Vibration marking self-adaptive control system and method based on depth real-time feedback

Abstract

The invention provides a vibration marking self-adaptive control system and method based on depth real-time feedback, and provides a method for online detection and feedback of the marking depth and dynamic regulation and control of parameters of vibration marking, which is fundamentally characterized in that the marking depth is rapidly and conveniently detected and fed back in real time in the marking process, and then the marking parameters are automatically adjusted. And the depth is consistent and controllable. The equipment is composed of four core mechanisms, namely an execution mechanism, a depth detection mechanism, a control system cabinet, a rack and an auxiliary system. And a closed-loop control architecture of'detection-decision-execution 'is constructed. A detection result is fed back through a depth sensor, and a mark meeting the target D0 is obtained. The method has the advantage that the problem that the marking depth of a part is out of tolerance due to the fact that the efficiency of manual sectioning of a sample piece for marking depth is low and the actual marking depth cannot be detected in real time is solved. The problem that the depths of curved surface / special-shaped workpieces are inconsistent due to different distances between the workpieces and the marking head is solved.

Description

Technical Field

[0001] This invention relates to the field of vibration marking control technology for aero-engines, and in particular to an adaptive control system and method for vibration marking based on real-time depth feedback, which is used to solve the problems of inability to detect the depth of vibration marking on aero-engine parts online, depth deviation, and inconsistent marking depth on curved / irregular parts. Background Technology

[0002] Vibration marking is a method of permanently marking characters or graphics by using a controlled mechanical device to create an array of indentations on the surface of a workpiece through high-frequency impact of a marking needle. It is currently widely used in the marking of aero-engines. This invention mainly addresses vibration marking by proposing a control system that detects the marking depth in real time and dynamically adjusts parameters. This achieves rapid and convenient online detection of the marking depth while avoiding problems such as depth deviation and inconsistency.

[0003] Considering that the impact of marking on component performance is controllable, it is necessary to control and detect the marking depth. Currently, marking relies on preset parameters, making it impossible to detect the actual marking depth in real time and preventing depth deviations, especially for curved / irregularly shaped parts, where inconsistent depths often occur due to varying distances between the workpiece and the marking head, leading to uncontrollable risks of deviations. Currently, marking depth detection is performed by manually cutting samples, which is inconvenient, time-consuming, inefficient, and prone to errors.

[0004] Therefore, this invention mainly targets vibration marking and proposes a control system for real-time detection of marking depth and dynamic adjustment of parameters, so as to achieve fast and convenient online detection of marking depth and avoid problems of depth deviation and inconsistency. Summary of the Invention

[0005] The purpose of this invention is to propose a control system that detects the marking depth in real time and dynamically adjusts the marking parameters. This system can realize online detection and feedback of the marking depth, thereby adjusting and controlling the marking parameters to achieve controllable and consistent marking depth. This can effectively improve the detection efficiency of the marking process for parts and ensure the delivery rate of parts.

[0006] This invention provides an adaptive control system and method for vibration marking based on real-time depth feedback. It provides a method for online detection and feedback of marking depth during vibration marking and dynamic adjustment of parameters. The key is to quickly and conveniently detect and feedback the marking depth in real time during the marking process, and then automatically adjust the marking parameters to achieve consistent and controllable depth and meet delivery requirements.

[0007] 1) Mechanical integration design The equipment mainly consists of four core components: the actuator (vibrating marking head, Z-axis lifting mechanism, XY-axis motion platform), the depth detection mechanism, the control system cabinet, and the frame and auxiliary systems. Unlike traditional marking equipment, this equipment is equipped with a depth detection mechanism to ensure real-time feedback of the marking depth. This mechanism uses a laser displacement sensor mounted on the side of the marking head to simultaneously scan the marking trajectory. Meanwhile, the control system cabinet contains an intelligent controller that compares the target depth D0 with the measured depth value Dm in real time, generating parameter pressure ΔP adjustment commands based on a fuzzy PID controller.

[0008] 2) Marking depth detection results - direct mapping of marking parameters Unlike traditional open-loop control architectures that detect marking depth after marking with preset parameters, a closed-loop control architecture of "detection-decision-execution" is constructed. A single-variable control model of "depth deviation ΔD → pressure adjustment ΔP" is established with a response speed of <100ms. The detection result is fed back by the depth sensor, ΔD is calculated by fuzzy PID, and the adjustment command ΔP is output to obtain the mark that meets the target D0.

[0009] Advantages of this invention: The vibration marking adaptive control system and method based on real-time depth feedback described in this invention solves the problem of low efficiency in manually cutting samples for marking depth by controlling the system to detect the marking depth in real time and dynamically adjust the marking parameters. It also solves the problem of marking depth exceeding tolerances caused by the inability to detect the actual marking depth in real time. Furthermore, it addresses the issue of inconsistent marking depths on curved / irregularly shaped parts due to varying distances between the workpiece and the marking head. Attached Figure Description

[0010] Figure 1 This is a schematic diagram of the core mechanism of the vibration marking equipment; Figure 2 It is a control flow diagram. Detailed Implementation

[0011] The present invention will be further explained below with reference to specific implementation schemes, but it is not limited to the present invention. The structures, proportions, sizes, etc. shown in the accompanying drawings are only used to complement the content disclosed in the specification, so as to enable those skilled in the art to understand and read, and are not intended to limit the conditions under which the present invention can be implemented. Therefore, they have no substantial technical significance. Any modification of the structure, change of the proportion relationship or adjustment of the size, without affecting the effect and purpose that the present invention can produce, should still fall within the scope of the technical content disclosed in the present invention.

[0012] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0013] This invention provides a control system that dynamically adjusts marking parameters by detecting marking depth in real time, as detailed below: Selection and installation of key components of the equipment's core structure Vibratory marking head: The key component is a cemented carbide marking needle, made of WC-Co material, with a diameter of Φ0.38mm and a preferred cone angle of 120°. The length of the marking needle extending out of the marking head is 15±0.1mm. A pressure sensor is integrated inside the marking head to collect axial pressure values ​​in real time. When the pressure exceeds 150N, the machine automatically stops.

[0014] Z-axis lifting mechanism: A servo motor drives a ball screw to control the downward pressure of the marking head (range 10-100N). Install the marking head assembly onto the Z-axis mounting plate.

[0015] XY-axis motion platform: adopts a cross slide structure. The X-axis base is fixed on the frame, the Y-axis is mounted on the X-axis slider, and the workpiece fixture is mounted on the Y-axis slider.

[0016] Depth detection mechanism: The key component is a laser displacement sensor, preferably a coaxial laser triangular reflector sensor with a resolution of 0.001mm. The sensor is securely mounted on the marking head using a bracket. The sensor's position and angle are adjusted so that its laser beam is focused at an angle of 45°±1° onto the impact point of the marking needle tip. The depth of the indentation is measured. When the depth of three consecutive marking points ΔD>0.03mm, the machine automatically stops and prompts for inspection of the marking needle.

[0017] Control system cabinet: Key components are industrial PLC and sensor data acquisition module. The industrial PLC acts as the main controller and implements PID fuzzy control: it receives the depth signal Dm and calculates the pressure adjustment amount: ΔP=k*(D0-Dm), where k is the energy transfer coefficient of the material to be labeled; the sensor data acquisition module is responsible for acquiring signals from the pressure sensor and the depth sensor.

[0018] Frame and auxiliary systems: A pneumatic system is recommended for driving the pneumatic clamps.

[0019] Other unmentioned components are the same as those in conventional vibration marking equipment.

[0020] The labeling process based on this system After the system is set up, the labeling process can be implemented. The specific process is as follows: Workpiece clamping and positioning: The workpiece is placed in the fixture, which automatically clamps it and moves it. The XY motion platform positions the workpiece in a preset position, and the Z-axis is moved to position the marking needle directly above the area to be marked. Calibration: Adjust the Z-axis so that the marking needle tip is 1mm away from the workpiece surface, depth sensing. The instrument synchronously records this reference plane; Parameter initialization: Open the marking system, enter the marking content, and ensure accuracy. Retrieve the initial parameters from the database. Initial pressure P0 = 50N, target marking depth D0 = 0.15mm, subsequent dotting depth fluctuation ≤ ±0.01mm; Marking Start-up and Depth Detection Calculation: The marking head begins marking with initial parameters. After a millisecond delay, the laser displacement sensor scans the impact dent and measures the initial actual depth value Dm1. If Dm1 is 0.12mm, the controller calculates the depth deviation ΔD = D0 - Dm1 = 0.03mm. Intelligent feedback adjustment and regulation: The pressure adjustment is calculated based on ΔD: ΔP = k * (D0 - Dm) = 8.5 (N / mm) * 0.03 (mm) = 0.25N, where 8.5 (N / mm) is the energy transfer coefficient of the stainless steel material. The controller sends a command to the Z-axis servo motor. The pressure is adjusted from 50N to 50.25N. Continuous Marking and Dynamic Adaptation: The marking head moves under the drive of the XY platform and marks the second point. At this time, the system adopts new parameters P0=50.25N. The sensor immediately measures the second point Dm2. If Dm2 is 0.0148mm, the controller calculates the new ΔD=0.002mm, determines that the depth is very close to the target value, and the system enters a stable state, continuing to mark and continuously detecting the depth until all marking is completed. After marking is completed, remove the workpiece and turn off the marking system.

[0021] Innovation: Online depth detection of vibration markings, with real-time parameter adjustment.

[0022] Matters not covered in this invention are common knowledge.

[0023] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A vibration marking adaptive control system based on deep real-time feedback, characterized in that: Specifically as follows: Selection and installation of key components of the equipment's core structure: Vibration marking head: The key component is a cemented carbide marking needle made of WC-Co material. The marking head integrates a pressure sensor to collect axial pressure values ​​in real time. Z-axis lifting mechanism: Servo motor drives ball screw to control the downward pressure of the marking head; the marking head assembly is installed on the Z-axis mounting plate; XY axis motion platform: adopts a cross slide structure; the X-axis base is fixed on the frame, the Y-axis is installed on the X-axis slider, and the workpiece fixture is installed on the Y-axis slider; Depth detection mechanism: The key component is a laser displacement sensor, preferably a coaxial laser triangular reflector sensor with a resolution of 0.001mm. The sensor is securely mounted on the marking head using a bracket. The sensor position and angle are adjusted so that the laser beam is focused at an angle of 45°±1° onto the impact point of the marking needle tip. The depth of the indentation is measured. When the depth of three consecutive points ΔD is greater than 0.03mm, the machine automatically stops and prompts for inspection of the marking needle. Control system cabinet: Key components are industrial PLC and sensor data acquisition module. Industrial PLC acts as the main controller and realizes PID fuzzy control: it receives the depth signal Dm and calculates the pressure adjustment: ΔP=k*(D0-Dm), where k is the energy transfer coefficient of the material to be labeled; the sensor data acquisition module is responsible for collecting signals from the pressure sensor and depth sensor. Frame and auxiliary systems: A pneumatic system is recommended for driving the pneumatic clamps.

2. A marking method for a vibration marking adaptive control system based on real-time depth feedback as described in claim 1, characterized in that: The process includes the following steps: After the system is built, the labeling process is implemented, and the specific process is as follows: Workpiece clamping and positioning: The workpiece is placed in the fixture, which automatically clamps it and moves it. The XY motion platform positions the workpiece in a preset position, and the Z-axis is moved to position the marking needle directly above the area to be marked. Calibration: Adjust the Z-axis so that the distance between the marking needle tip and the workpiece surface is 1mm, and the depth sensor records this reference plane simultaneously; Parameter initialization: Open the labeling system, enter the labeling content and ensure it is accurate, and retrieve the initial parameters from the database; Marking start-up and depth detection calculation: The marking head starts marking with initial parameters, and the laser displacement sensor scans the impact dent after a millisecond delay; Intelligent feedback regulation and control: The pressure regulation amount is calculated based on ΔD; Continuous marking and dynamic adaptation: The marking head moves under the drive of the XY platform, marks the second point, and determines that the depth is very close to the target value. The system enters a stable state, continues marking, and continuously detects the depth until all marking content is completed. After marking is completed, remove the workpiece and turn off the marking system.

Images