210 is covered with a micro-porous sound transmission-air flow deflector, lateral pulsed jet nozzle arrays are arranged on both sides of the track, the gas flow system 400 is connected to a low-pressure blower 420 to generate a main suspension air film, the electromagnetic system 300 is used to generate a traveling wave magnetic field and an auxiliary suspension force, and the acoustic pressure self-centering module 210 is used to generate an acoustic pressure standing wave valley; S2, placing the copper bar at the starting point of the gas-magnetic hybrid suspension track; S3, starting the low-pressure blower 420 and the electromagnetic system 300, providing 80% of the suspension force by the gas flow system 400 and 20% of the suspension force by the electromagnetic system 300, so that the copper bar is stably suspended at a target height of 5 10mm, and driving the copper bar at a speed of 0.5 2m / s non-contact conveying by generating a traveling wave magnetic field by the electromagnetic system 300; S4, after the copper bar is conveyed to the processing station 200 and decelerated to stop, the lateral position detection sensor arranged on both sides of the track is used to monitor the lateral offset of the copper bar in real time, the lateral pulsed jet is triggered to achieve rough positioning within ±3mm, and the acoustic pressure self-centering module 210 is activated to generate an acoustic pressure standing wave valley in the X-Y plane, the copper bar is passively locked from the rough positioning position to the center point of the acoustic pressure valley by the acoustic radiation force, and precise positioning within ±0.1mm is achieved; Thanks to the near-zero friction characteristics brought about by the air-magnetic hybrid suspension, the copper busbar is in an equivalent microgravity floating state, at which point the horizontal resistance of the copper busbar approaches zero; at the same time, the airflow system, through laminar flow control technology, reduces the viscous damping force of the air film shear flow. Reduced to the millinewton level to ensure it is less than the sound radiation force generated by the sound pressure self-centering module. Although the acoustic radiation force is usually in the range of micronewtons to millinenewtons, in the air-magnetic hybrid suspension environment constructed in this invention, the frictional resistance has been reduced to below the same order of magnitude.

[0021] In a two-dimensional equivalent microgravity field constructed by air-magnetic hybrid levitation, the coefficient of friction in the horizontal direction is... According to Newton's second law At this point, the net external force is not zero, even if the sound radiation force is zero. The acceleration generated Only Level, given sufficient setup time, can be determined using the displacement formula. The time integration effect is still sufficient to cause a massive object to undergo millimeter-level displacement correction and eventually converge to the center of the potential well. It should be noted that this system utilizes the impulse theorem. The time-cumulative effect; despite the acoustic radiation force The instantaneous value is much smaller than that of a typical mechanical driving force, but the coefficient of friction created by the air-magnetic hybrid suspension is much higher. In extremely low damping environments, as long as the system is given With its response time, the continuous millinewton acoustic radiation force is sufficient to overcome the inertia of the 20kg copper busbar and generate effective displacement. This process is similar to the attitude adjustment of a spacecraft by a micro-thruster in a microgravity environment.

[0022] To ensure that the weak acoustic radiation force can effectively overcome the horizontal component of gravity, the levelness of the track installation at the processing station must be strictly controlled. Within this range, to ensure that the component of gravity along the direction of motion is less than the sound radiation force. That is, satisfying the mechanical inequality ,in For the quality of copper busbars, This refers to the maximum permissible inclination angle of the track; specifically, based on experimental measurements, for mass... Standard copper busbars, when the track level is controlled within At that time, the gravitational component that causes it to slide down. This resistance is much smaller than the acoustic radiation force. The driving conditions are met.

[0023] In order to maintain this microgravity balance condition for a long time in the industrial field, the support structure of the gas-magnetic hybrid suspension track adopts a dynamic active leveling mechanism. When the inclination rate exceeds due to micro-settlement of the foundation, the system generates a reverse torque by adjusting the local electromagnetic suspension force distribution to offset the component of gravity along the motion direction, ensuring that the copper bar is always on the equivalent horizontal plane of zero potential energy gradient, thereby guaranteeing the dominant control of the acoustic radiation force on the copper bar.

[0024] Therefore, the bottom support seat of the gas-magnetic hybrid suspension track needs to be equipped with an automatic leveling mechanism with high sensitivity electronic level feedback, and an electronic level with precision better than is used to complete calibration during installation, ensuring that the component of gravity along the motion direction is strictly less than the acoustic radiation force; under this condition, although the acoustic radiation force is only in the order of millinewton, within the action time of , according to the impulse theorem , the accumulated impulse is sufficient to make the large mass copper bar overcome the extremely low gas film viscous resistance and produce effective displacement. In order to prevent the large mass copper bar from overshooting and oscillating due to inertia when it reaches the center of the acoustic pressure valley, the system adopts a phase offset electronic damping strategy: When the lateral position detection sensor detects that the speed of the copper bar approaching the center of the potential well exceeds the threshold, the hybrid suspension controller (600) adjusts the phase distribution of the ultrasonic array through FPGA at a high speed, causing the acoustic pressure standing wave valley to produce a small reverse displacement, forming an active acoustic damping force to absorb the kinetic energy of the copper bar. The specific damping control logic is: the hybrid suspension controller applies a phase offset according to the real-time speed , satisfying , where is the damping gain coefficient, with unit: , ensuring that the copper bar converges without overshooting at the center of the acoustic pressure valley.

[0025] When the main suspension gas film thickness generated by the air flow system is stable at the target height of 5 10mm, the air shear viscous effect is significantly reduced due to the larger suspension gap, and the equivalent friction coefficient in the horizontal direction is about , and the corresponding gas film viscous damping force ; although the inertia of the 20kg copper bar is large, according to , it can produce an acceleration of about under the action of the acoustic radiation force for about , and it only takes about 1 2 seconds to complete the millimeter-level fine adjustment. In this embodiment, the acoustic pressure self-centering module uses a high-strength ultrasonic array with a total acoustic power of 500W, which can generate an acoustic radiation force of about on the focal plane , satisfying The driving condition.

[0026] Even if the equivalent friction coefficient of the industrial gas film is slightly higher than the ideal value in the laboratory, for example, reaching The high-frequency vibration energy generated by the ultrasonic array is transmitted to the surface of the copper bar, triggering the effect of acoustic lubrication, causing the copper bar and the gas film interface to produce micron-level high-frequency jitter, converting macroscopic static friction into dynamic friction, thereby significantly reducing the starting resistance and ensuring that the millinewton-level acoustic radiation force is sufficient to drive the copper bar.

[0027] Need to be particularly pointed out is that the micro-hole sound transmission-air flow guide plate covering the surface of the acoustic pressure self-centering module plays a key role in flow field isolation, which transmits ultrasonic waves while diverting the bottom main suspension airflow to the surrounding laminar flow, effectively shielding the disturbance of the turbulent airflow to the central acoustic pressure potential well. Specifically, the micro-hole diameter of the micro-hole sound transmission-air flow guide plate is much smaller than the turbulent scale of the main suspension airflow, and the turbulent airflow output by the low-pressure blower is rectified into a laminar airflow film with a Reynolds number The guide plate is designed to have high aerodynamic flow resistance and low acoustic impedance, and its micro-hole structure acts as an acoustic low-pass filter while establishing a gas film static pressure gradient sufficient to support the copper bar, effectively isolating the aerodynamic noise and turbulent pulsation of the bottom fan, ensuring the phase consistency of the upper sound field is not destroyed by the shear layer, thereby ensuring the effectiveness of the sound field driving and ensuring that the weak acoustic radiation force is dominant in dynamics.

[0028] Using the focused sound field synthesized by the high-power ultrasonic array, under the near-zero friction working condition of gas-magnetic hybrid suspension, the time integral effect of acoustic radiation force can also overcome the mass inertia of the copper bar, and the copper bar will produce a small acceleration accumulation along the acoustic pressure gradient and gradually converge to the center of the potential well within a few seconds. At the same time, the high-frequency vibration of the ultrasonic wave can effectively eliminate the possible residual local viscous damping of the gas film; S5, starting the processing equipment of the processing station 200 to perform processing on the precisely positioned copper bar; In view of the technical problems in the prior art that the contact type scheme such as a roller and a robot gripper causes the copper bar surface to be easily damaged, heavy load positioning and transfer are slow, and flexible type changing efficiency is low, the embodiment of the present application provides an automatic copper bar conveying and processing method; the core of the method is to utilize the synergistic effect of electromagnetic field, flow field, airflow and sound field three physical fields to realize the full-process contactless conveying and high-precision positioning of heavy copper bars. The implementation process of the method is as follows: In S1, the system hardware is constructed, including a gas-magnetic hybrid suspension track as the main conveying path, and processing stations 200 arranged at predetermined points of the track, such as punch press and bending machine positions; the gas-magnetic hybrid suspension track integrates a gas flow system 400 providing main suspension force and an electromagnetic system 300 providing propulsion force and auxiliary suspension force; the gas flow system 400 is preferably connected to a low-pressure blower 420 of large flow and low pressure, rather than a high-pressure air compressor, to reduce energy consumption; In the processing station 200, such as the lower die table of a punch press, an acoustic pressure self-centering module 210 is embedded therein, which is an ultrasonic array of a specific frequency, and the array surface is covered with a micro-perforated acoustic transmission-air flow deflector, which is used to divert the bottom suspension airflow to the four directions while transmitting ultrasonic waves. The deflector preferably adopts a stainless steel mesh plate or a micro-perforated ceramic plate with a thickness of , and the micro-perforated aperture is designed to be , and the porosity is controlled to be ; and the plate thickness is designed to satisfy The micro-perforated acoustic transmission-air flow deflector is reversely designed based on the principle of micro-perforated plate sound absorption structure, which utilizes the acoustic mass of micro-perforations and the compliance of back cavity air cushion to form a Helmholtz resonator structure, adjusts the aperture and pitch ratio to match the acoustic impedance and air characteristic impedance, so as to realize high transmission of acoustic waves; at the same time, the static pressure difference established on both sides of the plate forces the airflow to accelerate and straighten in the micro-perforations, and after the outflow, a high-rigidity laminar flow air column is formed, which effectively suppresses the transverse turbulent pulsation, providing a uniform density medium channel for acoustic wave propagation and preventing acoustic wave phase distortion due to turbulent scattering; wherein is the wavelength of 40 kHz ultrasonic waves in air, about 8.5 mm, which ensures that the plate is in the acoustic long-wave region, and the acoustic transmission coefficient and the phase distortion can be ignored; This parameter combination makes the deflector present low acoustic impedance characteristics to ultrasonic waves, while forming sufficient back pressure damping to the low-pressure large-flow suspension airflow, forcing the airflow to be laminar and flow horizontally, preventing turbulent airflow from destroying the acoustic pressure standing wave field; considering the airflow leakage caused by micro-perforations, the hybrid suspension controller introduces a flow compensation coefficient of 1.15 1.25 when calculating the rotation speed of the low-pressure blower at the processing station, to ensure that the air film pressure after passing through the deflector is still sufficient to support the copper bar.

[0029] In S2, the copper bar to be processed is placed at the starting point of the track; In S3, hybrid suspension conveying is performed; the system starts the low-pressure blower 420 and the electromagnetic system 300; the airflow system 400 uniformly overflows low-pressure high-flow air from the track surface to form a stable air cushion, i.e., a main suspension air film, which bears about 80% of the gravity of the copper bar; the electromagnetic system 300 provides the remaining about 20% of the suspension force and actively closed-loop controls to keep the copper bar and the track surface at a physical gap of 5-10 mm, realizing non-contact stable suspension; at the same time, the traveling wave magnetic field generated by the linear motor winding 310 in the electromagnetic system 300 drives the copper bar as a moving object at a speed of 0.5 2 m / s non-contact along the track; In S4, precise positioning is performed; when the copper bar is driven by the electromagnetic system 300 to above the machining station 200 and decelerated to stop, the copper bar is still in a low-friction suspended state at this time; the system first uses the lateral pulsed jet flow of the track to control the X-Y plane position of the copper bar within a rough positioning range of ±3 mm; due to the limited effective capture potential well range of the acoustic pressure standing wave valley, this rough positioning step is a necessary prerequisite for realizing subsequent acoustic passive precise positioning; the acoustic pressure self-centering module 210 below the machining station 200 is activated; the ultrasonic array of the module is started to interfere to generate an acoustic pressure standing wave valley with the lowest energy in the X-Y plane of the suspended copper bar; the copper bar as a rigid reflector is pushed by non-contact acoustic radiation force, which is like an invisible spring, and uses the time integration effect to automatically and passively capture and lock the copper bar from the rough position of ±3 mm to the center point of the acoustic pressure valley; the center point strictly corresponds to the theoretical center of the machining die, and the copper bar is kept in the acoustic field for 1-2 seconds to realize precise positioning of ±0.1 mm; seconds, the inertia residual is completely eliminated by using the time integration effect, thereby realizing precise positioning of ±0.1 mm; In S5, after the copper bar is accurately locked by the acoustic field, the machining equipment such as the punch is started to perform machining.

[0030] In the step of S3, the step of stably suspending at the target height comprises: A Z-axis height sensor 500 is arranged along the air-magnetic hybrid suspension track to monitor the vertical distance between the bottom surface of the copper bar and the surface of the air-magnetic hybrid suspension track in real time; A hybrid suspension controller 600 is arranged to set and control the constant speed of the low-pressure blower (420) according to the nominal weight and bottom area of the copper bar to generate constant airflow to provide 80% of the suspension force; The Z-axis height sensor 500 detects the vertical distance in real time and compares it with the target height to generate a height deviation signal; The height deviation signal is the difference between the target height and the real-time vertical distance . The signal is input to the PID closed-loop control algorithm, and after proportional, integral, and differential operations, a current compensation instruction for the electromagnetic suspension coil 320 is output. The hybrid suspension controller 600 dynamically adjusts the current amplitude applied to the electromagnetic system 300 according to the height deviation signal and its rate of change, to compensate for the height deviation and keep the vertical distance stable at the target height. This embodiment specifically defines the closed-loop control logic for realizing Z-axis and vertical direction stable suspension in S3, that is, the cooperative strategy of the pneumatic base load and electromagnetic regulation and control. To realize this control, the Z-axis height sensor 500 and the hybrid suspension controller 600 are provided in the system. The working process is as follows: when the system is started or the copper bar specification is selected, the hybrid suspension controller 600 converts the air film base pressure value required to provide 80% suspension force according to the nominal weight and bottom area of the copper bar, and sets and locks the speed of the low-pressure blower 420 according to the air film base pressure value, so that it generates constant air flow as the base load. The distribution ratio of 80% air flow and 20% electromagnetic is set here because the air flow suspension has the characteristics of large bearing capacity and low energy consumption, and is suitable for bearing the main static constant load. Although the electromagnetic suspension has relatively high energy consumption, it has a millisecond-level fast response bandwidth and is suitable for bearing the dynamic adjustment load. The combination of the two ensures energy saving under heavy load and realizes high dynamic and static precision. During the conveying process, the Z-axis height sensor 500 monitors the vertical distance between the bottom surface of the copper bar and the track surface in real time, for example, every millisecond. The system compares the real-time detected vertical distance with the preset target height, for example, 7 mm, to generate a height deviation signal. The hybrid suspension controller 600 receives the height deviation signal and dynamically adjusts the current amplitude applied to the electromagnetic suspension coil 320 in the electromagnetic system 300 according to the signal only. This control process is independent of the traveling wave magnetic field control of the linear motor winding 310, ensuring that the vertical suspension force adjustment does not interfere with the horizontal propulsion speed. For example, when the actual height is lower than the target height, the hybrid suspension controller increases the current to increase the electromagnetic repulsive force and push the copper bar back to the target height. When the actual height is higher than the target height, the hybrid suspension controller reduces the current to reduce the electromagnetic repulsive force, so that the gravity prevails and the copper bar falls back to the target height. Through this active closed-loop feedback, the electromagnetic field compensates for the possible slight pressure fluctuations of the air film or ground vibrations at a high speed, ensuring the high stability of the heavy copper bar in the Z-axis height.

[0031] The steps of S4 include a flexible conversion step: When switching different specifications of copper bars, the nominal weight and bottom area of the copper bar are selected in the hybrid suspension controller 600. The hybrid suspension controller automatically converts and sets the base rotation speed of the low-pressure blower 420 according to the nominal weight and the base area, to provide the air film base pressure value corresponding to 80% suspension force; The air film base pressure value is calculated by the formula , wherein is the nominal weight; is the base area; is the effective air film bearing area coefficient of the gas-magnetic hybrid suspension track, and the value range is , which depends on the distribution density of surface micropores or slits; is the gravitational acceleration; the hybrid suspension controller 600 internally pre-stores a fan rotation speed-static pressure characteristic curve table, and maps the calculated to the target rotation speed instruction of the low-pressure blower 420 through table lookup or fitting algorithm; The hybrid suspension controller automatically adjusts the reference current of the electromagnetic system 300 to provide the reference force corresponding to 20% suspension force, while the closed-loop feedback logic of the target height remains unchanged; The embodiment specifically defines a flexible conversion method for different specifications of copper bars, solving the pain point of slow mechanical conversion in the prior art; When the production task needs to switch from one specification of copper bar to another, for example, 30 kg, the operator does not need to make any mechanical adjustment, but only needs to select the nominal weight and base area corresponding to the new copper bar in the hybrid suspension controller 600; After the hybrid suspension controller receives the new specification parameters, it will automatically convert and set the pure electrical parameters and fluid parameters: Air flow conversion: the hybrid suspension controller automatically recalculates and sets the base rotation speed required by the low-pressure blower 420 according to the new nominal weight and base area, so that it generates a corresponding constant air flow, for example, to provide about 235N of 80% base support force; Electromagnetic conversion: the hybrid suspension controller automatically adjusts the reference current of the electromagnetic system 300 to provide a corresponding reference force, for example, about 59N of 20% reference force; During the process, the Z-axis closed-loop feedback logic for maintaining the target height remains unchanged; at the same time, the hybrid suspension controller, according to the newly selected copper bar bottom area parameter, directly retrieves the internal stored phase hologram library for standard specification copper bars; for non-standard specification copper bars, the Gerchberg-Saxton iterative algorithm thread is started for real-time FPGA acceleration; the algorithm takes the plane wave phase or the converged phase at the last moment as the initial value of iteration, reloads the ultrasonic array phase control parameters matched with the new specification copper bar geometry, to ensure that the generated acoustic pressure standing wave valley morphology adapts to the new workpiece acoustic reflection boundary conditions; since the entire switching process only involves instantaneous adjustment of electrical and fluid parameters, there is no need to replace or adjust mechanical clamps, baffles or fixtures, thus achieving efficient flexible type changing.

[0032] In the step of S4, the working frequency of the ultrasonic array of the acoustic pressure self-centering module 210 is 40 kHz; The embodiment specifically defines the preferred working parameters of the acoustic pressure self-centering module 210 in S4; in the precise positioning step of S4, the acoustic pressure self-centering module 210 is activated to generate an acoustic pressure standing wave valley for capturing and locking the copper bar; in this embodiment, the working frequency of the ultrasonic array used by the module is set to 40 kHz; this frequency is verified to be able to effectively interfere in the X-Y plane of the copper bar suspension to generate an acoustic pressure standing wave valley with sufficient stiffness, i.e. acoustic radiation force, to passively push and lock heavy copper bars within a deviation range of, for example, ±3 mm to the center point, for example, ±0.1 mm.

[0033] In the step of S4, the nozzle array of the lateral pulsed jet is arranged on both sides of the gas-magnetic hybrid suspension track, and its gas source is communicated with the gas flow system 400 or independently arranged; the pulsed gas flow is ejected by opening the electromagnetic valve in milliseconds, to push the copper bar back to the center line.

[0034] In order to prevent overshoot oscillation, the lateral pulsed jet adopts a pulse width modulation control mode, and as the copper bar approaches the center line, the duty cycle and frequency of the jet pulse are gradually reduced to achieve smooth soft landing coarse positioning; The embodiment specifically defines the working mechanism of the lateral pulsed jet for realizing coarse positioning in S4; the lateral pulsed jet is used to control the lateral drift of the copper bar within a captureable range, for example, ±3 mm, before the activation of the acoustic field precise self-centering in S4; In this embodiment, the nozzle array of the pulsed jet is part of the gas flow system 400, and its gas source can be shared with the main suspension gas flow system 400 or independently arranged; when the lateral position detection sensor detects that the copper bar has lateral drift, the electromagnetic valve on the corresponding side is triggered to open in milliseconds, to eject a short and powerful air hammer-like pulsed gas flow, non-contacting to push the copper bar back to the track center line, thus completing the coarse attitude control.

[0035] The step of S5 further comprises: The copper bar is transported to a downstream station and the processing debris on the surface of the copper bar is blown off in line by using a Coanda effect wall-attached nozzle arranged at the station; The embodiment adds an optional in-line debris removal step after the processing step in S5; metal debris is generated during the processing of the copper bar, and if the debris is attached to the surface of the copper bar, it may affect the reliability of subsequent electrical connection; Therefore, after the processing in S5 is performed, the copper bar is transported to a downstream debris removal station by using the mixed suspension transportation method in S3; the station is provided with a Coanda effect wall-attached nozzle, and a curved flow guide vane is arranged above the outlet of the nozzle for inducing high-speed airflow to change the flow direction and flow closely along the flat surface of the copper bar; when the copper bar passes through, the nozzle uses high-speed airflow to perform non-contact in-line blowing on the surface of the copper bar by using the wall-attached effect, effectively removing the debris generated during the processing.

[0036] The Z-axis height sensor 500 is a laser height sensor or an eddy current sensor; The embodiment specifically defines the specific hardware implementation of the Z-axis height sensor 500 in the above; in order to realize non-contact real-time monitoring of the Z-axis height, the Z-axis height sensor 500 preferably adopts a non-contact sensor; in the embodiment, the sensor can be specifically implemented as a laser height sensor, for example, based on laser triangulation or an eddy current sensor; both of the two sensors can meet the requirements of high-speed and high-precision monitoring of the vertical distance between the bottom surface of the suspended copper bar and the surface of the track and the suspension height in an industrial environment.

[0037] Embodiment 2: Please refer to Figures 1-3 An automatic copper bar conveying and processing device, comprising: An air-magnetic hybrid suspension track for constructing a main conveying path of the copper bar; a bottom support seat of the air-magnetic hybrid suspension track is configured with an active leveling mechanism for keeping the track levelness within ±0.1 mm; A processing station 200 arranged at a predetermined processing point of the air-magnetic hybrid suspension track; The air-magnetic hybrid suspension track is composed of a plurality of stator units 110 connected in series, and the stator unit 110 integrally integrates: An electromagnetic system 300 including a linear motor winding 310 for propelling the copper bar and an electromagnetic suspension coil 320 for auxiliary suspension; An airflow system 400 including a composite air duct 410 for main suspension, and the airflow system 400 is connected to an external low-pressure blower 420; The lower part of the processing station 200 is embedded with a sound pressure self-centering module 210, the array surface of the sound pressure self-centering module 210 is covered with a micro-porous sound transmission-airflow deflector, the sound pressure self-centering module 210 is an ultrasonic array, used to generate a sound pressure standing wave trough in the X-Y plane of the copper bar suspension, to passively and precisely position the copper bar; The device further comprises: A lateral position detection sensor for detecting the lateral position of the copper bar; A Z-axis height sensor 500 installed along the gas-magnetic hybrid suspension track, used to monitor the vertical distance between the bottom surface of the copper bar and the surface of the gas-magnetic hybrid suspension track in real time; A lateral pulsed jet nozzle array 700 installed on both sides of the gas-magnetic hybrid suspension track, used to push the copper bar back to the center line during transportation; A hybrid suspension controller 600 electrically connected to the low-pressure blower 420, the electromagnetic system 300 and the Z-axis height sensor 500; the hybrid suspension controller 600 is configured to execute an automated copper bar transportation processing method.

[0038] The hybrid suspension controller 600 calculates the phase hologram required to form a sound pressure standing wave trough in the target focal plane based on a pre-established phase hologram library or a real-time FPGA-accelerated Gerchberg-Saxton iterative algorithm or holographic acoustic tweezers phase inversion algorithm, and introduces the nominal bottom surface size and shape of the current processing specification copper bar as the total reflection boundary condition in the calculation, specifically, in the iterative process of phase inversion, the sound field complex amplitude constraint of the target plane is modified as: ; Where is the sound reflection coefficient matrix, in the copper bar bottom surface area , the rest of the area , the mentioned here is not based on the real-time deviation position of the copper bar, but a static mask matrix constructed based on the geometric projection of the copper bar when it is located at the ideal processing center point; the hologram calculated by the algorithm essentially constructs a sound potential well in space that coincides with the ideal position, regardless of where the copper bar is currently located in the coarse positioning range, it will be subject to a restoring force pointing to the center of the potential well, is the pre-set target sound pressure amplitude distribution.

[0039] In the amplitude constraint step of the iterative algorithm, the target sound field complex amplitude is defined as: ; Where is the imaginary unit; and a weighted cost function is introduced: ; in, These are the gradient weight coefficients, and their value range is set to... To balance amplitude accuracy and potential well stiffness, this range is based on standard atmospheric pressure (101.3 kPa) and room temperature ( The empirical value for air density calibration under environmental conditions; if changes in ambient temperature cause a change in air density exceeding [a certain value]... It needs to be calibrated through experiments. Corrections are made to maintain the stiffness characteristics of the sound pressure gradient.

[0040] Experiments show that when At that time, the optimization weights focused too much on amplitude approximation, causing the gradient term at the center of the sound pressure valley to be affected. If the stiffness is too small, the resulting acoustic trap will not have sufficient stiffness to overcome the residual air viscous damping; while when At that time, although the gradient increases significantly, the sidelobe noise of the phase hologram increases sharply, disrupting the monotonicity of the main potential well and causing the copper busbar to oscillate without convergence; the second term in the formula Gradient used to maximize the center of the sound pressure standing wave trough This ensures that an acoustic stiffness capable of overcoming residual damping of the air film is formed at the center of the sound pressure valley; simultaneously, an effect on the cost function is introduced. Constraints on global gradients within the capture range; This embodiment provides an automated copper busbar conveying and processing device or system for performing the above-described method; the main structure of the device includes a pneumatic-magnetic hybrid suspension track and a processing station 200; A gas-magnetic hybrid levitation track forms the main conveying path for the copper busbars. Structurally, this track is modular, consisting of multiple stator units 110 connected end-to-end, allowing for easy expansion according to production line length requirements. Within each stator unit 110, two core systems are integrated: Electromagnetic system 300: This system includes two functional coils: one is a linear motor winding 310 for generating a traveling wave magnetic field to drive the copper busbar forward, and the other is an electromagnetic levitation coil 320 for providing auxiliary levitation force, such as 20% and Z-axis dynamic adjustment force. Airflow system 400: This system includes a composite air duct 410 inside the stator unit 110, for example, with micropores or slits on the surface, and the air duct is connected to an external low-pressure blower 420 to generate a bottom laminar air film that provides the main levitation force, such as 80%. Processing station 200, such as a punch or bending machine, is arranged at a predetermined processing point of the track; its key feature is that in the lower part of the processing station 200, such as the lower die table inside the punch, a built-in acoustic pressure self-centering module 210 is installed; the module is an ultrasonic array, which functions to generate an acoustic pressure standing wave trough in the X-Y plane of the copper bar suspension after the copper bar is transported into position, and uses acoustic radiation force to passively, i.e. non-servo feedback, precisely position the copper bar.

[0041] On the basis of the above-mentioned device, the key components required to realize active closed-loop control of the Z-axis are added; The device further comprises: Z-axis height sensor 500: such as the above-mentioned laser height sensor or eddy current sensor; as part of the air-magnetic hybrid suspension track, they are installed along the track, or at least at key stations, for real-time monitoring of the Z-axis vertical distance of the copper bar; Hybrid suspension controller 600: this is a core control unit; In terms of connection, the hybrid suspension controller 600 is electrically connected to the low-pressure blower 420 for controlling its speed; the electromagnetic system 300 for controlling its current amplitude; and the Z-axis height sensor 500 for receiving feedback signals; In terms of functional configuration, the hybrid suspension controller 600 is configured to execute the above-mentioned pneumatic base load and electromagnetic regulation logic; according to the height deviation signal fed back by the Z-axis height sensor 500 in real time, the difference between the actual height and the target height, the hybrid suspension controller dynamically adjusts the current of the electromagnetic suspension coil 320 at high speed, so as to actively compensate for various disturbances and keep the copper bar at the preset target height, such as 5-10mm.

[0042] The device is also provided with an online scrap removal module downstream of the processing station 200, which contains a Coanda effect wall-attached nozzle directed at the surface of the copper bar, and the nozzle is connected to a high-pressure gas source for stripping the processing debris on the surface of the copper bar with high-speed wall-attached gas flow; On the basis of the above-mentioned device, the components required to realize rough positioning in the X-Y plane are added; The device further comprises a lateral pulsed jet nozzle array 700; In terms of installation location, the nozzle array is installed on both sides of the air-magnetic hybrid suspension track; In terms of system affiliation, the nozzle array, or its gas source, is part of the entire air flow system 400, controlled by solenoid valves at the millisecond level; In function, the nozzle array is used to monitor and correct the lateral, X-axis drift of the copper bar during its transport S3 or upon arrival at the processing station 200 S4; when the copper bar deviates from the centerline, the corresponding side nozzles emit a pulse of air to push it back to the centerline, achieving a rough positioning of, for example, ±3 mm, providing a reliable initial range for the subsequent acoustic field precision positioning.

[0043] It should be noted that the above examples are only used to illustrate the technical solutions of the present application rather than limit the present application. Although the present application has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present application can be modified or equivalently replaced without departing from the spirit and scope of the present application.

Claims

1. An automated copper busbar conveying and processing method, characterized in that, include: S1. A gas-magnetic hybrid suspension track integrating an electromagnetic system (300) and an airflow system (400) is set up, and a processing station (200) with a sound pressure self-centering module (210) embedded in the lower part is set up at a predetermined processing point. The array surface of the sound pressure self-centering module (210) is covered with a microporous sound transmission-airflow guide plate. Lateral pulse jet nozzle arrays are set on both sides of the track. The airflow system (400) is connected to a low-pressure blower (420) to generate a main suspension air film. The electromagnetic system (300) is used to generate a traveling wave magnetic field and an auxiliary suspension force. The sound pressure self-centering module (210) is used to generate a sound pressure standing wave trough. S2. Place the copper busbar at the starting point of the air-magnetic hybrid levitation track; S3. Start the low-pressure blower (420) and the electromagnetic system (300). The airflow system (400) provides 80% levitation force and the electromagnetic system (300) provides 20% levitation force, so that the copper busbar is stably suspended at 5. A target height of 10mm is achieved, and a traveling wave magnetic field is generated by an electromagnetic system (300) to drive the copper busbar at 0.5... Non-contact conveying at a speed of 2m / s; S4. After the copper busbar is conveyed to the processing station (200) and decelerated and stopped, the lateral position detection sensors set on both sides of the track monitor the lateral offset of the copper busbar in real time, trigger the lateral pulse jet to achieve a rough positioning of ±3mm, and activate the sound pressure self-centering module (210) to generate a sound pressure standing wave valley in the XY plane. The sound radiation force is used to passively lock the copper busbar from the rough positioning position to the center point of the sound pressure valley, achieving a precise positioning of ±0.1mm. S5. Start the processing equipment at the processing station (200) to perform processing on the precisely positioned copper busbar.

2. The automated copper busbar conveying and processing method according to claim 1, characterized in that, In step S3, the steps for stabilizing the aircraft at the target height include: A Z-axis height sensor (500) is installed along the air-magnetic hybrid levitation track to monitor the vertical distance between the bottom surface of the copper busbar and the surface of the air-magnetic hybrid levitation track in real time; A hybrid suspension controller (600) is set up to control the low-pressure blower (420) to maintain a constant speed based on the nominal weight and bottom area of ​​the copper busbar, thereby generating a constant airflow to provide 80% suspension force. The Z-axis height sensor (500) detects the vertical distance in real time and compares it with the target height to generate a height deviation signal; The hybrid suspension controller (600) dynamically adjusts the current amplitude applied to the electromagnetic system (300) at high speed according to the height deviation signal and its rate of change to compensate for the height deviation and keep the vertical distance stable at the target height.

3. The automated copper busbar conveying and processing method according to claim 2, characterized in that, The S2 step is preceded by a flexible transformation step: When switching between different specifications of copper busbars, select the nominal weight and bottom area of ​​the copper busbar in the hybrid suspension controller (600); The hybrid suspension controller (600) automatically calculates and sets the base speed of the low-pressure blower (420) based on the nominal weight and bottom area to provide the air film base pressure value corresponding to 80% suspension force; The hybrid suspension controller (600) automatically adjusts the reference current of the electromagnetic system (300) to provide a reference force corresponding to 20% of the suspension force, while the closed-loop feedback logic of the target height remains unchanged.

4. The automated copper busbar conveying and processing method according to claim 1, characterized in that, In step S4, the ultrasonic array of the sound pressure self-centering module (210) operates at a frequency of 40kHz.

5. The automated copper busbar conveying and processing method according to claim 1, characterized in that, In step S4, the nozzle array of the lateral pulse jet is set on both sides of the gas-magnetic hybrid suspension track. Its air source is connected to or independently set with the airflow system (400). The pulse airflow is ejected by the solenoid valve in milliseconds, pushing the copper busbar back to the center line.

6. The automated copper busbar conveying and processing method according to claim 1, characterized in that, Following steps S5 are: The copper busbar is transported to the downstream station, where a Coanda effect wall-mounted nozzle is installed to blow away machining debris from the surface of the copper busbar online.

7. The automated copper busbar conveying and processing method according to claim 2, characterized in that, The Z-axis height sensor (500) is either a laser height sensor or an eddy current sensor.

8. An automated copper busbar conveying and processing device, characterized in that, include: A gas-magnetic hybrid suspension track is used to construct the main transport path for the copper busbars. The bottom support of the air-magnetic hybrid levitation track is equipped with an active leveling mechanism to maintain the track's horizontality. within; The processing station (200) is set at the predetermined processing point of the air-magnetic hybrid suspension track; The air-magnetic hybrid levitation track is composed of multiple stator units (110) connected in series, and the stator unit (110) integrates the following: The electromagnetic system (300) includes a linear motor winding (310) for propelling the copper busbar and an electromagnetic levitation coil (320) for assisting levitation. The airflow system (400) includes a composite air duct (410) for the main suspension and is connected to an external low-pressure blower (420). The lower part of the processing station (200) is embedded with a sound pressure self-centering module (210). The array surface of the sound pressure self-centering module (210) is covered with a microporous sound transmission-airflow guide plate. The sound pressure self-centering module (210) is an ultrasonic array used to generate sound pressure standing wave valleys in the XY plane where the copper busbar is suspended, so as to perform passive precision positioning of the copper busbar. The device further includes: Lateral position detection sensor, used to detect the lateral position of the copper busbar; A Z-axis height sensor (500) is installed along the air-magnetic hybrid suspension track to monitor the vertical distance between the bottom surface of the copper busbar and the surface of the air-magnetic hybrid suspension track in real time. Lateral pulse jet nozzle arrays (700) are installed on both sides of the air-magnetic hybrid levitation track to push the copper busbar back to the centerline during transport; A hybrid suspension controller (600) is electrically connected to a low-pressure blower (420), an electromagnetic system (300), and a Z-axis height sensor (500); the hybrid suspension controller (600) is configured to perform an automated copper busbar conveying process as described in any one of claims 1 to 7.

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