Modularized self-adaptive laser-assisted machining device and method

Abstract

The invention relates to the technical field of laser-assisted milling machining, and discloses a modularized self-adaptive laser-assisted machining device and method.The modularized self-adaptive laser-assisted machining device comprises a data acquisition module used for acquiring the three-dimensional shape of a workpiece before machining and acquiring physical parameters of the workpiece in the machining process; the electromechanical execution module is used for controlling the laser to pass through the to-be-machined area in the machining process; the laser light path module is used for emitting laser in the machining process and adjusting physical parameters of the laser; the data processing module is electrically connected with the data acquisition module, the electromechanical execution module and the laser light path module, and the data processing module is used for processing data acquired by the data acquisition module and generating double-path control instruction streams in parallel in a single processing period; and the laser light path module is driven to adjust laser parameters and adjust an advancing strategy of the electromechanical execution module.

Description

Technical Field

[0001] This invention relates to the field of laser-assisted milling technology, specifically to a modular adaptive laser-assisted machining device and method. Background Technology

[0002] With the increasing demand for high-performance materials (such as carbon fiber composites and ceramic matrix composites) in aerospace and other fields, higher requirements are being placed on the precision machining technology of these materials. However, due to the high hardness, low fracture toughness, and high wear resistance of these materials, traditional machining processes can easily lead to problems such as rapid tool wear, excessive cutting forces, and poor surface integrity, posing a serious challenge to the precision machining of composite materials. Laser-assisted machining technology can significantly improve the cutting performance of materials by locally softening them, but at present, this technology is mainly applied to relatively simple right-angle cutting and planar milling conditions. In complex curved surface milling, the challenge of laser-workpiece-tool coordinated control remains.

[0003] Currently, laser-assisted machining mainly employs two processes: in-situ laser-assisted cutting and off-axis laser-assisted cutting. While in-situ laser-assisted cutting offers advantages such as precise heating position and high energy utilization, it suffers from drawbacks including complex system integration, high cost of specialized tools, and poor flexibility in spot adjustment. It is also prone to irradiation blind spots in multi-axis or complex trajectory machining. Existing off-axis laser-assisted machining processes typically use an external laser head, mounted independently of the tool. This offers high flexibility in clamping position, relatively simple system setup, and requires no special modification to the cutting tool in practical applications, making it highly adaptable to various processes and thus a widely used approach. However, highly integrated off-axis laser-assisted machining machines have high development costs, while the simple approach of placing the laser device externally on the spindle side faces the technical challenge of achieving precise dynamic coordination between the laser and the cutting point. Furthermore, in traditional laser-assisted cutting, the laser spot size is typically an order of magnitude smaller than the workpiece width, and the laser relies primarily on linear movement for preheating. When process parameters are not properly controlled, large temperature gradients can easily occur, leading to subsurface damage. Existing systems of this type lack adaptive control capabilities when processing materials with complex curved surface features and anisotropic thermophysical properties, making it difficult to achieve dynamic optimization of laser energy distribution and thermal management control based on material properties and the geometric characteristics of the processing area.

[0004] Meanwhile, existing laser-assisted processing is a purely open-loop process, where processing quality and surface consistency depend on initial parameter settings, making it difficult to dynamically maintain the target preheating state throughout the entire process. Existing laser control systems are typically only used to set the initial laser parameters, lacking real-time in-situ monitoring and feedback mechanisms for key parameters (such as temperature field and stress) during processing, making it difficult to form an effective "processing-monitoring-adjustment" closed-loop control. Affected by system drift, workpiece geometric changes, and heat accumulation, existing laser-assisted processing systems struggle to maintain a stable target temperature field distribution in dynamic environments, easily leading to localized overheating or underheating, severely impacting processing quality and efficiency. Therefore, a novel laser-assisted processing system and method with multi-parameter collaborative monitoring and adaptive control capabilities is urgently needed.

[0005] Therefore, the industry urgently needs a new laser-assisted machining system and method that can integrate advanced laser control algorithms and intelligent machining trajectory adjustment modules, and combine the material properties and complex structural features of the workpiece to achieve high-quality and efficient milling of high-end equipment parts, thus solving the above problems. Summary of the Invention

[0006] The purpose of this invention is to address the shortcomings of the aforementioned technologies by providing a modular adaptive laser-assisted processing device and method to solve the problems described above.

[0007] To achieve the above objectives, the modular adaptive laser-assisted processing device designed in this invention includes: a data acquisition module, used to acquire the three-dimensional parameters of the workpiece before processing and to acquire the physical parameters of the workpiece during processing.

[0008] The laser optical path module is used to emit laser light during processing and to adjust the physical parameters of the laser light. The electromechanical actuation module is used to adjust the position of the laser spot in the laser optical path submodule; The data processing module is electrically connected to the data acquisition module, the electromechanical execution module, and the laser optical path module. The data processing module is used to process the data acquired by the data acquisition module and generate dual control command streams in parallel within a single processing cycle, which drive the laser optical path module to adjust the laser parameters and the electromechanical execution module to adjust the travel strategy.

[0009] Furthermore, the device also includes a pluggable connection assembly for docking the device with a machine tool.

[0010] Furthermore, before processing, the electromechanical execution module is driven to perform a no-load run based on the CAD model of the workpiece. During the no-load run, the data acquisition module acquires the three-dimensional appearance features of the workpiece and sends the data to the data processing module in combination with the preset material properties. Combining all the above information, the initial laser configuration parameters and the preset walking trajectory of the electromechanical execution module are generated.

[0011] During processing, the data acquisition module collects the physical information of the workpiece surface in real time to construct a geometric-temperature-force multiphysics field, and synchronously feeds it back to the data processing module. The data processing module synchronously receives the fused information stream, cyclically calls the laser temperature field inverse model, and generates dual control command streams in parallel within a single processing cycle. These streams drive the laser optical path module to adjust laser parameters in real time, and the electromechanical execution module to adjust the laser spot point and laser scanning parameters in real time. When the data acquisition module detects a sudden change in workpiece curvature or a local temperature gradient exceeding a set threshold, it activates the laser temperature field inverse model to update the laser scanning strategy in a timely manner. This eliminates the preheating blind zone and ensures that the heat-affected zone tends to be near the surface of the workpiece in the thickness direction and does not exceed the processing area in the width direction.

[0012] Furthermore, the data processing module archives the entire machining process of this workpiece to support subsequent process iterations and optimizations.

[0013] Preferably, the laser optical path module includes: a shaping optical path, an optical bench, a laser galvanometer, and a laser. The optical bench is hollow, forming a cavity. The shaping optical path is located inside the optical bench, the laser galvanometer is located at one end of the optical bench, and the laser passes through the other end of the optical bench. The output end of the laser is located within the cavity and faces the shaping optical path. In this design, the laser emits a Gaussian beam, which, after passing through the shaping optical path inside the optical bench, generates a flat-top beam. The laser galvanometer then changes the direction of the laser beam, ensuring that the adjusted laser meets the requirements for heating the workpiece surface.

[0014] Preferably, the shaping optical path includes: a micro-adjustment frame, a beam expander, and a six-axis adjustment frame. The micro-adjustment frame, beam expander, and six-axis adjustment frame are sequentially arranged in the accommodating cavity along the direction away from the laser, and the micro-adjustment frame, beam expander, and six-axis adjustment frame are movably connected to the inner wall of the optical bench. In this design, the purpose is to achieve beam shaping, adjusting Gaussian light into a flat-top beam. A laser provides the Gaussian beam, and a beam expander amplifies the beam diameter. The beam expander is mounted on a fine-adjustment frame via connectors and is used to move back and forth along the optical axis during optical path adjustment. The fine-adjustment frame is used for precise alignment of the incident light, ensuring coaxiality of subsequent optical paths and assisting in focusing and spacing. A six-axis adjustment frame is used to install and align the shaping mirror pair, providing six degrees of freedom coaxial adjustment so that the shaped light enters the galvanometer's optical axis. The six-axis adjustment frame, fine-adjustment frame, and beam expander are all fixed to a slide rail support by connecting fasteners, allowing for back-and-forth movement. This allows for overall back-and-forth sliding along the optical axis, facilitating coarse adjustment of the spacing between segments. Once in position, the frame is locked. The fine-adjustment frame, beam expander, and six-axis adjustment frame can be moved by motors, which is within the scope of understanding for those skilled in the art and will not be elaborated upon further in this application.

[0015] Preferably, the data acquisition module includes: a rangefinder, an infrared indicator, and a coaxial camera. The rangefinder is positioned next to the laser galvanometer and is electrically connected to the data analysis module; the infrared indicator is positioned next to the laser galvanometer and is electrically connected to the data analysis module; the coaxial camera is positioned next to the laser galvanometer and is electrically connected to the rangefinder and the data analysis module. In this design, the rangefinder is used to measure the relative distance between the laser emission port and the workpiece surface, the infrared indicator is used to indicate the laser spot irradiation area, and the coaxial camera is used to confirm the position of the spot. The three components work together to confirm the laser focal length. The data is fed back to the data processing module, which processes the obtained data and then generates a dual-channel control command stream to drive the laser optical path module to adjust the laser parameters in real time and the electromechanical execution module to adjust the laser spot landing point and laser travel speed in real time.

[0016] Preferably, the data acquisition module further includes: an infrared camera, a visible light camera, and an ultrasonic sensor. The infrared camera is detachably mounted on the CNC machine tool and electrically connected to the data processing module; the visible light camera is detachably mounted on the CNC machine tool and electrically connected to the data processing module; the ultrasonic sensor is detachably mounted on the CNC machine tool and electrically connected to the data processing module. In this design, the ultrasonic sensor is fixed to the side of the machine tool spindle via a flexible ring clamp, and the infrared camera is connected to the machine tool bearing seat via a detachable magnetic adsorption clamp. The infrared sensor and the visible light camera are located on opposite sides of the machine tool. Before and during the machining process, the infrared camera is used to dynamically monitor the temperature field and its gradient distribution in the area to be machined, the ultrasonic sensor is used to collect acoustic vibration information in real time, and the visible light camera is used to collect the geometric features of the workpiece.

[0017] Preferably, the electromechanical execution module includes: a chassis, a lifting platform, a horizontal moving platform, and an angle adjuster. The lifting platform is mounted on the chassis and fixedly connected to the chassis. The horizontal moving platform is movably mounted on the lifting platform, and the angle adjuster is rotatably mounted on the horizontal moving platform. The laser optical path module is mounted on the electromechanical execution module via the angle adjuster. In this design, the lifting platform is mainly used for adjusting the position of the laser optical path module in the Z-axis direction, the moving platform is mainly used for adjusting the position of the laser optical path module in the X and Y directions, and the angle adjuster is mainly used for adjusting the emission angle of the laser optical path module. The entire electromechanical execution module can control the laser optical path module to move freely within its working range. The lifting platform, horizontal moving platform, and angle adjuster are controlled by motors, which is understandable to those skilled in the art and will not be elaborated upon further in this application.

[0018] Preferably, the data processing module has a housing and a control panel, the electromechanical execution module is mounted on the housing and fixedly connected to the housing, and the control panel is mounted on the housing through the electromechanical execution module.

[0019] A modular adaptive laser-assisted processing method includes the following steps: S1. Connect the modular adaptive laser-assisted processing device to the machine tool to be processed; S2. Input the physical and mechanical parameters of the workpiece material to be processed and the processing requirements to the data processing module; S3. Start the machine tool to perform a no-load run and acquire the three-dimensional shape features of the workpiece to be processed; S4. Call the inverse laser temperature field model to generate initial laser configuration parameters, as well as preset parameters for the laser optical path module and electromechanical execution module; S5. Processing begins, and the data acquisition module remains active. S6. The data processing module cyclically calls the inverse laser temperature field model based on the data acquired by the data acquisition module, dynamically corrects the laser configuration parameters in real time, and sends dual control command streams from the laser optical path module and the electromechanical execution module until the processing is completed.

[0020] Preferably, the laser temperature field inverse model constructs an online estimate of the current temperature field and geometric features of the workpiece based on the data acquired by the data acquisition module in each control cycle, and solves for the laser configuration parameters in the rolling time domain. The configuration parameters include at least the laser power, spot size, scanning path, and scanning speed.

[0021] The preferred inverse laser temperature field model includes: a temperature prediction module and a temperature constraint module; The temperature prediction module is used to predict the temperature of arbitrary laser trajectories, forming a rapid evaluation of the objective function and constraints. The laser heat source used for modeling is a moving elliptical Gaussian heat source and / or a flat-topped spot heat source. The solution primarily employs the Green's function, with the core function being: in The temperature at time t is given, and P is the laser power. and These are the half-lengths of the major and minor axes of the laser spot, respectively. η is the instantaneous position of the laser spot, η is the laser thermal absorptivity of the workpiece material, α is the thermal diffusivity of the material, k is the thermal conductivity of the material, ρ is the density of the material, and c is the heat capacity of the material. The temperature constraint module, based on the temperature field and geometric feature data acquired by the data acquisition module, inversely solves the laser parameters in the rolling time domain to minimize the deviation between the temperature distribution in the target area and the target temperature distribution. The inverse solution uses the target temperature as a benchmark, employing the minimization of the sum of squared differences between the evaluation results from the temperature prediction module and the target temperature as the objective function. Laser parameter optimization is performed while satisfying the following constraints: the residual workpiece material temperature reaches the material thermal softening threshold but does not exceed the material phase transition threshold; the laser power is constrained by the upper and lower limits of the laser output; the laser scanning preheating width is close to the workpiece width; and the laser scanning speed and acceleration do not exceed the upper limit of the mechanism's capacity. Before processing, the performance parameters of the material to be processed and the constraint parameters are input into the data processing module to complete the initial setting of the laser parameters. During processing, the input end of the data processing module receives fused data from the data acquisition module in real time. When a curvature mutation or temperature gradient exceeding a preset threshold is detected, event-driven replanning is triggered to update the laser parameters online, thereby achieving uniform control of the preheating volume and avoiding overheating in a dynamic processing environment.

[0022] Compared with the prior art, the present invention has the following advantages: 1. This application enables non-destructive functional upgrades of outdated machining equipment. It reconstructs the thermo-coupling machining capabilities of machine tools through pluggable devices and achieves protocol compatibility with most domestic machine tool control systems based on the NC-Link protocol communication interface, thus solving the problems of modular scalability and cost.

[0023] 2. Solve the problems of uneven preheating and optical path obstruction in complex structural components. Establish a dynamic collaborative control mechanism between the tool and the optical beam. Based on real-time geometric feature detection, dynamically plan the beam scanning trajectory to achieve uniform preheating of workpieces with arbitrary curvature, improve preheating efficiency, and avoid tool obstruction of the optical path.

[0024] 3. Solve the problem of inaccurate control in the heat-affected zone. Construct a closed-loop thermal field sensing-control chain, and based on the fusion of data from multiple sensors, complete the inverse solution of the nonlinear mapping between the heat source and the temperature field. Dynamically adjust parameters such as laser power and irradiation angle to reduce the thickness fluctuation of the heat-affected zone and effectively eliminate surface and subsurface damage to the workpiece. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the modular adaptive laser-assisted processing device of the present invention; Figure 2 This is a schematic diagram of the data acquisition module (infrared camera, visible light camera, and ultrasonic sensor); Figure 3 This is a structural schematic diagram of the electromechanical actuator module; Figure 4 This is a schematic diagram of the laser optical path module. Figure 5This is a cross-sectional view of the laser optical path module; Figure 6 This is a workflow diagram.

[0026] The components in the diagram are labeled as follows: Laser optical path module 1, optical bench 11, laser galvanometer 12, laser 13, micro-adjustment frame 141, beam expander 142, six-axis adjustment frame 143, electromechanical actuator module 2, lifting platform 21, horizontal moving platform 22, angle adjuster 23, data processing module 3, control panel 31, data acquisition module 4, rangefinder 41, infrared indicator 42, coaxial camera 43, infrared camera 44, visible light camera 45, ultrasonic sensor 46, pluggable connection assembly 5. Detailed Implementation

[0027] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings and embodiments. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. 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 invention.

[0028] The modular adaptive laser-assisted processing device includes: a data acquisition module 4, used to acquire the three-dimensional parameters of the workpiece before processing and to acquire the physical parameters of the processing area during processing.

[0029] Laser optical path module 1 is used to emit laser light during processing and adjust the physical parameters of the laser light. Electromechanical actuation module 2 is used to adjust the position of the laser spot in the laser optical path submodule; The data processing module 3 is electrically connected to the data acquisition module 4, the electromechanical execution module 2 and the laser optical path module 1 respectively. The data processing module 3 is used to process the data acquired by the data acquisition module 4 and generate dual control command streams in parallel within a single processing cycle, which drive the laser optical path module 1 to adjust the laser parameters and the electromechanical execution module 2 to adjust the travel strategy respectively.

[0030] Furthermore, the device also includes a pluggable connection assembly 5 for docking the device with a machine tool.

[0031] Furthermore, before processing, the electromechanical execution module 2 is driven to perform a no-load run based on the CAD model of the workpiece. During the no-load run, the data acquisition module 4 acquires the three-dimensional appearance features of the workpiece and sends the data to the data processing module 3 in combination with the preset material properties. Combining all the above information, the initial laser configuration parameters and the preset travel trajectory of the electromechanical execution module 2 are generated.

[0032] During processing, the data acquisition module 4 collects the physical information of the workpiece surface in real time to construct a geometric-temperature-force multi-physics field, and synchronously feeds it back to the data processing module 3. The data processing module 3 synchronously receives the fused information stream, cyclically calls the laser temperature field inverse model, and generates dual control command streams in parallel within a single processing cycle to drive the laser optical path module 1 to adjust laser parameters in real time and the electromechanical execution module 2 to adjust the laser spot point and laser travel speed in real time. When the data acquisition module 4 detects a sudden change in workpiece curvature or a local temperature gradient exceeding a set threshold, it activates the laser temperature field inverse model to update the laser scanning strategy in a timely manner to eliminate the preheating blind zone and ensure that the heat-affected zone tends to be close to the workpiece surface in the thickness direction and does not exceed the processing area in the width direction.

[0033] Furthermore, the data processing module 3 archives the entire process of machining this workpiece to support subsequent process iterations and optimizations.

[0034] In one specific embodiment, the laser optical path module 1 includes: a shaping optical path, an optical bench 11, a laser galvanometer 12, and a laser 13. The optical bench 11 is hollow, forming a cavity. The shaping optical path is disposed inside the optical bench 11. The laser galvanometer 12 is disposed at one end of the optical bench 11, and the laser 13 passes through the other end of the optical bench 11. The output end of the laser 13 is located within the cavity and faces the shaping optical path. In this embodiment, the laser 13 emits a Gaussian beam, which, after passing through the shaping optical path inside the optical bench 11, generates a flat-top beam. The laser mirror 12 then changes the direction of the laser beam, ensuring that the adjusted laser meets the requirements for heating the workpiece surface.

[0035] In one specific embodiment, the shaping optical path includes: a micro-adjustment frame 141, a beam expander 142, and a six-axis adjustment frame 143. The micro-adjustment frame 141, the beam expander 142, and the six-axis adjustment frame 143 are sequentially arranged in the accommodating cavity along a direction away from the laser 13, and the micro-adjustment frame 141, the beam expander 142, and the six-axis adjustment frame 143 are movably connected to the inner wall of the optical bench 11. In this embodiment, the purpose is to achieve beam shaping, adjusting the Gaussian light into a flat-top beam. Laser 13 provides the Gaussian beam, and beam expander 142 amplifies the beam diameter. Beam expander 142 is mounted on fine-adjustment bracket 141 via a connector, allowing it to move back and forth along the optical axis during optical path adjustment. Fine-adjustment bracket 141 is used for precise alignment of the incident light, ensuring coaxiality of the subsequent optical path and assisting in focusing and spacing. Six-axis adjustment bracket 143 is used to install and align the shaping mirror pair, providing six degrees of freedom coaxial adjustment so that the shaped light enters the galvanometer optical axis. Six-axis adjustment bracket 143, fine-adjustment bracket 141, and beam expander 142 are all fixed to the slide rail support by connecting fasteners, enabling back-and-forth movement. This allows for overall back-and-forth sliding along the optical axis, facilitating coarse adjustment of the spacing between segments. After being moved into position, they are locked. Fine-adjustment bracket 141, beam expander 142, and six-axis adjustment bracket 143 can be moved by motors, which is understandable to those skilled in the art and will not be elaborated upon further in this application.

[0036] In one specific embodiment, the data acquisition module 4 includes: a rangefinder 41, an infrared indicator 42, and a coaxial camera 43. The rangefinder 41 is located beside the laser galvanometer 12 and is electrically connected to the data analysis module; the infrared indicator 42 is located beside the laser galvanometer 12 and is electrically connected to the data analysis module; the coaxial camera 43 is located beside the laser galvanometer 12 and is electrically connected to the data analysis module. In this embodiment, the rangefinder 41 is used to measure the relative distance between the laser spot and the workpiece surface, the infrared indicator is used to indicate the laser spot irradiation area, and the coaxial camera 43 is used to confirm the position of the spot. The three work together to confirm the laser focal length. The data is fed back to the data processing module 3, which processes the obtained data and then sends out a dual-channel control command stream to drive the laser optical path module 1 to adjust the laser parameters in real time and the electromechanical execution module 2 to adjust the laser spot landing point and laser travel speed in real time.

[0037] In one specific embodiment, the data acquisition module 4 further includes an infrared camera 44, a visible light camera 45, and an ultrasonic sensor 46. The infrared camera 44 is detachably mounted on the CNC machine tool and is electrically connected to the data processing module 3; the visible light camera 45 is detachably mounted on the CNC machine tool and is electrically connected to the data processing module 3; the ultrasonic sensor 46 is detachably mounted on the CNC machine tool and is electrically connected to the data processing module 3. In this embodiment, the ultrasonic sensor 46 is fixed to the side of the machine tool spindle by a flexible ring clamp, and the infrared camera 44 is connected to the machine tool bearing seat by a detachable magnetic adsorption clamp. The infrared sensor and the visible light camera 45 are located on opposite sides of the machine tool. Before and during the machining process, the infrared camera 44 is used to dynamically monitor the temperature field and its gradient distribution in the area to be machined, the ultrasonic sensor 46 is used to collect acoustic vibration information in real time, and the visible light camera 45 is used to collect the geometric features of the workpiece.

[0038] In one specific embodiment, the electromechanical execution module 2 includes a chassis, a lifting platform 21, a horizontal moving platform 22, and an angle adjuster 23. The lifting platform 21 is mounted on the chassis and fixedly connected to the chassis. The horizontal moving platform 22 is movably mounted on the lifting platform 21, and the angle adjuster 23 is rotatably mounted on the horizontal moving platform 22. The laser optical path module 1 is mounted on the electromechanical execution module 2 via the angle adjuster 23. In this embodiment, the lifting platform 21 is mainly used for adjusting the position of the laser optical path module 1 in the Z-axis direction, the moving platform is mainly used for adjusting the position of the laser optical path module 1 in the X and Y directions, and the angle adjuster 23 is mainly used for adjusting the emission angle of the laser optical path module 1. The entire electromechanical execution module 2 can control the laser optical path module 1 to move freely within its working range. The lifting platform 21, the horizontal moving platform 22, and the angle adjuster 23 are controlled by motors, which is understandable to those skilled in the art and will not be elaborated upon further in this application.

[0039] In one specific embodiment, the data processing module 3 has a housing and a control panel 31, the electromechanical execution module 2 is disposed on the housing and is fixedly connected to the housing, and the control panel 31 is disposed on the housing through the electromechanical execution module 2.

[0040] A modular adaptive laser-assisted processing method includes the following steps: S1. Connect the modular adaptive laser-assisted processing device to the machine tool to be processed; S2. Input the physical and mechanical parameters of the workpiece to be processed and the processing requirements to the data processing module 3; S3. Start the machine tool to perform a no-load run and acquire the three-dimensional features of the workpiece to be processed; S4. Call the inverse laser temperature field model to generate initial laser configuration parameters, as well as preset parameters for the laser optical path module and electromechanical execution module; S5. Start processing, while data acquisition module 4 remains on. S6. The data processing module cyclically calls the inverse laser temperature field model based on the data acquired by the data acquisition module, dynamically corrects the laser configuration parameters in real time, and sends dual control command streams from the laser optical path module and the electromechanical execution module until the processing is completed.

[0041] In one specific embodiment, the inverse optical temperature field model constructs an online estimate of the current temperature field and geometric features of the workpiece based on the data acquired by the data acquisition module 4 in each control cycle, and solves for the laser configuration parameters in the rolling time domain. The configuration parameters include at least the laser power, spot size, scanning path, and scanning speed.

[0042] The preferred inverse laser temperature field model includes: a temperature prediction module and a temperature constraint module; The temperature prediction module is used to predict the temperature of arbitrary laser trajectories, forming a rapid evaluation of the objective function and constraints. The laser heat source used for modeling is a moving elliptical Gaussian heat source and / or a flat-topped spot heat source. The solution primarily employs the Green's function, with the core function being: in The temperature at time t is given, and P is the laser power. and These are the half-lengths of the major and minor axes of the laser spot, respectively. η is the instantaneous position of the laser spot, η is the laser thermal absorptivity of the workpiece material, α is the thermal diffusivity of the material, k is the thermal conductivity of the material, ρ is the density of the material, and c is the heat capacity of the material. The temperature constraint module, based on the temperature field and geometric feature data acquired by the data acquisition module 4, inversely solves the laser parameters in the rolling time domain to minimize the deviation between the temperature distribution in the target area and the target temperature distribution. The inverse solution uses the target temperature as a benchmark, employing the minimization of the sum of squared differences between the evaluation results of the temperature prediction module and the target temperature as the objective function. Laser parameter optimization is performed while satisfying the following constraints: the residual workpiece material temperature reaches the material thermal softening threshold but does not exceed the material phase transition threshold; the laser power is constrained by the upper and lower limits of the laser 13 output; the laser scanning preheating width is close to the workpiece width; and the laser scanning speed and acceleration do not exceed the upper limit of the mechanism's capacity. Before processing, the performance parameters of the material to be processed and the constraint parameters are input into the data processing module 3 to complete the initial setting of the laser parameters. During processing, the input end of the data processing module 3 receives fused data from the data acquisition module 4 in real time. When a curvature mutation or temperature gradient exceeding a preset threshold is detected, event-driven replanning is triggered to update the laser parameters online, thereby achieving uniform control of the preheating volume and avoiding overheating in a dynamic processing environment.

[0043] Example 1 First, the workpiece to be processed is clamped on the machine tool, and this device is connected to the machine tool. The infrared camera 44, visible light camera 45, and ultrasonic sensor 46 are then installed on the machine tool. After completing the above preparations, a single idle pass is performed according to the machine tool's original toolpath program. The main purpose of this step is to allow the data acquisition module 4 to collect the three-dimensional shape data of the workpiece. Then, the material properties of the workpiece, including density, thermal conductivity, and other physical information, are input into the data processing module 3. The data processing module 3 generates laser information based on the above information, including the changes in laser power and spot size throughout the processing, as well as the path, speed, and angle adjustment that the electromechanical execution module 2 should drive the laser optical path module 1 through during the entire processing.

[0044] Once the machine tool is equipped with cutting tools and machining begins, data acquisition module 4 operates continuously throughout the process. It monitors the surface temperature of the workpiece in real time, checking for sudden changes in workpiece curvature or local temperature gradients exceeding set thresholds. If any of these occur, the laser temperature field inverse model is immediately activated to update the laser scanning strategy, eliminating preheating blind spots and ensuring the heat-affected zone approaches the workpiece surface in the thickness direction and does not exceed the machining area in the width direction. This process is repeated iteratively, continuously correcting and calibrating the preheating path and temperature gradient until machining is complete. After machining, all process data is archived for subsequent process optimization.

[0045] It should be noted that the above description of the technical solutions is exemplary, and this specification may be embodied in different forms and should not be construed as limiting it to the technical solutions set forth herein. Rather, providing these descriptions will ensure that the disclosure of this invention is thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Furthermore, the technical solutions of this invention are defined only by the scope of the claims.

[0046] The aspects disclosed in this specification and claims are merely examples, and therefore, this specification and claims are not limited to the details shown. In the foregoing description, detailed descriptions of relevant known functions or configurations have been omitted where it would unnecessarily obscure the focus of this specification and claims.

[0047] Finally, it should be noted that the above description is a further detailed explanation of the invention in conjunction with specific embodiments. It should not be considered that the specific implementation of the invention is limited to these descriptions. For those skilled in the art, any simple substitutions made without departing from the concept of the invention should be considered within the scope of protection of this invention. The above embodiments are merely representative examples of the invention. Obviously, the invention is not limited to the above embodiments and many variations are possible. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the invention should be considered within the scope of protection of this invention.

Claims

1. A modular adaptive laser-assisted machining device, electrically connected to a numerical control machine tool, characterized in that, The application relates to a laser processing system, which comprises the following parts: a data acquisition module (4) for acquiring the three-dimensional parameters of a workpiece before processing and collecting the physical parameters of the workpiece during processing; a laser light path module (1) for emitting laser light during processing and adjusting the physical parameters of the laser light; an electromechanical execution module (2) for adjusting the spot position of the laser light path sub-module (1); a data processing module (3) electrically connected with the data acquisition module (4), the electromechanical execution module (2) and the laser light path module (1), the data processing module (3) is used for processing the data collected by the data acquisition module (4) and generating double-path control instruction streams in parallel in a single processing cycle to drive the laser light path module (1) to adjust the laser parameters and adjust the travel strategy of the electromechanical execution module (2).

2. The modular, adaptive laser-assisted machining device of claim 1, wherein, The laser light path module (1) comprises a shaping light path, an optical bench (11), a laser galvanometer (12) and a laser (13); the optical bench (11) is internally hollow and forms a containing cavity, the shaping light path is arranged in the interior of the optical bench (11), the laser galvanometer (12) is arranged at one end of the optical bench (11), the laser (13) is arranged at the other end of the optical bench (11), the output end of the laser (13) is located in the containing cavity, and the output end of the laser (13) faces the shaping light path.

3. The modular, adaptive laser-assisted machining device of claim 2, wherein, The shaping light path comprises a fine adjustment frame (141), a beam expander (142) and a six-axis adjustment frame (143); the fine adjustment frame (141), the beam expander (142) and the six-axis adjustment frame (143) are sequentially arranged in the containing cavity in a direction away from the laser (13), and the fine adjustment frame (141), the beam expander (142) and the six-axis adjustment frame (143) are movably connected with the inner wall of the optical bench (11).

4. The modular, adaptive laser-assisted machining device of claim 2, wherein, The data acquisition module (4) comprises a range finder (41), an infrared indicator (42) and a coaxial camera (43), the range finder (41) is arranged beside the laser galvanometer (12) and is electrically connected with the data analysis module, the infrared indicator (42) is arranged beside the laser galvanometer (12) and is electrically connected with the data analysis module, and the coaxial camera (43) is arranged beside the laser galvanometer (12) and is electrically connected with the data analysis module.

5. The modular, adaptive laser machining apparatus of claim 1, wherein, The data acquisition module (4) further comprises an infrared camera (44), a visible light camera (45) and an ultrasonic sensor (46), the infrared camera (44) is detachably arranged on the numerical control machine tool and is electrically connected with the data processing module (3), the visible light camera (45) is detachably arranged on the numerical control machine tool and is electrically connected with the data processing module (3), and the ultrasonic sensor (46) is detachably arranged on the numerical control machine tool and is electrically connected with the data processing module (3).

6. The modular, adaptive laser machining apparatus of claim 1, wherein, The electromechanical execution module (2) comprises a chassis, a lifting platform (21), a horizontal moving platform (22) and an angle adjuster (23), the lifting platform (21) is arranged on the chassis, the lifting platform (21) is fixedly connected with the chassis, the horizontal moving platform (22) is movably arranged on the lifting platform (21), and the angle adjuster (23) is rotatably arranged on the horizontal moving platform (22); the laser light path module (1) is arranged on the electromechanical execution module (2) through the angle adjuster (23).

7. The modular, adaptive laser-assisted machining device of claim 6, wherein, The data processing module (3) has a shell and a control panel (31), the electromechanical execution module (2) is arranged on the shell, the electromechanical execution module (2) is fixedly connected with the shell, and the control panel (31) is arranged on the shell through the electromechanical execution module (2).

8. A modular adaptive laser-assisted machining method using the modular adaptive laser-assisted machining device according to any one of claims 1 to 7, characterized in that, The method comprises the following steps: S1, connecting the modular adaptive laser auxiliary machining device to a machine tool; S2, inputting physical and mechanical parameters of a workpiece to be machined and machining requirements to the data processing module (3); S3, starting the machine tool to perform empty walking to obtain three-dimensional characteristics of the workpiece to be machined; S4, calling a laser temperature field inverse solution model to generate initial laser configuration parameters and parameter presets of the laser light path module (1) and the electromechanical execution module (2); S5, starting machining, and simultaneously, the data acquisition module (4) is continuously turned on; S6, the data processing module (3) cyclically calls the laser temperature field inverse solution model according to data obtained by the data acquisition module (4), dynamically corrects laser configuration parameters and double-path control instruction streams of the laser light path module (1) and the electromechanical execution module (2) in real time, and stops until machining is completed.

9. The modular, adaptive laser-assisted machining method of claim 8, wherein, The laser temperature field inverse solution model in step S6 constructs online estimation of a current temperature field and geometric characteristics of the workpiece based on data obtained by the data acquisition module (4) in each control period, and solves laser configuration parameters in a rolling time domain, wherein the configuration parameters at least include laser power, spot size, scanning path and scanning speed.

10. The modular, adaptive laser-assisted machining method of claim 9, wherein, The laser temperature field inverse solution model comprises a temperature prediction module and a temperature constraint module; The temperature prediction module is used for temperature prediction of an arbitrary laser track, and is used for rapid evaluation of a target function and constraints, a modeling laser heat source is a moving elliptical Gaussian heat source and / or a flat-top spot heat source, mainly adopts Green function solution, and a core function is: wherein is the temperature at time t, P is the laser power, and are the half-lengths of the long and short axes of the laser spot, respectively, is the instantaneous position of the laser spot, η is the laser heat absorption rate of the workpiece material, α is the thermal diffusivity of the material, k is the thermal conductivity of the material, ρ is the density of the material, and c is the thermal capacity of the material; The temperature constraint module inversely solves the laser parameters on the rolling time domain based on the temperature field and geometric feature data collected by the data acquisition module (4) to minimize the deviation between the target region temperature distribution and the target temperature distribution; the inverse solution takes the target temperature as the benchmark, adopts the difference between the evaluation results of the temperature prediction module and the target temperature, and minimizes the sum of squares as the objective function, and the laser parameters are optimized under the following constraints: the residual workpiece material temperature reaches the material thermal softening threshold and does not exceed the material phase change threshold, the laser power is constrained by the upper and lower limits of the laser output, the laser scanning preheating width can approach the workpiece width, and the laser scanning speed and acceleration do not exceed the upper limit of the mechanism capability. Before processing, the material performance parameters and constraint parameters to be processed are input into the data processing module (3) to complete the initial setting of the laser parameters; during the processing, the input end of the data processing module (3) receives the fusion data from the data acquisition module (4) in real time, and when the curvature mutation or the temperature gradient exceeds the preset threshold is detected, the event-driven re-planning is triggered to update the laser parameters online, thereby realizing the uniform control of the preheating volume and avoiding overheating under the dynamic processing environment.

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