Casting grinding, clamping and supporting device

Abstract

The invention discloses a casting grinding, clamping and supporting device, relates to the technical field of casting machining, and aims to solve the problems of poor adaptive capacity, low cooperative control precision, lack of real-time monitoring and weak adaptability in the prior art. The device comprises a casting information sensing module, a clamping parameter decision-making module, a supporting posture regulation and control module, a grinding collaborative adaptation module, a real-time monitoring feedback module and a central control module, clamping and supporting parameters are decided through sensing casting information and an intelligent algorithm, synchronous adaptation with grinding movement is achieved, the parameters are dynamically corrected in combination with real-time monitoring feedback, full-process closed-loop control is formed, and the grinding efficiency is improved. The casting polishing device can adapt to polishing of various castings without replacing mechanical assemblies, the polishing precision, stability and machining efficiency are effectively improved, and the casting polishing device is suitable for various casting polishing scenes.

Description

Technical Field

[0001] This invention belongs to the field of casting processing technology, and in particular relates to a casting grinding clamping support device. Background Technology

[0002] In the casting process, the grinding process is a key step to improve the surface accuracy of castings, remove burrs and excess gating gates, and the stability of the clamping support system directly determines the grinding accuracy and operational safety.

[0003] Existing technologies related to casting grinding, clamping, and support mostly rely on fixed mechanical components to achieve clamping and support, which presents numerous technical bottlenecks:

[0004] Firstly, it lacks adaptive control capabilities and cannot dynamically adjust the clamping force and support posture according to castings of different materials, shapes, and sizes. This can easily lead to over-clamping causing casting deformation or under-clamping causing casting displacement during grinding.

[0005] Secondly, the low precision of the coordinated control between clamping and support makes it difficult to match the movement trajectory of the grinding tool and the grinding intensity, resulting in insufficient support stability and affecting the surface roughness of the grinding surface.

[0006] Third, the lack of a real-time monitoring and feedback adjustment mechanism makes it impossible to promptly detect stress changes, displacement deviations, and the operating status of the clamping support system during the grinding process, which can easily lead to safety hazards.

[0007] Fourth, the system has poor adaptability. Different mechanical components need to be replaced for different working conditions such as large and complex castings, thin-walled and easily deformable castings, and small precision castings. The system has poor versatility, which increases processing costs and operation time.

[0008] In existing technologies, improvements to casting grinding clamping supports mostly focus on optimizing the mechanical structure, failing to construct a comprehensive intelligent collaborative control system at the system level. This fails to fundamentally address the aforementioned issues of adaptability, collaboration, safety, and compatibility. Therefore, there is an urgent need to construct a casting grinding clamping support device with a pure system architecture. Through modular design, intelligent algorithm control, and full-process monitoring and feedback, this device can achieve precise clamping and stable support for casting grinding under different working conditions, thereby improving grinding quality and efficiency. Summary of the Invention

[0009] The purpose of this invention is to provide a clamping and support device for grinding castings, which solves the problems of poor adaptability, low precision of collaborative control, lack of real-time monitoring and feedback, and weak adaptability of existing clamping and support methods that rely on mechanical structures. By constructing an intelligent control system with a pure system architecture, it can achieve precise clamping and stable support during the grinding process of castings of different materials, shapes, and sizes.

[0010] To achieve the above objectives, the present invention provides the following technical solution:

[0011] A casting grinding clamping support device, characterized in that it includes a casting information sensing module, a clamping parameter decision module, a support posture control module, a grinding coordination and adaptation module, a real-time monitoring feedback module, and a central control module.

[0012] The casting information sensing module is used to collect the material properties, geometric parameters, and surface condition information of the casting to be ground, and transmit the collected information to the central control module.

[0013] The clamping parameter decision module is connected to the central control module, receives casting information transmitted by the central control module, and determines the clamping force threshold, clamping area distribution and clamping timing that are suitable for the current casting based on the preset clamping parameter database and intelligent decision algorithm.

[0014] The support posture control module is connected to the central control module, receives instructions from the central control module, and adjusts the distribution of support points and support strength according to the geometric parameters of the casting and the requirements of the grinding area to form a support posture that fits the surface of the casting.

[0015] The grinding coordination and adaptation module is connected to the central control module and the external grinding system respectively. It receives the casting information and clamping support parameters transmitted by the central control module and outputs coordination signals to the external grinding system to achieve synchronous adaptation between the clamping support and the grinding movement.

[0016] The real-time monitoring and feedback module is used to collect the stress changes, displacement deviations, actual values ​​of clamping force and support strength of the casting in real time during the grinding process, and transmit the monitoring data to the central control module.

[0017] The central control module is electrically connected to the casting information sensing module, clamping parameter decision module, support posture control module, grinding collaboration adaptation module, and real-time monitoring feedback module, respectively. It is used to receive data transmitted by each module, generate control commands through the built-in collaborative control algorithm and send them to each execution module, and make dynamic corrections based on real-time monitoring feedback data to achieve closed-loop control of the entire process.

[0018] Furthermore, the casting information sensing module includes a material identification unit, a geometric parameter acquisition unit, and a surface condition detection unit;

[0019] The material identification unit is used to determine the material type of the casting through spectral analysis or density detection, and to obtain mechanical property parameters such as the elastic modulus and yield strength of the material.

[0020] The geometric parameter acquisition unit is used to acquire the three-dimensional model data of the casting through three-dimensional scanning or visual imaging, and extract geometric parameters such as the size, shape, and surface features of the casting.

[0021] The surface condition detection unit is used to detect surface condition information such as burr distribution, unevenness, and defect location on the surface of the casting.

[0022] Furthermore, the intelligent decision-making algorithm of the clamping parameter decision module adopts an algorithm combining case-based reasoning and fuzzy PID. The specific process is as follows: First, historical cases similar to the current casting information are matched from the clamping parameter database to obtain the initial clamping parameters; then, the initial clamping parameters are optimized by the fuzzy PID algorithm to determine the final clamping force threshold, clamping area distribution, and clamping timing. The clamping parameter database stores the optimal clamping parameter cases corresponding to castings of different materials, shapes, and sizes.

[0023] Furthermore, the support point distribution of the support posture control module adopts an adaptive gridding strategy. The support area of ​​the casting is divided into several grid units according to the geometric parameters of the casting. The number and position of the support points are determined by evaluating the load-bearing requirements of each grid unit. The support strength adopts a graded control method, which dynamically adjusts the support strength of each support point according to the load distribution of the grinding area.

[0024] Furthermore, the real-time monitoring feedback module includes a stress monitoring unit, a displacement monitoring unit, a clamping force monitoring unit, and a support strength monitoring unit;

[0025] The stress monitoring unit is used to collect stress distribution and stress change data in real time during the casting grinding process through a stress sensor array;

[0026] The displacement monitoring unit is used to collect displacement deviation data of the casting in real time through visual monitoring or laser ranging.

[0027] The clamping force monitoring unit is used to collect the actual clamping force value of each clamping area in real time;

[0028] The support strength monitoring unit is used to collect the actual support strength value of each support point in real time.

[0029] Furthermore, the collaborative control algorithm of the central control module is used to achieve collaborative matching of clamping parameters, support posture and grinding parameters. Its core logic is: taking the surface accuracy requirements of casting grinding as the target, establishing a mapping relationship model between clamping force, support strength and grinding speed and grinding feed, and correcting the parameters of the mapping relationship model through real-time monitoring data to ensure dynamic adaptation of each parameter during the grinding process.

[0030] The beneficial effects of the present invention after adopting the above structure are as follows:

[0031] (1) The present invention adopts a pure system architecture design, abandons the traditional clamping support method that relies on fixed mechanical structures. Through modular collaboration of casting information perception, parameter decision, attitude control, collaborative adaptation and monitoring feedback, it realizes adaptive clamping support for castings of different materials, shapes and sizes, greatly improving the system's versatility and adaptability. It can meet the grinding needs of various castings without replacing mechanical components.

[0032] (2) The clamping parameter decision module of the present invention adopts an intelligent algorithm that combines case reasoning and fuzzy PID, which can accurately match the clamping requirements of different castings and effectively avoid casting deformation caused by over-clamping and offset caused by insufficient clamping; the adaptive grid division strategy and graded support strength control of the support posture control module ensure the precise fit between the support posture and the surface of the casting, and improve the support stability.

[0033] (3) The present invention realizes the synchronous coordination between the clamping support and the external grinding system through the grinding coordination adaptation module. Combined with the coordination control algorithm of the central control module, a dynamic mapping relationship between the clamping support parameters and the grinding parameters is established to ensure the accurate matching of each parameter during the grinding process and significantly improve the surface accuracy of the casting grinding.

[0034] (4) The real-time monitoring feedback module and the central control module of the present invention form a closed-loop control of the whole process, which can sense key data such as stress changes and displacement deviations in the grinding process in real time, and dynamically correct the clamping support parameters, effectively improving the safety and stability of the grinding process and reducing safety hazards. Attached Figure Description

[0035] The accompanying drawings are provided to further understand the present invention and form part of the specification. They are used together with the embodiments of the present invention to explain the invention and do not constitute a limitation thereof.

[0036] Figure 1 This is a flowchart illustrating the core workflow of the casting grinding clamping support device of the present invention. Detailed Implementation

[0037] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0038] like Figure 1 As shown in Example 1, grinding and clamping support for small precision cast iron parts:

[0039] This embodiment addresses the grinding requirements of small precision cast iron parts (material: gray cast iron, size: 150mm×80mm×50mm, surface accuracy requirement Ra≤0.8μm), and utilizes the casting grinding clamping and support device of this invention to achieve precise clamping and stable support.

[0040] The casting information perception module works as follows: the material identification unit determines that the casting is gray cast iron through spectral analysis and obtains its elastic modulus of 110 GPa and yield strength of 200 MPa; the geometric parameter acquisition unit obtains the three-dimensional model data of the casting through three-dimensional scanning and extracts key dimensions and surface features; the surface condition detection unit detects that there are a small number of burrs on the surface of the casting, mainly distributed in the edge area.

[0041] The clamping parameter decision module works as follows: It matches historical cases of similar small precision gray cast iron parts from the clamping parameter database to obtain an initial clamping force threshold of 0.8-1.2 kN. The clamping area consists of four symmetrically distributed regions along the edge of the casting. The initial parameters are optimized using a fuzzy PID algorithm, ultimately determining a clamping force threshold of 1.0 kN. The clamping sequence is synchronous clamping, and the distribution of the clamping area is fine-tuned based on the edge contour from the 3D scan. The deviation calculation formula for the fuzzy PID algorithm is as follows:

[0042] e(t) = r(t) - y(t)

[0043] In the formula, e(t) is the clamping force deviation value at time t, r(t) is the preset threshold of clamping force at time t, and y(t) is the actual collected value of clamping force at time t;

[0044] The support posture control module works as follows: Based on the 3D model data of the casting, an adaptive meshing strategy is used to divide the support area into 5×5 mesh units. After evaluating the load-bearing requirements of each mesh unit, 6 support points are determined and evenly distributed in the non-grinding area at the bottom of the casting. The support strength is controlled in stages, with the support point strength in the grinding area set at 1.5kN and the support point strength in other areas set at 1.0kN.

[0045] The grinding coordination and adaptation module works as follows: it receives clamping and support parameters transmitted from the central control module, outputs coordination signals to the external grinding system, sets the grinding speed to 8000 r / min and the grinding feed rate to 0.1 mm / r, and ensures the synchronous adaptation between the grinding movement and the clamping support.

[0046] The real-time monitoring and feedback module works as follows: During the grinding process, the stress monitoring unit collects the stress distribution of the casting in real time, the displacement monitoring unit monitors the displacement deviation of the casting, and the clamping force monitoring unit and the support strength monitoring unit collect the actual values ​​in real time. The monitoring data is transmitted to the central control module, which dynamically corrects the clamping force and support strength through a collaborative control algorithm to ensure that the stress change is ≤5MPa and the displacement deviation is ≤0.02mm.

[0047] After grinding, the surface accuracy of the casting was Ra=0.6μm, with no deformation or damage, meeting the requirements of precision machining.

[0048] Example 2: Grinding and clamping support for large and complex cast steel parts:

[0049] This embodiment addresses the grinding requirements of large and complex cast steel parts (material: ZG270-500, dimensions: 1200mm×800mm×600mm, with multiple irregular curved surfaces), and utilizes the device of this invention to achieve stable clamping support.

[0050] The casting information perception module works as follows: the material identification unit determines that the casting is ZG270-500 cast steel with an elastic modulus of 210 GPa and a yield strength of 270 MPa; the geometric parameter acquisition unit acquires the three-dimensional model data of the complex curved surface through three-dimensional scanning; the surface condition detection unit detects that there are many burrs on the surface of the casting and there are local uneven defects.

[0051] The clamping parameter decision module works as follows: it matches historical cases to obtain an initial clamping force threshold of 5-8kN, and combines the complex contour of the 3D scan to determine 8 clamping areas, which are distributed in the boss and edge load-bearing areas of the casting; after optimization by the fuzzy PID algorithm, the clamping force threshold of 5-7kN for different clamping areas is determined, and segmented timing clamping is adopted to avoid stress concentration in the casting caused by simultaneous clamping.

[0052] The support attitude control module works as follows: The adaptive meshing strategy divides the support area into 15×15 mesh units. After assessing the load-bearing requirements, 12 support points are determined and non-uniformly distributed according to the complex curved surface features. The support focuses on supporting the weak areas of the casting and the areas with large grinding loads. The support strength is controlled in stages, with the maximum support strength set at 10kN and the minimum support strength set at 6kN.

[0053] The grinding coordination and adaptation module works by outputting coordination signals to the external grinding system and dynamically adjusting the grinding speed (4000-6000 r / min) and grinding feed (0.2-0.3 mm / r) according to the load requirements of different grinding areas, thereby achieving dynamic adaptation between clamping support and grinding motion.

[0054] The real-time monitoring and feedback module works by using multiple stress and displacement sensor arrays for comprehensive monitoring. The central control module dynamically adjusts the clamping force in the clamping area and the support strength at the support points based on the monitoring data to ensure that the casting displacement deviation is ≤0.1mm and to prevent shaking during the grinding process.

[0055] After grinding, the casting has good overall stability with no obvious deformation, and the grinding precision of the complex curved surface meets the design requirements.

[0056] Example 3: Grinding and clamping support for thin-walled aluminum alloy castings:

[0057] This embodiment addresses the grinding requirements of thin-walled aluminum alloy castings (material: 6061 aluminum alloy, dimensions: 500mm×300mm×5mm, easily deformable), and utilizes the device of this invention to achieve flexible clamping support.

[0058] The casting information perception module works as follows: the material identification unit determines that the casting is 6061 aluminum alloy with an elastic modulus of 69 GPa and a yield strength of 110 MPa; the geometric parameter acquisition unit acquires a three-dimensional model of the thin-walled structure and clarifies the distribution of the thin-walled region; the surface condition detection unit detects that there are few surface burrs, and the main requirement is to remove the residue from the gating system.

[0059] The clamping parameter decision module works as follows: it matches historical cases to obtain the initial clamping force threshold of 0.3-0.5kN, optimizes it through a fuzzy PID algorithm, determines the clamping force threshold to be 0.4kN, adopts a flexible clamping method, and expands the clamping area to the edge reinforcement part of the thin-walled area to avoid excessive local pressure leading to deformation.

[0060] The attitude control module works as follows: The adaptive meshing strategy divides the support area into 10×10 mesh units, determines 10 support points, and distributes them evenly at the bottom of the thin-walled casting, using an elastic support method; the support strength is set to 0.5kN to ensure support uniformity and avoid excessive local support strength that could cause the thin wall to sink.

[0061] The grinding collaboration adaptation module works by outputting collaboration signals to the external grinding system, setting low-load grinding parameters, grinding speed of 6000 r / min, and grinding feed rate of 0.08 mm / r, and focusing on controlling the impact of grinding load on thin-walled castings.

[0062] The real-time monitoring and feedback module focuses on monitoring stress changes and displacement deviations in the thin-walled area. The central control module dynamically adjusts the clamping force and support strength based on the monitoring data to ensure that stress changes are ≤2MPa and displacement deviations are ≤0.01mm.

[0063] After grinding, the casting is free from deformation, has a smooth surface, and the gating and riser residue is completely removed, meeting the requirements for thin-walled part processing.

[0064] Example 4: Grinding and clamping support for high-temperature alloy castings:

[0065] This embodiment addresses the grinding requirements of high-temperature alloy castings (material: Inconel 718, dimensions: 300mm×200mm×100mm, used in high-temperature conditions, with high surface precision requirements), and utilizes the device of this invention to achieve precise clamping and support.

[0066] The casting information perception module works as follows: the material identification unit determines that the casting is an Inconel 718 high-temperature alloy with an elastic modulus of 190 GPa and a yield strength of 960 MPa; the geometric parameter acquisition unit acquires a high-precision three-dimensional model; and the surface condition detection unit detects the presence of oxide scale on the surface, which needs to be removed by grinding.

[0067] The clamping parameter decision module works as follows: it matches historical cases to obtain an initial clamping force threshold of 2-3kN, and after optimization by a fuzzy PID algorithm, it determines the clamping force threshold to be 2.5kN. The clamping area is the upper and lower end faces of the casting, and a symmetrical clamping method is adopted to ensure uniform force during the clamping process.

[0068] Support posture control module operation: The adaptive meshing strategy divides the support area into 8×8 mesh units, determines 8 support points, and distributes them in the non-grinding area at the bottom of the casting; the support strength is set to 3kN to ensure the stability of the casting during the grinding process;

[0069] The grinding collaboration module works by outputting a collaboration signal to the external grinding system, setting the grinding speed to 10,000 r / min and the grinding feed rate to 0.12 mm / r, and cooperating with the cooling system to prevent the temperature from getting too high during the grinding of high-temperature alloys and affecting the performance.

[0070] The real-time monitoring and feedback module works as follows: In addition to monitoring the conventional stress, displacement, clamping force, and support strength, a temperature monitoring unit is added to collect the temperature of the grinding area in real time; the central control module adjusts the grinding parameters and clamping support parameters according to the temperature data to ensure that the temperature of the grinding area is ≤150℃.

[0071] After grinding, the oxide scale on the surface of the casting is completely removed, and the surface accuracy Ra = 0.5μm, which meets the requirements for use under high temperature conditions.

[0072] Example 5: Continuous grinding and clamping support for multiple batches of castings:

[0073] This embodiment addresses the continuous grinding requirements of multiple batches of different types of castings (in order: small precision cast iron castings from Embodiment 1, thin-walled aluminum alloy castings from Embodiment 3, ordinary carbon steel castings, ductile iron castings, and stainless steel castings), verifying the continuous adaptability of the device of the present invention.

[0074] The casting information sensing module works as follows: for each batch of castings, it sequentially completes material identification, geometric parameter acquisition, and surface condition detection. The acquired data is transmitted to the central control module in real time, enabling rapid switching and identification of information from multiple batches of castings.

[0075] The clamping parameter decision module works by quickly matching and optimizing clamping parameters for each batch of castings based on a clamping parameter database and intelligent decision-making algorithms, without the need for manual intervention, thus achieving automatic switching and adaptation of clamping parameters.

[0076] The support posture control module works by automatically adopting the corresponding adaptive meshing strategy based on the geometric parameters of each batch of castings to determine the distribution of support points and support strength, thereby enabling rapid adjustment of the support posture.

[0077] The grinding collaboration adaptation module works by automatically outputting corresponding collaboration signals to the external grinding system based on the characteristics of each batch of castings, adjusting grinding parameters, and realizing continuous collaboration in the grinding process of multiple batches.

[0078] Real-time monitoring and feedback module operation: During each batch of grinding, key data is monitored in real time and fed back to the central control module. The central control module dynamically corrects parameters to ensure the stability and accuracy of grinding each batch of castings.

[0079] After continuous grinding, the surface accuracy of each batch of castings met the design requirements, and the batch switching time was ≤5min, which greatly improved the continuous processing efficiency and verified the excellent adaptability and continuity of the device of the present invention.

Claims

1. A clamping and supporting device for grinding castings, characterized in that: It includes a casting information sensing module, a clamping parameter decision module, a support posture control module, a grinding collaboration adaptation module, a real-time monitoring and feedback module, and a central control module. The casting information sensing module is used to collect the material properties, geometric parameters and surface condition information of the casting to be ground, and transmit the collected information to the central control module. The clamping parameter decision module is connected to the central control module. It receives casting information and determines the clamping force threshold, clamping area distribution, and clamping timing that are suitable for the current casting based on the clamping parameter database and intelligent decision algorithm. The support posture control module is connected to the central control module. Based on the geometric parameters of the casting and the requirements of the grinding area, it adjusts the distribution of support points and the support strength to form a support posture that fits the surface of the casting. The grinding coordination and adaptation module is connected to the central control module and the external grinding system respectively. It receives casting information and clamping support parameters, and outputs coordination signals to the external grinding system to achieve synchronous adaptation between clamping support and grinding movement. The real-time monitoring and feedback module is used to collect the stress changes, displacement deviations, actual clamping force values ​​and actual support strength values ​​of the casting during the grinding process in real time, and transmit the monitoring data to the central control module. The central control module is electrically connected to each of the other modules. It is used to receive data from each module, generate and issue control commands, and make dynamic corrections based on real-time monitoring feedback data to achieve closed-loop control of the entire process.

2. The casting grinding clamping support device according to claim 1, characterized in that: The casting information sensing module includes a material identification unit, a geometric parameter acquisition unit, and a surface condition detection unit. The material identification unit determines the casting material type and obtains its mechanical property parameters such as elastic modulus and yield strength through spectral analysis or density detection. The geometric parameter acquisition unit acquires the casting's three-dimensional model data and extracts its size, shape, and surface features through three-dimensional scanning or visual imaging. The surface condition detection unit is used to detect the distribution of burrs, the degree of unevenness, and the location of defects on the casting surface.

3. The casting grinding clamping support device according to claim 1, characterized in that: The intelligent decision-making algorithm of the clamping parameter decision module adopts a combination of case reasoning and fuzzy PID. The specific process is as follows: first, the initial clamping parameters are obtained by matching historical cases similar to the current casting information from the clamping parameter database; then, the initial clamping parameters are optimized by the fuzzy PID algorithm to determine the final clamping parameters. The clamping parameter database stores optimal clamping parameter examples for castings of different materials, shapes, and sizes.

4. The casting grinding clamping support device according to claim 1, characterized in that: The support posture control module adopts an adaptive gridding strategy, which divides the support area into several grid units according to the geometric parameters of the casting, and determines the number and location of support points by evaluating the load-bearing requirements of each grid unit; the support strength adopts a graded control method, which dynamically adjusts the support strength of each support point according to the load distribution in the grinding area.

5. The casting grinding clamping support device according to claim 1, characterized in that: The real-time monitoring and feedback module includes a stress monitoring unit, a displacement monitoring unit, a clamping force monitoring unit, and a support strength monitoring unit. The stress monitoring unit collects stress distribution and stress change data in real time during the casting grinding process through a stress sensor array. The displacement monitoring unit collects casting displacement deviation data in real time through visual monitoring or laser ranging. The clamping force monitoring unit and the support strength monitoring unit are used to collect the actual clamping force value of each clamping area and the actual support strength value of each support point in real time, respectively.

6. The casting grinding clamping support device according to claim 1, characterized in that: The central control module has a built-in collaborative control algorithm. This algorithm aims to meet the surface precision requirements of casting grinding, establishes a mapping relationship model between clamping force, support strength, grinding speed, and grinding feed, and corrects the model parameters through real-time monitoring data to achieve dynamic adaptation of each parameter.

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