Eccentric shaft forging process optimization method and system based on image generation

Abstract

The invention discloses an eccentric shaft forging process optimization method and system based on image generation, and relates to the technical field of mechanical manufacturing, and the method comprises the following steps: establishing a forging forming monitoring mechanism, recording a forming image sequence, and extracting a symmetrical section with appearance change entering a stable state; identifying a time interval in which the appearance change speed of the eccentric area is reduced but the local part is still changed, performing brightness track analysis on an image in the interval, determining the time when the brightness change direction is reverse, and generating a metal fiber trend change risk mark; adjusting the process rhythm according to the mark to form a delayed shaping time sequence; segmented rhythm control is carried out along the sequence, and deformation release at unequal time intervals is inserted in the forming process, so that metal flow is expanded segment by segment. According to the invention, dynamic identification of internal deformation in a shape stable stage is realized, and early termination of shaping caused by misjudgment is avoided; and through risk marking and segmented rhythm control, internal metal flow line continuous transition is promoted, the forming quality is improved, and the service life is prolonged.

Description

Technical Field

[0001] This invention relates to the field of mechanical manufacturing technology, specifically to an image-based method and system for optimizing the eccentric shaft forging process. Background Technology

[0002] Image-based optimization of the eccentric shaft forging process refers to the process of collecting or constructing multi-source image information reflecting the billet morphology, metal flow, deformation area distribution, and forming stage characteristics during the eccentric shaft forging production. This image information is then generated, reconstructed, synthesized, and fused to form an image representation of the forging process that comprehensively expresses the characteristics of different processes. This allows for a direct depiction of the deformation law and eccentric structure forming state of the eccentric shaft under different forging processes. Based on this, the forging sequence, deformation distribution, heating rhythm, and forming rhythm are specifically adjusted using the deformation unevenness, material accumulation, eccentric load concentration, and local defect trends presented after image synthesis and fusion. This enables the forging process to be optimized around the forming requirements of the asymmetric structure of the eccentric shaft, thereby achieving visualized analysis and precise optimization at the process level.

[0003] The existing technology has the following shortcomings: Under current technological conditions, during the final forging stage of eccentric shafts, the forming results obtained from image generation mainly reflect the external geometric contour of the forging. When the generated image exhibits approximately symmetrical shape features at this stage, the forging process optimization process may misjudge that the current deformation state has reached sufficient equilibrium, thus prematurely ending the critical shaping process that should have continued in the process control. However, in the actual forging process, the metal inside the eccentric structure is still in a complex asymmetric plastic flow state, and the orientation of the internal metal fibers has not yet completed a continuous transition. Premature termination of shaping will cause abrupt reversal or even interruption of the metal fiber flow lines in the eccentric part. Such defects are difficult to identify through appearance images during the forming stage, but after the eccentric shaft is put into service, under long-term alternating loads, they will rapidly evolve into weak areas with high local stress concentration, thus significantly increasing the risk of instantaneous fatigue fracture of the eccentric shaft during operation.

[0004] The information disclosed in the background section is only intended to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0005] The purpose of this invention is to provide an image-based method and system for optimizing the eccentric shaft forging process, in order to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an image-based method for optimizing the eccentric shaft forging process, comprising the following steps: Establish a continuous monitoring mechanism for the forging stage of eccentric shafts, record the shape changes at each forming moment in chronological order as a forming image sequence, extract the symmetrical segments where the shape changes have entered a stable state from the forming image sequence, and use them to identify the stage where the appearance is stable but the internal deformation has not ended. By comparing the before and after images of symmetrical sections where the shape changes have entered a stable state, the time intervals in which the shape change rate of the off-center region decreases but the local shape is still changing are identified, thus forming a prompt section where the appearance is stable but the interior is still changing. Brightness trajectory analysis is performed on the eccentric region forming image in the prompting section to determine the time position when the brightness change direction reverses, and a risk marker for the change of metal fiber orientation is generated to indicate the risk of sudden changes in internal metal flow. Based on the risk markers for changes in the direction of metal fibers, the process rhythm is adjusted for the forming section corresponding to the risk markers, so that the eccentric area is kept under controlled deformation in the section and the forming time is delayed, thus forming a delayed forming time sequence. The forming rhythm control is implemented in segments along the delayed forming time sequence. Deformation release processes with unequal time intervals are inserted during continuous forming, so that the metal flow inside the eccentric area unfolds segment by segment, forming a staggered adjustment path, reducing the risk of metal fiber abrupt change caused by shape symmetry.

[0007] Preferably, the steps for establishing a continuous monitoring mechanism for the eccentric shaft forging stage are as follows: The monitoring area of ​​the forming equipment is arranged in correspondence with the forming area of ​​the eccentric shaft blank. The shape change information of the eccentric shaft during the forming process is obtained through a multi-angle imaging device, and a time reference for continuous acquisition is established to ensure the time continuity of image recording. The continuously formed images are archived in chronological order. Geometric feature parameters of the eccentric part, main axis region and transition zone are extracted from each frame of the image to generate shape change curves to reflect the evolution process of the eccentric axis shape. Symmetry analysis was performed on the shape change curve during the time interval of gradual change. By comparing the contour differences of adjacent images, the symmetrical segments where the shape change was stable were identified, and the stage where the appearance was stable but the internal deformation was not yet finished was marked. By marking symmetrical sections with stable shape changes in the forming image sequence, a correspondence is established between stable appearance and incomplete internal deformation, which can be used for key monitoring and data analysis in subsequent forming processes.

[0008] Preferably, when establishing the correspondence between stable appearance and incomplete internal deformation, a time identifier is inserted into the forming image sequence to synchronously associate the time information of each frame of forming image with the eccentric shaft outline information, so that the shape change curve and the time sequence form a correspondence. This enables dynamic matching of the eccentric shaft shape change and internal deformation state during continuous monitoring, providing accurate time basis for subsequent risk analysis and shaping rhythm adjustment.

[0009] Preferably, the steps for comparing the before and after forming images of the symmetrical segment where the shape change has entered a stable state are as follows: The symmetrical section with stable shape change is taken as the central interval of time series analysis. The forming images corresponding to adjacent time nodes are selected and organized, and the perspective and scale of the images are uniformly adjusted to form a continuous shape change trajectory. Contour feature comparison is performed on the symmetrical segments with stable shape changes in the time series and the formed images of the time nodes before and after them to identify the time intervals in which the shape change rate of the eccentric region decreases but the local shape continues to change. The formed images within the identified time interval are continuously superimposed to determine the extension direction of the morphological changes in the local area and form a comprehensive judgment that the appearance is stable but the internal structure is still changing. The identified time intervals are labeled in the formed image sequence to establish the time boundaries of the prompting segments and form a state record that is stable in appearance but still changing internally.

[0010] Preferably, when marking the identified time interval in the forming image sequence, the start and end times of the time interval are set to correspond with the forming process time axis, and the duration of local morphological changes and the trend of eccentric area changes are recorded, so that the prompting section has a time positioning function in the subsequent forming process, so as to realize real-time identification and process rhythm adjustment of the appearance is stable but the internal is still changing.

[0011] Preferably, for a prompting section where the appearance is stable but the internal structure is still changing, the steps for performing brightness trajectory analysis on the eccentric region shaping image within the prompting section are as follows: Within the prompting section, the continuous shaped image of the off-center region is divided into regions and brightness is extracted. The brightness information of the off-center part and the transition area is recorded in time sequence to form a continuous brightness distribution sequence. By comparing the brightness change trajectory of the off-center area within the prompt section over time, the continuous trend of brightness change direction is determined and the time position of the reverse change in brightness direction is captured. By comparing the time location where the brightness direction changes in the opposite direction with the corresponding formed image, local areas with drastic brightness changes are identified and a temporal-spatial correlation is established to determine the formed segment. Based on the reverse change time position of the brightness change direction, a risk marker for the change in metal fiber orientation is generated, and the risk marker is embedded in the formed image sequence to indicate the risk of abrupt changes in internal metal flow.

[0012] Preferably, in the process of generating risk markers for changes in the orientation of metal fibers, by introducing time-series tracking of the direction of brightness change in the continuous forming images of the warning section, the duration of the reverse change in brightness is correlated with the metal flow trend inside the eccentric region, so that the risk markers can reflect the dynamic process of metal fiber orientation adjustment, thereby achieving time-series-based rhythmic control in the subsequent shaping stage.

[0013] Preferably, the steps for adjusting the process rhythm of the forming section corresponding to the risk marker based on the risk marker of the metal fiber orientation change are as follows: Match the time position corresponding to the risk mark of metal fiber orientation change with the time axis of the forming image sequence to determine the specific forming section where the risk mark is located and establish the synchronization relationship between the risk mark and the process time axis; Within the forming section corresponding to the risk mark, the process rhythm is re-planned. By extending the plastic action time, the eccentric area is kept under controlled deformation and the continuous transition of metal fiber flow is achieved. The revised rhythm arrangement is embedded into the overall shaping process, forming a delayed shaping time sequence and setting smooth transition sections on the time axis to ensure the continuity of rhythm adjustment; The end point of the shaping process is constrained by using the delayed shaping time sequence as the time control benchmark, so that the internal metal flow reaches a continuous state before the shaping process is terminated.

[0014] Preferably, the steps for segmented adjustment of the forming rhythm control along the delayed forming time sequence are as follows: The delayed shaping time series is divided into segments according to the evolution characteristics of metal flow within the eccentric region, so that each segment corresponds to an independent controlled deformation interval, and the start and end times of the segments correspond to the time positions of the risk markers for changes in the direction of metal fibers. By introducing deformation release processes with unequal time intervals between the segments of the delayed forming time sequence, the metal flow in the eccentric region can achieve staged stress relief and flow direction adjustment during continuous forming. The segmented rhythm of the delayed shaping time series is coordinated in an integrated manner, so that the controlled deformation and deformation release process form a continuous cyclical rhythm structure and achieve a staggered adjustment path in time. Using the delayed forming time sequence as the rhythm benchmark for the forging process, the segmented deformation and deformation release processes are carried out alternately, and the end point of the forming process is constrained.

[0015] An image-based eccentric shaft forging process optimization system includes a forming monitoring module, a stable zone identification module, a risk analysis module, a rhythm adjustment module, and a rhythm control module. The forming monitoring module establishes a continuous monitoring mechanism for the forming stage of eccentric shaft forging. It records the shape changes at each forming moment in chronological order as a forming image sequence, and extracts the symmetrical segments from the forming image sequence that have entered a stable state of shape change, which are used to identify the stage where the appearance is stable but the internal deformation has not ended. The stable region identification module compares the before and after images of symmetrical sections where the shape changes have entered a stable state over time. It identifies the time interval in which the shape change rate of the off-center region decreases but the local shape is still changing, forming a prompt section where the appearance is stable but the interior is still changing. The risk analysis module performs brightness trajectory analysis on the eccentric region forming image in the warning section, determines the time position when the brightness change direction reverses, and generates a risk marker for the change in metal fiber orientation to indicate the risk of sudden changes in internal metal flow. The rhythm adjustment module adjusts the process rhythm of the forming section corresponding to the risk mark based on the risk mark of the metal fiber direction change, so that the eccentric area maintains controlled deformation in the section and delays the forming time, forming a delayed forming time sequence. The rhythm control module implements segmented adjustment of forming rhythm control along the delayed forming time sequence. During the continuous forming process, it inserts deformation release processes with unequal time intervals, so that the metal flow inside the eccentric area unfolds segment by segment, forming an adjustment path with staggered rhythms, reducing the risk of metal fiber abrupt changes caused by shape symmetry.

[0016] The technical effects and advantages provided by the present invention in the above technical solution are as follows: This invention establishes a continuous monitoring mechanism during the eccentric shaft forging stage and combines it with time-series image analysis to achieve dynamic identification of the internal deformation state during the stabilization phase of the external shape. This transforms the judgment criteria for the forging process from external morphology to the synergistic characteristics of the external shape and internal flow. By identifying the indicator sections where the external shape is stable but the internal structure is still changing, misjudgments in symmetrical external shapes can be effectively avoided. This allows the forming process to continue until the continuous transition of metal flow is complete, thereby improving the control accuracy of the eccentric shaft forming stage and ensuring the continuity of the internal structure and the balance of plastic flow.

[0017] This invention incorporates risk markers indicating changes in metal fiber orientation into process rhythm adjustment and segmented rhythm control. This creates a temporal rhythm stagger between the delayed forming time sequence and the unequal intervals of deformation release, promoting the gradual unfolding of internal metal flow in the eccentric region. This rhythmic control method achieves smooth adjustment of internal stress and flow direction in the eccentric region, reducing abrupt changes in streamlines caused by premature termination of forming or concentrated rhythm. It ensures a continuous transition of internal metal fiber orientation during the forming process, improving forming quality and service life. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0019] Figure 1 This is a flowchart of the image-based eccentric shaft forging process optimization method of the present invention; Figure 2 This is a schematic diagram of the module of the image-based eccentric shaft forging process optimization system of the present invention. Detailed Implementation

[0020] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in many forms and should not be construed as limited to the examples set forth herein; rather, they are provided so that the description of this disclosure will be more complete and fully convey the concept of the exemplary embodiments to those skilled in the art.

[0021] This invention provides, for example Figure 1 The image-based optimization method for eccentric shaft forging process shown includes the following steps: Establish a continuous monitoring mechanism for the forging stage of eccentric shafts, record the shape changes at each forming moment in chronological order as a forming image sequence, extract the symmetrical segments where the shape changes have entered a stable state from the forming image sequence, and use them to identify the forming stage where the appearance is basically stable but the internal deformation has not yet ended. By recording and analyzing images throughout the entire process, continuous tracking of the eccentric shaft's shape changes during the forging stage is achieved. This allows for the identification of the forming stage where the shape change has entered a stable state but internal deformation has not yet ended, thus providing a basis for subsequent forming rhythm control. The specific steps are as follows: Before the eccentric shaft forging begins, the monitoring area of ​​the forming equipment is aligned with the forming area of ​​the eccentric shaft blank. A multi-angle imaging device acquires information on the shape changes of the eccentric shaft during the forming process, and a continuous acquisition time reference is established to ensure the temporal continuity of image recording. This imaging device should cover the entire deformation range of the eccentric shaft, especially the deformation area of ​​the eccentric part, so as to completely record the shape evolution of the eccentric shaft from the initial forming stage to the final forging stage. The core of the forming monitoring mechanism lies in establishing a continuous acquisition time reference, so that each forming stamping or plastic deformation corresponds to a specific time point and is triggered synchronously with the image acquisition signal, thereby ensuring the continuity and traceability of the forming images in time series. In this process, each frame of the forming image contains the contour information of the current eccentric shaft shape and the time marker of the deformation stage, which is used to construct the time series image basis required for subsequent analysis.

[0022] After obtaining continuous forming images, these images are archived in chronological order, and shape features are extracted from each frame. To accurately capture the dynamic changes in the eccentric shaft's shape, geometric feature parameters of the eccentric portion, main axis region, and eccentric transition zone in each frame need to be extracted, including the eccentric radius, contour curvature, and cross-sectional shape variation trends. By extracting these geometric feature parameters frame by frame, a shape change curve reflecting the evolution of the eccentric shaft's shape can be generated. As the forging process progresses, when the shape change curve changes smoothly within a certain time interval, and the geometric differences between adjacent frames significantly decrease, it can be determined that the shape change in that interval has entered a stable state. This stage typically corresponds to the stage where the eccentric shaft's external morphology has been basically formed, but the internal metal flow is not yet completely uniformly distributed. Through this process, a preliminary correspondence between shape change and time series is established, providing a foundation for subsequent extraction of segments where shape change has entered a stable state.

[0023] After identifying the time intervals where the shape change curve gradually flattens, further symmetry analysis can be performed on the continuous forming images within these intervals to determine the truly symmetrical segments that represent the stable shape state. Specifically, symmetry analysis can be performed on the time intervals where the shape change curve enters a stable state. By comparing the contour differences between adjacent images, the symmetrical segments where the shape change has entered a stable state can be identified, and the stage where the appearance is stable but the internal deformation has not yet ended can be marked. In this step, the shape contours of adjacent images in the time series are compared, and the shape differences of the eccentric shaft along the axial and radial directions are analyzed. When the shape exhibits approximately symmetrical or stable geometric relationships in multiple directions, it can be determined that the segment belongs to the symmetrical segment where the shape change has entered a stable state. At this point, it is also necessary to combine the shape change curve generated in the previous sub-step to cross-compare the change rate of the symmetrical segment to ensure that its change rate is at a low level. Through the above comparison, the stable appearance interval of the eccentric shaft during the forming process can be accurately determined, and this interval serves as a key reference for subsequent stage analysis. At this point, although the appearance has reached a stable state, based on forming experience and the characteristics of internal metal flow, the internal deformation at this stage is often not yet complete. Therefore, this section needs to be specially marked so as to extend the forming duration of the corresponding stage in process control and prevent premature termination of the forming process.

[0024] The identified symmetrical segments where the shape changes have entered a stable state are marked throughout the entire forming image sequence, and a correspondence is established between stable appearance and incomplete internal deformation, forming a complete forming stage identification mechanism. In establishing this correspondence, time identifiers are inserted into the forming image sequence, synchronously linking the time information of each frame with the eccentric shaft's outline information. This establishes a correspondence between the shape change curve and the time series, enabling dynamic matching of the eccentric shaft's shape changes and internal deformation state during continuous monitoring. This allows for focused monitoring of this segment in subsequent forming processes. When the eccentric shaft enters this stage, the monitoring mechanism continuously tracks subtle trends in shape changes, capturing potential minor changes while maintaining a stable shape, providing data support for subsequent risk analysis and process adjustments. The key to this stage is establishing a clear determination zone of "stable appearance but ongoing internal deformation," thus providing a clear boundary in the forging process on the timeline. Through this time-layered monitoring, the entire eccentric shaft forming process can be recorded and accurately identified at each stage, providing a basis for preventing external symmetry from masking internal deformation.

[0025] By comparing the before and after images of symmetrical sections where the shape changes have entered a stable state (i.e., comparing them in chronological order), the time intervals in which the shape change rate of the off-center region decreases but the local shape is still changing are identified, forming a prompt section where the appearance is stable but the interior is still changing, which is used to reflect the state where the stable appearance masks the internal deformation adjustment. By performing time-extended analysis on symmetrical segments in an established continuous forming image sequence where the shape changes have entered a stable state, a comparative relationship is constructed to reveal the continuous deformation characteristics where internal metal flow still exists even in a stable external state, thus forming a suggestive segment where the external appearance is stable but the internal structure is still changing. The specific steps are as follows: After extracting the symmetrical segment where the shape change has reached a stable state, this symmetrical segment is used as the central interval for time series analysis. The forming images corresponding to adjacent time nodes (e.g., multiple adjacent time nodes) are then organized. Each set of time nodes is arranged according to the chronological order of the forging process, placing the symmetrical segment where the shape change has reached a stable state in the middle of the sequence. In this way, a continuous shape change trajectory can be formed in the time dimension, including both the rapid deformation stage before the shape stabilizes and the subtle changes after stabilization. Based on this, the viewpoint and scale of the images are uniformly adjusted to form a continuous shape change trajectory. Specifically, all selected forming images are uniformly adjusted to the same viewpoint and scale to ensure spatial comparability between images. This unification process allows the shape changes of the eccentric shaft at different stages of the forming process to be reflected in a continuous form, providing an accurate basis for subsequent comparative analysis.

[0026] Contour feature comparison was performed on symmetrical segments in the time series where the shape change reached a stable state, and the forming images corresponding to the time points before and after them. The focus was on observing the shape change trend of the eccentric region to identify time intervals where the rate of shape change in the eccentric region decreased but the local morphology continued to change. During this process, frame-by-frame comparisons were made of the shape changes around the main axis region, the eccentric part, and the transition section of the eccentric axis. Through step-by-step comparison in time sequence, it was found that as the forming stage progressed, the overall contour change rate of the eccentric part slowed down significantly, while the morphology of local detail areas continued to adjust. For example, in the eccentric end face or the transition region of the eccentric radius, the change in the shape contour was smaller, but its local contour lines still showed slight deformation signs. This difference reflects that although the appearance has entered a stable state, the internal stress and metal flow are still in a slow adjustment phase. By continuously observing the continuity of this local morphology in the time series, the time interval range where the rate of shape change significantly decreased but the local morphology continued to change can be confirmed.

[0027] After identifying time intervals where the rate of change in the overall shape decreases but local morphology continues to change, the formed images within this time interval are continuously superimposed to determine the direction of extension of local morphological changes and form a comprehensive judgment that the appearance is stable while the internal structure is still changing. In this process, adjacent images in the time series are continuously superimposed, allowing the macroscopic stability characteristics of the overall shape and the microscopic local changes to be presented comprehensively within the same field of view. Through this superimposed observation, it can be found that although the overall outline tends to overlap, the subtle contours of local areas still exhibit fluctuations or shifts. Especially in areas where stress is concentrated at the eccentric points, local morphology shows very small-scale deformation extension or shrinkage, which corresponds to the slow flow and orientation adjustment of the internal metal fibers. By comparing these local changes at consecutive time points, a time interval with a stable appearance but continuous internal deformation can be identified, and this interval is confirmed as the core time range of the indication segment.

[0028] The time intervals where the rate of change in the external shape slows down but local morphology continues to change are marked in the forming image sequence to establish the time boundary of the prompting section and form a state record of stable appearance but still changing internally. When marking the identified time intervals in the forming image sequence, the start and end times of the time intervals can be set to correspond to the forming process time axis, and the duration of local morphological changes and the trend of eccentric region changes are recorded, enabling the prompting section to have a time positioning function in subsequent forming processes. Specifically, to ensure that the prompting section has clear identification significance in subsequent process adjustments, the start and end times corresponding to the interval need to be aligned with the forming process time axis, forming a state record of stable appearance but still changing internally. This record includes information such as the start and end times of the stable external shape change section, the duration of local morphological changes, and the trend of eccentric region changes. In the subsequent forging process, when the external shape image of the eccentric shaft enters the prompting section, it can be determined from this time range that the current forging is in a state of stable appearance but still internally deforming. By clearly indicating the boundaries of sections in the forming image sequence, subsequent forming control stages can implement delayed forming or rhythm adjustment measures for those sections, thereby preventing premature termination of the forming process due to the shape reaching a stable state. This step not only enables time comparison of shape changes but also establishes a dynamic relationship between external stability and continuous internal deformation on the time axis, providing a fundamental reference for precise control of the forging process.

[0029] For the warning section where the appearance is stable but the internal structure is still changing, the brightness trajectory analysis is performed on the forming image of the eccentric area in the warning section to determine the time position when the brightness change direction reverses and generate a risk marker for the change of metal fiber direction, which is used to indicate the forming section where the internal metal flow may change abruptly. By continuously tracking the brightness of the formed image of the off-center region within the indicated section, the implicit trends in the internal flow and orientation changes of the metal are revealed from a temporal perspective. Furthermore, by identifying the reverse features of the brightness change direction, forming sections where abrupt changes in metal fiber orientation may occur are determined, providing a basis for the dynamic adjustment of subsequent process rhythms. The specific steps are as follows: Within the obtained indication section, where the appearance is stable but the internal structure is still changing, the continuous forming images of the eccentric region are divided into regions and brightness extracted. The brightness information of the eccentric part and the transition zone is recorded in chronological order to form a continuous brightness distribution sequence. Since the shape change corresponding to the indication section has entered a stable state, traditional geometric feature changes are insufficient to reflect the internal plastic flow. Therefore, this step subdivides the brightness layer of the eccentric part in the eccentric shaft forming image to establish a continuous brightness distribution that can be used to observe minute changes in the metal surface state. Specifically, in the image of the eccentric shaft forming region, the key area including the eccentric part and its transition zone is selected as the analysis range. The brightness information within this range is recorded in chronological order, so that each frame corresponds to the brightness distribution state of the eccentric region surface at a specific time point. In this process, the brightness information at each time point forms a one-to-one correspondence with the time series, thus constituting the basic data of brightness trajectory reflecting changes in the metal flow state. Through this preparation process, the eccentric region within the indication section is transformed into a time series that can be continuously analyzed for brightness, providing a prerequisite for subsequent determination of the direction of brightness change.

[0030] After establishing a continuous brightness distribution sequence, the brightness change trajectory around the eccentric region within the indicated section is compared over time to determine the continuous trend of brightness change direction and capture the time position where the brightness direction reverses. This step involves comparing the trend of brightness intensity change in the eccentric region in each frame of the forming image over time to observe its variation with the forging rhythm. In the stage of stable appearance, the overall brightness change rate is usually low, but in the stress-concentrated parts of the eccentric region, the brightness may still fluctuate slightly. This fluctuation reflects the coupling relationship between surface temperature, plastic strain, and metal flow direction adjustment. By comparing continuous time series, it can be found that the brightness gradually changes in a certain direction within a certain time interval, such as a trend from bright to dark or from dark to bright. This trend usually corresponds to the main direction of metal flow. As the forming process continues, when the internal stress state of the metal is adjusted or the flow direction is locally reversed, the direction of brightness change will also reverse, forming a trend opposite to the previous stage. By continuously comparing time series, the time position where this change from positive to negative can be accurately captured. The forming moment corresponding to this time position reflects the critical state of metal fiber flow direction adjustment.

[0031] After determining the time point at which the brightness change direction reverses, this time point is compared with the corresponding forming image to identify local areas of drastic brightness change and establish a temporal-spatial correlation to determine the forming segment. Specifically, several frames of forming images before and after this time point are comprehensively compared to analyze the spatial distribution characteristics of the metal fiber orientation change. At this point, combined with the continuous brightness trajectory within the indicated segment, the local area with the most drastic brightness change within the off-center region can be identified. These areas often correspond to the parts where the internal metal flow direction begins to redistribute. By observing the continuity of brightness changes in these local areas in the time series, it can be found that when the brightness direction reverses, the originally continuously extending brightness band distribution will show slight breaks or shifts. This phenomenon characterizes the abrupt trend of metal fiber orientation in internal plastic flow. By correlating the time position with the spatial position, a temporal-spatial composite relationship can be formed in the forming image of the off-center region, thereby determining the specific forming segment, which is the key area where the metal fiber flow direction is at risk of change. This process realizes the mapping from the brightness change trajectory to the metal flow trend, revealing the actual dynamics of internal fiber orientation adjustment under a stable appearance state.

[0032] After identifying the time position of the reversal in the direction of brightness change and its corresponding forming segment, a risk marker is generated for that forming segment to create a risk marker for changes in metal fiber orientation that can be used for forging process control. Specifically, the risk marker is generated based on the time position of the reversal in the direction of brightness change and embedded in the forming image sequence to indicate the risk of abrupt changes in internal metal flow. Furthermore, during the generation of the risk marker, a time series tracking of the direction of brightness change can be introduced into the continuous forming images of the indicated segment, correlating the duration of the reversal in brightness change with the metal flow trend within the eccentric region. This allows the risk marker to reflect the dynamic process of metal fiber orientation adjustment. This risk marker corresponds one-to-one with a specific moment on the timeline and uses its spatial position in the forming image as a reference, forming a temporally and spatially correlated identification mark. By embedding this risk marker in the continuous forming image sequence, time periods during which abrupt changes in metal flow may occur can be quickly identified in subsequent forming processes. When the forging process enters this risk zone, the forming rhythm can be adjusted or the forming time extended based on the risk marker indication, thereby ensuring the continuity of metal flow and the smooth transition of fiber orientation within the eccentric part. The generation of this marker not only reflects the temporal characteristics of metal flow but also provides a dynamic reference for the forging process based on image information. Through the establishment of risk markers, hidden internal structural changes during the appearance stabilization stage can be clearly recorded, making the monitoring of the forming process more comprehensive and the process control more precise.

[0033] Based on the risk markers for changes in the direction of metal fibers, the process rhythm is adjusted for the forming section corresponding to the risk markers, so that the eccentric area is kept under controlled deformation in the section and the forming time is delayed, forming a delayed forming time sequence, which is used to constrain the end point of the forming process. The generated metal fiber orientation change risk markers are mapped and correlated with the time series of the forming process. By identifying and extending the rhythm of risk sections, the forming rhythm is dynamically reconstructed, ensuring that the eccentric region maintains a continuously controlled plastic deformation state within the corresponding risk marker section. This creates a delayed forming time series to constrain the end point of the forming process. The specific steps are as follows: After obtaining the risk markers for changes in metal fiber orientation, the corresponding time positions of these risk markers are matched with the time axis of the forming image sequence to determine the specific forming segment where the risk marker is located and to establish a synchronization relationship between the risk marker and the process time axis. Since the risk marker reflects the possibility of abrupt changes in the internal flow direction of the metal, its corresponding time position is usually in a stage where the external shape is stabilizing but the internal structure is still adjusting. In this stage, the external contour change of the eccentric region has smoothed out, while the internal metal fiber flow direction is still being fine-tuned. If the forming process is terminated at this point, it can easily lead to discontinuities or local twisting of the streamlines. To prevent this, this step establishes a synchronization relationship between the risk marker and the process time axis to determine the time range covered by the risk marker and defines it as the target segment for rhythm adjustment. This segment becomes the key interval requiring time delay control during the forging process, providing an accurate time reference for subsequent rhythm extension.

[0034] After identifying the forming section corresponding to the risk marker, the process rhythm for that section is replanned. By extending the plastic action time, the eccentric region is kept under controlled deformation, and the continuous transition of metal fiber flow is achieved, thus realizing controlled forming and extension. This step refines the deformation rhythm of the eccentric region based on the time range of the risk marker. Specifically, within the risk section, the forming is no longer completed according to the original process rhythm. Instead, the plastic action time is extended to allow the metal fiber flow to continue its continuous transition. To ensure controlled deformation during the extended process, this step controls the time interval and deformation rate of the forging rhythm, maintaining a low stress rate in the eccentric region within the time corresponding to the risk marker, allowing the internal metal flow to continue without compromising appearance stability. Once the metal fibers have completed their directional transition at the eccentric location, the forming process gradually enters the final stage. This extended control method effectively avoids abrupt changes in internal flow direction caused by premature termination of forming within the risk section, thereby ensuring the continuity of internal metal flow in the eccentric shaft.

[0035] After replanning the rhythm of the risk sections, the replanned rhythm arrangement is embedded into the overall forming process, forming a delayed forming time sequence with smooth transition sections on the time axis to ensure the continuity of rhythm adjustment. This time sequence is based on the original process time axis, forming a new rhythm distribution by extending the forming duration in the sections corresponding to the risk markers. The delayed forming time sequence includes not only the main extended period corresponding to the risk markers but also smooth transition sections before and after them to ensure the continuity and controllability of rhythm adjustment. By setting continuous gradual transition sections in the delayed forming time sequence, a natural transition from the regular rhythm to the delayed rhythm can be achieved during forging, allowing the stress release within the eccentric region and the adjustment of the metal flow direction to be completed synchronously. In this process, the time position of the risk markers becomes the core node of rhythm extension, and the end point of the forming process will be redefined based on the end of the delayed sequence. Thus, after the process rhythm is rearranged, the end of the forming process is no longer solely based on the stability of the external shape but on the continuous state of the internal metal flow.

[0036] After establishing a delayed forming time sequence, it is used to constrain the end point of the forming process, thereby establishing a dynamic correspondence between external shape stability and internal flow equilibrium. Specifically, the delayed forming time sequence can be used as a time control benchmark to constrain the end point of the forming process, ensuring that the internal metal flow reaches a continuous state before terminating the forming process. In this step, the delayed forming time sequence serves as a time control benchmark for the forging rhythm, used to determine the termination time of the forming process. When the eccentric shaft enters the final segment of the delayed forming time sequence during the forming process, the system does not immediately terminate the forming process. Instead, it continues to maintain the controlled deformation of the eccentric region according to the rhythmic extension law of the time sequence, allowing the internal metal fibers to complete a smooth transition of direction under continuous plastic action. When the end of the time sequence is reached, it indicates that the internal metal flow has reached a continuous state and the stress state has reached equilibrium. At this point, the forming process is terminated, thus achieving process termination guided by the internal structural state. Through this delayed constraint method, premature termination under the cover of external appearance stability can be effectively prevented, ensuring that the internal structure of the eccentric region achieves a full transition during controlled deformation. This process ultimately forms a rhythm extension closed loop based on risk labeling, which keeps the forging process consistent with the evolution of the internal metal flow in the time dimension, thus achieving the goal of optimizing the control of the shaping stage.

[0037] The forming rhythm control is implemented in segments along the delayed forming time sequence. Deformation release processes with unequal time intervals are inserted during continuous forming, so that the metal flow inside the eccentric area unfolds segment by segment, forming a staggered adjustment path, which reduces the risk of internal metal fiber mutation caused by the appearance of symmetrical shape from the process level. By further reconstructing the temporal structure of the formed delayed forming time sequence, the continuous delayed forming stages are divided into multiple controlled segmented deformation intervals. Deformation release stages with different time intervals are rhythmically inserted between these intervals to achieve step-by-step unfolding of metal flow and segment-by-segment balance of internal stress. This creates a staggered rhythmic structure in the time dimension of the entire eccentric shaft forging process, thereby improving the continuity and orientation consistency of the internal metal flow. The specific steps are as follows: After forming the delayed shaping time series, the time series is segmented according to the evolution characteristics of metal flow within the eccentric region, so that each segment corresponds to a relatively independent controlled deformation interval. The principle of segmentation is based on the temporal characteristics corresponding to the risk markers of metal fiber orientation changes, ensuring that the start and end times of each segment correspond to the time positions of the risk markers. In practice, the entire delayed shaping time series is divided into several continuous but unequal-length time segments, each used to achieve a specific stage of plastic adjustment. In this way, the continuous shaping stage is transformed into a series of rhythmic controlled periods, within which the stress state, deformation velocity, and flow direction of the eccentric region are in a stable and controllable dynamic equilibrium. This segmentation not only refines the shaping process on the time axis but also provides clear time boundaries for the subsequent insertion of the deformation release stage, enabling the controlled deformation and release processes to alternate in an orderly manner over time.

[0038] By introducing deformation release processes with unequal time intervals between segments of the delayed forming time sequence, the metal flow in the eccentric region can achieve phased stress relief and flow direction adjustment during continuous forming. The deformation release process refers to moderately reducing the stress intensity and deformation rate in the eccentric region while maintaining forming continuity, allowing the internal metal fiber flow to unfold step-by-step along the time dimension. In this process, the duration of each deformation release segment is set according to the stress accumulation and flow trend of the previous segment, creating an alternating rhythmic relationship between the release stage and the controlled deformation stage. This unequal time interval arrangement allows the eccentric region to achieve different degrees of stress relaxation and flow adjustment at different time points, avoiding concentrated strain at a single time node, thereby preventing abrupt changes in direction or breakage of internal metal flow lines due to stress abrupt changes. Through this process, the delayed forming time sequence transforms from a single delay into a dynamic sequence with a rhythmic structure, making the metal flow in the eccentric region more balanced, continuous, and controllable.

[0039] After the deformation release phase is completed, the segmented rhythm of the entire delayed forming time sequence is coordinated in an integrated manner, forming a continuous cyclical rhythmic structure between the controlled deformation and deformation release processes, and achieving a staggered rhythmic adjustment path in time. This coordination process uses the time axis as the main line, smoothly connecting the deformation intensity and release interval of each segment, ensuring that the forging rhythm continues continuously on a macroscopic level, while forming a staggered rhythmic adjustment path on a microscopic level. Through this rhythmic structure, the metal flow within the eccentric region no longer exists in a continuous, unidirectional manner, but rather presents a rhythmic expansion process unfolding segment by segment in time. Each deformation release corresponds to a subtle adjustment of the internal flow direction, allowing the metal fiber orientation to naturally transition between multiple stress applications and relaxations. Especially in the eccentric region, the flow deviation caused by its structural asymmetry can be effectively corrected through this segmented rhythmic control, achieving a smooth transfer of the internal metal flow direction in the time dimension, thereby preventing local flow reversal caused by the apparent symmetry of the external shape.

[0040] After completing the staggered segmented control, the entire delayed forming time sequence is used as the rhythm benchmark for the forging process, allowing the segmented deformation and deformation release processes to alternate and constrain the end point of the forming process. In this stage, the segmented deformation and deformation release processes alternate according to a predetermined rhythm, allowing the internal metal flow in the eccentric region to unfold segment by segment over time and gradually approach equilibrium. As each segmented rhythm progresses, the stress field and flow field inside the eccentric shaft exhibit a transitional characteristic from concentration to dispersion, and from abrupt changes to gradual smoothing over time. When the last rhythm segment is completed, the metal fiber direction in the eccentric region reaches a continuous state and the flow is sufficient, at which point the forming process naturally enters the final stage. The end point of forming is determined based on the end of the delayed forming time sequence, thus ensuring that external stability and internal equilibrium are achieved simultaneously. Through this staggered rhythm adjustment path, the eccentric shaft maintains external stability while its internal metal flow is fully extended, streamline continuity is maintained, and internal stress is released segment by segment, achieving a unity of external shape and internal flow state at the process level throughout the forging process.

[0041] This invention establishes a continuous monitoring mechanism during the eccentric shaft forging stage and combines it with time-series image analysis to achieve dynamic identification of the internal deformation state during the stabilization phase of the external shape. This transforms the judgment criteria for the forging process from external morphology to the synergistic characteristics of the external shape and internal flow. By identifying the indicator sections where the external shape is stable but the internal structure is still changing, misjudgments in symmetrical external shapes can be effectively avoided. This allows the forming process to continue until the continuous transition of metal flow is complete, thereby improving the control accuracy of the eccentric shaft forming stage and ensuring the continuity of the internal structure and the balance of plastic flow.

[0042] This invention incorporates risk markers indicating changes in metal fiber orientation into process rhythm adjustment and segmented rhythm control. This creates a temporal rhythm stagger between the delayed forming time sequence and the unequal intervals of deformation release, promoting the gradual unfolding of internal metal flow in the eccentric region. This rhythmic control method achieves smooth adjustment of internal stress and flow direction in the eccentric region, reducing abrupt changes in streamlines caused by premature termination of forming or concentrated rhythm. It ensures a continuous transition of internal metal fiber orientation during the forming process, improving forming quality and service life.

[0043] This invention provides, for example Figure 2 The image-based eccentric shaft forging process optimization system shown includes a forming monitoring module, a stable zone identification module, a risk analysis module, a rhythm adjustment module, and a rhythm control module. The forming monitoring module establishes a continuous monitoring mechanism for the forming stage of eccentric shaft forging. It records the shape changes at each forming moment in chronological order as a forming image sequence, and extracts the symmetrical segments from the forming image sequence that have entered a stable state of shape change, which are used to identify the stage where the appearance is stable but the internal deformation has not ended. The stable region identification module compares the before and after images of symmetrical sections where the shape changes have entered a stable state over time. It identifies the time interval in which the shape change rate of the off-center region decreases but the local shape is still changing, forming a prompt section where the appearance is stable but the interior is still changing. The risk analysis module performs brightness trajectory analysis on the eccentric region forming image in the warning section, determines the time position when the brightness change direction reverses, and generates a risk marker for the change in metal fiber orientation to indicate the risk of sudden changes in internal metal flow. The rhythm adjustment module adjusts the process rhythm of the forming section corresponding to the risk mark based on the risk mark of the metal fiber direction change, so that the eccentric area maintains controlled deformation in the section and delays the forming time, forming a delayed forming time sequence. The rhythm control module implements segmented adjustment of forming rhythm control along the delayed forming time sequence. During the continuous forming process, it inserts deformation release processes with unequal time intervals, so that the metal flow inside the eccentric area unfolds segment by segment, forming an adjustment path with staggered rhythms, reducing the risk of metal fiber abrupt changes caused by shape symmetry.

[0044] The image-based eccentric shaft forging process optimization method provided in this embodiment of the invention is implemented through the image-based eccentric shaft forging process optimization system described above. For details of the specific methods and processes of the image-based eccentric shaft forging process optimization system, please refer to the embodiment of the image-based eccentric shaft forging process optimization method described above, which will not be repeated here.

[0045] The foregoing has only described certain exemplary embodiments of the present invention by way of illustration. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the foregoing drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. An image-based optimization method for eccentric shaft forging process, characterized in that, Includes the following steps: Establish a continuous monitoring mechanism for the forging stage of eccentric shafts, record the shape changes at each forming moment in chronological order as a forming image sequence, and extract the symmetrical segments from the forming image sequence where the shape changes have entered a stable state. By comparing the before and after images of symmetrical sections where the shape changes have entered a stable state, the time intervals in which the shape change rate of the off-center region decreases but the local shape is still changing are identified, thus forming a prompt section where the appearance is stable but the interior is still changing. Brightness trajectory analysis is performed on the eccentric region forming image in the warning section to determine the time position when the brightness change direction reverses, and a risk marker for the change in the direction of metal fiber is generated. Based on the risk markers for changes in the direction of metal fibers, the process rhythm is adjusted for the forming section corresponding to the risk markers, so that the eccentric area is kept under controlled deformation in the section and the forming time is delayed, thus forming a delayed forming time sequence. The forming rhythm control is implemented in segments along the delayed forming time sequence. Deformation release processes with unequal time intervals are inserted during continuous forming, so that the metal flow inside the eccentric region unfolds segment by segment, forming a staggered adjustment path.

2. The method for optimizing the eccentric shaft forging process based on image generation according to claim 1, characterized in that, The steps for establishing a continuous monitoring mechanism for the forging stage of eccentric shafts are as follows: The monitoring area of ​​the forming equipment is arranged in correspondence with the forming area of ​​the eccentric shaft blank. The shape change information of the eccentric shaft during the forming process is obtained through a multi-angle imaging device, and a time reference for continuous acquisition is established to ensure the time continuity of image recording. The continuously formed images are archived in chronological order. Geometric feature parameters of the eccentric part, main axis region and transition zone are extracted from each frame of the image to generate shape change curves to reflect the evolution process of the eccentric axis shape. Symmetry analysis was performed on the shape change curve during the time interval of gradual change. By comparing the contour differences of adjacent images, the symmetrical segments where the shape change was stable were identified, and the stage where the appearance was stable but the internal deformation was not yet finished was marked. By annotating symmetrical sections with stable shape changes in the formed image sequence, a correspondence is established between stable appearance and incomplete internal deformation.

3. The method for optimizing the eccentric shaft forging process based on image generation according to claim 2, characterized in that, When establishing the correspondence between stable appearance and incomplete internal deformation, time identifiers are inserted into the forming image sequence to synchronously associate the time information of each frame of forming image with the eccentric shaft outline information, so that the shape change curve and the time sequence form a correspondence, thereby realizing dynamic matching between the eccentric shaft shape change and internal deformation state during continuous monitoring.

4. The method for optimizing the eccentric shaft forging process based on image generation according to claim 2, characterized in that, The steps for comparing the before and after forming images of a symmetrical segment whose shape has stabilized are as follows: The symmetrical section with stable shape change is taken as the central interval of time series analysis. The forming images corresponding to adjacent time nodes are selected and organized, and the perspective and scale of the images are uniformly adjusted to form a continuous shape change trajectory. Contour feature comparison is performed on the symmetrical segments with stable shape changes in the time series and the formed images of the time nodes before and after them to identify the time intervals in which the shape change rate of the eccentric region decreases but the local shape continues to change. The formed images within the identified time interval are continuously superimposed to determine the extension direction of the morphological changes in the local area and form a comprehensive judgment that the appearance is stable but the internal structure is still changing. The identified time intervals are labeled in the formed image sequence to establish the time boundaries of the prompting segments and form a state record that is stable in appearance but still changing internally.

5. The image-based eccentric shaft forging process optimization method according to claim 4, characterized in that, When marking the identified time intervals in the forming image sequence, the start and end times of the time intervals are set to correspond with the forming process time axis, and the duration of local morphological changes and the trend of eccentric area changes are recorded, so that the prompting section has time positioning function in the subsequent forming process.

6. The method for optimizing the eccentric shaft forging process based on image generation according to claim 4, characterized in that, For a prompt section where the appearance is stable but the internal structure is still changing, the steps for brightness trajectory analysis of the eccentric region shaping image within the prompt section are as follows: Within the prompting section, the continuous shaped image of the off-center region is divided into regions and brightness is extracted. The brightness information of the off-center part and the transition area is recorded in time sequence to form a continuous brightness distribution sequence. By comparing the brightness change trajectory of the off-center area within the prompt section over time, the continuous trend of brightness change direction is determined and the time position of the reverse change in brightness direction is captured. By comparing the time location where the brightness direction changes in the opposite direction with the corresponding formed image, local areas with drastic brightness changes are identified and a temporal-spatial correlation is established to determine the formed segment. Based on the reverse change time position of the brightness change direction, a risk marker for the change in metal fiber orientation is generated, and the risk marker is embedded in the formed image sequence to indicate the risk of abrupt changes in internal metal flow.

7. The image-based eccentric shaft forging process optimization method according to claim 6, characterized in that, In the process of generating risk markers for changes in the orientation of metal fibers, by introducing time-series tracking of brightness change direction into the continuous forming image of the warning section, the duration of the reverse brightness change is correlated with the metal flow trend inside the eccentric region, so that the risk markers can reflect the dynamic process of metal fiber orientation adjustment.

8. The method for optimizing the eccentric shaft forging process based on image generation according to claim 6, characterized in that, Based on the risk markers indicating changes in the direction of metal fibers, the steps for adjusting the process rhythm of the forming sections corresponding to the risk markers are as follows: Match the time position corresponding to the risk mark of metal fiber orientation change with the time axis of the forming image sequence to determine the specific forming section where the risk mark is located and establish the synchronization relationship between the risk mark and the process time axis; Within the forming section corresponding to the risk mark, the process rhythm is re-planned. By extending the plastic action time, the eccentric area is kept under controlled deformation and the continuous transition of metal fiber flow is achieved. The revised rhythm arrangement is embedded into the overall shaping process, forming a delayed shaping time sequence and setting smooth transition sections on the time axis to ensure the continuity of rhythm adjustment; The end point of the shaping process is constrained by using the delayed shaping time sequence as the time control benchmark, so that the internal metal flow reaches a continuous state before the shaping process is terminated.

9. The method for optimizing the eccentric shaft forging process based on image generation according to claim 8, characterized in that, The steps for segmented adjustment of the forming rhythm control along the delayed forming time sequence are as follows: The delayed shaping time series is divided into segments according to the evolution characteristics of metal flow within the eccentric region, so that each segment corresponds to an independent controlled deformation interval, and the start and end times of the segments correspond to the time positions of the risk markers for changes in the direction of metal fibers. By introducing deformation release processes with unequal time intervals between the segments of the delayed forming time sequence, the metal flow in the eccentric region can achieve staged stress relief and flow direction adjustment during continuous forming. The segmented rhythm of the delayed shaping time series is coordinated in an integrated manner, so that the controlled deformation and deformation release process form a continuous cyclical rhythm structure and achieve a staggered adjustment path in time. Using the delayed forming time sequence as the rhythm benchmark for the forging process, the segmented deformation and deformation release processes are carried out alternately, and the end point of the forming process is constrained.

10. An image-based eccentric shaft forging process optimization system, used to implement the image-based eccentric shaft forging process optimization method according to any one of claims 1-9, characterized in that, It includes a forming monitoring module, a stable zone identification module, a risk analysis module, a rhythm adjustment module, and a rhythm control module: The forming monitoring module establishes a continuous monitoring mechanism for the forming stage of eccentric shaft forging, records the shape changes at each forming moment in chronological order as a forming image sequence, and extracts the symmetrical segments from the forming image sequence where the shape changes have entered a stable state. The stable region identification module compares the before and after images of symmetrical sections where the shape changes have entered a stable state over time. It identifies the time interval in which the shape change rate of the off-center region decreases but the local shape is still changing, forming a prompt section where the appearance is stable but the interior is still changing. The risk analysis module performs brightness trajectory analysis on the eccentric region forming image in the warning section to determine the time and location when the brightness change direction reverses, and generates a risk marker for the change in the direction of metal fibers. The rhythm adjustment module adjusts the process rhythm of the forming section corresponding to the risk mark based on the risk mark of the metal fiber direction change, so that the eccentric area maintains controlled deformation in the section and delays the forming time, forming a delayed forming time sequence. The rhythm control module implements segmented adjustment of the forming rhythm control along the delayed forming time sequence. During the continuous forming process, it inserts deformation release processes with unequal time intervals, so that the metal flow inside the eccentric area unfolds segment by segment, forming an adjustment path with staggered rhythms.

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