Cutter handle automatic production line and machining process based on intelligent cutter system

Abstract

The invention provides an automatic cutter handle production line based on an intelligent cutter system and a machining process. On the premise of guaranteeing the product machining efficiency and automatic intelligent production, in the whole intelligent cutter system-based cutter handle automatic production line operation and machining process implementation process, intelligent cutter wear state monitoring system software of a PC end upper computer monitors all intelligent cutters in a production line in real time through intelligent cutter embedded sensor data, and the intelligent cutter wear state monitoring system software is used for monitoring the intelligent cutter wear state in the production line. Comprise but are not limited to wear states and operation parameters of the intelligent external turning tool, the intelligent grooving turning tool and the intelligent milling cutter. The intelligent tool wear state monitoring system can give an early warning of tool breakage or end of service life in advance, and automatically calls a standby tool or prompts replacement, so that stable operation of a production line and high-precision consistency of tool holder products are ensured.

Description

Technical Field

[0001] This invention relates to the fields of intelligent manufacturing and CNC machining technology, and in particular to an automated production line and machining process for tool holders based on an intelligent tool system. Background Technology

[0002] As a critical component connecting the spindle and the cutting tool in a machine tool, the manufacturing precision of the tool holder directly affects the machining accuracy and tool life. Low-precision tool holders amplify vibrations and runouts, which not only lead to workpiece scrap due to out-of-tolerance conditions but also accelerate tool wear and even cause spindle damage, posing a serious threat to production efficiency and equipment safety.

[0003] Currently, the machining of tool holders typically employs traditional turning tools and milling cutters, performed in stages on multiple machines such as lathes and milling machines. The typical process route includes: rough and finish turning of the outer diameter, milling of the keyway, drilling of through holes, finishing of the taper shank, and tapping. This traditional production model has several significant drawbacks:

[0004] A. The existing process relies heavily on the experience of operators to set cutting parameters, and the entire machining process lacks real-time monitoring and feedback of key physical quantities such as cutting force, temperature, and vibration; it is impossible to provide early warning and intervention for possible abnormalities, making it difficult to effectively guarantee the quality consistency of batch-produced tool holders.

[0005] B. Workpieces need to be transferred, positioned and clamped multiple times between machine tools with different functions. This relies heavily on manual loading and unloading, which not only results in high labor intensity and low processing efficiency, but also inevitably introduces repeated positioning errors due to multiple clamping, directly increasing the cumulative error and scrap risk of the workpiece.

[0006] C. Information is isolated between units in the existing production line, making it impossible to achieve data collection, process parameter optimization, and accurate traceability of product quality throughout the entire processing process, which restricts the further upgrading of tool holder manufacturing towards automation, intelligence, and digitalization.

[0007] Therefore, developing an automated production line and processing technology for tool holders based on intelligent tool systems has become an urgent need to improve the level of tool holder manufacturing and meet the stringent requirements of high-end manufacturing. Summary of the Invention

[0008] The purpose of this invention is to provide an automated production line and processing technology for tool holders based on an intelligent tool system, in order to solve the problems existing in the prior art.

[0009] The technical solution adopted to achieve the purpose of this invention is as follows: an automated production line for tool holders based on an intelligent tool system, comprising a processing unit, a logistics unit, and an intelligent tool system.

[0010] The intelligent tooling system includes an intelligent milling cutter, an intelligent grooving tool, an intelligent external turning tool, a signal processing circuit box, and a PC-based host computer. Each of the intelligent milling cutter, intelligent grooving tool, and intelligent external turning tool integrates a vibration sensor and a PVDF force sensor. The intelligent milling cutter also integrates a temperature sensor. The sensor signals from the intelligent milling cutter, intelligent grooving tool, and intelligent external turning tool are connected to the signal processing circuit box. The signal processing circuit box communicates with the PC-based host computer. The PC-based host computer is equipped with intelligent tool wear condition monitoring system software.

[0011] The machining unit adopts a triangular, wraparound layout based on a top-down view. The three vertices of the triangular shape are occupied by a first CNC lathe, a second CNC lathe, and a vertical machining center. The first CNC lathe's cutter head is equipped with intelligent grooving tools and intelligent external turning tools for the first-order external turning and V-groove machining. The second CNC lathe's cutter head is equipped with intelligent grooving tools and intelligent external turning tools for the second-order taper shank finishing and internal threading. The vertical machining center's spindle is equipped with intelligent milling cutters for the third-order high-precision milling of keyways.

[0012] The logistics unit includes a robotic arm, a tilting table, a transfer table, a loading area, and a unloading area. The robotic arm is located at the center of the triangular layout. It is used to grip and transport workpieces. The robotic arm's working radius covers the entire processing unit. The tilting table is located adjacent to the first CNC lathe. It is used for workpiece orientation rotation. The transfer table is located adjacent to the second CNC lathe. It serves as a buffer between processes. The loading and unloading areas are arranged adjacent to each other at the bottom of the production line. They are used for centralized material management.

[0013] During tool holder machining, vibration sensors and PVDF force sensors collect vibration acceleration and cutting force signals in real time. Temperature sensors monitor temperature changes in the milling area. The raw sensor signals undergo preliminary conditioning and analog-to-digital conversion in the signal processing circuit box before being transmitted to a PC-based host computer. The PC-based host computer dynamically displays the corresponding sensor data based on the selected applicable tool, providing the operator with intuitive feedback on the machining status. The PC-based host computer automatically processes the received time-series data, extracting feature values ​​strongly correlated with tool wear. When a feature value exceeds a safety threshold, the system determines that the tool has abnormal wear or breakage and issues an audible and visual warning signal on the software interface, prompting operator intervention. Through continuous monitoring, the PC-based host computer estimates the remaining tool life, achieving predictive maintenance.

[0014] Furthermore, the production line is surrounded by a safety protection unit with a safety interlock mechanism to achieve human-machine isolation. The safety protection unit includes a safety fence, fence posts, and a safety door. The fence posts are vertically fixed support components to the ground. The safety fence and fence posts form a closed rectangular area. The loading and unloading areas are located within this closed rectangular area. The safety door is a movable component integrated into the safety fence.

[0015] Furthermore, the safety protection unit also includes a loading switch and a unloading switch. These switches are installed outside the safety fence, directly facing the loading and unloading areas. The loading and unloading switches allow the operator to initiate loading or unloading requests outside the safety isolation zone, with the robotic arm automatically executing the subsequent material handling or placement procedures.

[0016] Furthermore, it also includes a supporting execution unit. The supporting execution unit includes an automatic bracing device, a sampling inspection table, a chip conveyor, and a chip conveyor. The automatic bracing device is arranged adjacent to the first CNC lathe. The automatic bracing device is used for the assembly and disassembly of bracing. The sampling inspection table is arranged in the gap between the first CNC lathe and the vertical machining center. The sampling inspection table is used to measure and verify the tool holder workpiece that has completed the third stage of machining.

[0017] The chip conveyor is located on the side of the second CNC lathe. It is used to transport and collect metal chips generated by the machining unit. The chip cart, acting as a collection container, is located directly below the chip conveyor outlet and is used for temporary storage and transfer of chips.

[0018] Furthermore, the automatic rivet tightening device includes support columns, a control cabinet, a three-jaw chuck, a slide table, a slide rail, a cylinder, a workpiece seat, an automatic rivet tightening spindle peripheral, status lights, a guide rail, a lead screw, the main body of the automatic rivet tightening device, an auxiliary frame for the automatic rivet tightening spindle, the automatic rivet tightening spindle, rivets, and a rivet gripper frame. The control cabinet controls the three-jaw chuck to position and clamp the workpiece. Subsequently, the cylinder and lead screw drive the automatic rivet tightening spindle to move precisely along the guide rail, and the rivet gripper frame grabs the rivet and performs the tightening action. The status lights display the real-time operating status of the equipment.

[0019] This invention also discloses an automated machining process for tool holders based on the above-mentioned production line, comprising the following steps:

[0020] S1. Loading and System Initialization. The operator places the tool holder blank in the loading area, clamps the corresponding intelligent tool on each machine tool, starts the intelligent tool system, and establishes a communication connection.

[0021] S2. First-order machining. The robotic arm picks up the blank and loads it into the first CNC lathe. The intelligent external turning tool and the intelligent grooving tool are used to complete the rough machining of the outer circle, V-groove, end face and inner hole.

[0022] S3. Workpiece flipping. The robotic arm transfers the workpiece that has completed the first stage of processing to the flipping table for a 180° turn.

[0023] S4. Second-order machining. The robotic arm picks up the flipped workpiece and loads it into the second CNC lathe to complete the finishing of the tapered shank shape and the taper of the internal threaded pull stud hole.

[0024] S5. Automatic Rivet Assembly. The robotic arm transfers the workpiece to the automatic rivet screwing device. The device automatically screws the rivet into the internal threaded hole of the workpiece to the preset torque.

[0025] S6. Third-stage machining. The robotic arm loads the workpiece with the pull studs into the vertical machining center and uses an intelligent milling cutter to mill the keyway with high precision.

[0026] S7. Quality Sampling and Unloading. The robotic arm delivers the completed workpieces to the sampling inspection station for offline inspection at a preset frequency, and then transfers the qualified parts to the automatic rivet-tightening device to remove the rivets before finally placing them in the unloading area.

[0027] Furthermore, during the processing of steps S2, S4, and S6, the PC-based host computer monitors the vibration, force, and temperature signals of each intelligent tool in real time. Once it determines that the tool wear has reached the threshold, it issues an early warning or automatically calls up a spare tool to achieve predictive maintenance.

[0028] The technical advantages of this invention are undeniable: While ensuring product processing efficiency and automated, intelligent production, the entire automated production line for tool holders based on the intelligent tool system operates and processes are automated. The PC-based intelligent tool wear monitoring system software uses embedded sensor data to monitor the wear status and operating parameters of all intelligent tools on the production line in real time, including but not limited to intelligent external turning tools, intelligent grooving tools, and intelligent milling cutters. This intelligent tool wear monitoring system can provide early warnings of tool breakage or the end of its lifespan, automatically calling up spare tools or prompting for replacement, thereby ensuring the stable operation of the production line and the high precision and consistency of the tool holder products. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of an automated production line for tool holders based on an intelligent tooling system.

[0030] Figure 2 A top view of an automated production line for tool holders based on an intelligent tooling system;

[0031] Figure 3 This is a schematic diagram of the components of an intelligent tooling system;

[0032] Figure 4 A schematic diagram showing the mounting of an intelligent cutting tool on a lathe tool turret.

[0033] Figure 5A schematic diagram of the clamping of an intelligent milling cutter on the spindle of a vertical machining center;

[0034] Figure 6 A schematic diagram showing the composition of the loading and unloading areas;

[0035] Figure 7 A schematic diagram illustrating the sequential machining process of tool holders on an automated production line.

[0036] Figure 8 A schematic diagram showing the robotic arm clamping a tool holder and workpiece onto the first CNC lathe.

[0037] Figure 9 A schematic diagram showing a robotic arm clamping a tool holder and workpiece onto a second CNC lathe.

[0038] Figure 10 Schematic diagram of a robotic arm moving a tool holder and workpiece to an automatic rivet tightening device for rivet installation;

[0039] Figure 11 A schematic diagram showing a robotic arm clamping a tool holder and workpiece onto a vertical machining center;

[0040] Figure 12 A schematic diagram illustrating how a robotic arm moves a tool holder and workpiece to an automatic rivet-tightening device to disassemble a rivet.

[0041] Figure 13 Flowchart of automated machining process for tool holders based on intelligent tooling systems;

[0042] Figure 14 A diagram of the software interface for monitoring the wear status of intelligent lathe tools on a PC-based host computer;

[0043] Figure 15 A diagram of the software interface for monitoring the wear status of intelligent milling cutters on a PC-based host computer.

[0044] In the diagram: 1. Safety gate; 2. Fence post; 3. Unloading switch; 4. Unloading area; 401. Tool holder workpiece; 402. Unloading forklift pallet; 403. Unloading positioning chassis; 404. Tool holder workpiece; 5. Safety fence; 6. Loading switch; 7. Loading area; 701. Tool holder blank; 702. Loading forklift pallet; 703. Loading positioning chassis; 8. Automatic screw-on / pulling device; 801. Support column; 802. Device control cabinet; 803. Three-jaw chuck; 804. Slide table; 805. Slide rail; 806. Cylinder; 807. Workpiece seat; 808. Automatic screw-on / pulling device spindle peripheral; 809. Status light; 810. Guide rail; 811. Lead screw; 812. Automatic screw-on / pulling device. The system includes: main body 812, automatic screw-in / stud spindle auxiliary frame 813, automatic screw-in / stud spindle 814, stud 815, stud gripper frame 816, intelligent tool system 9, intelligent milling cutter 901, intelligent grooving tool 902, intelligent external turning tool 903, signal line 904, signal processing circuit box 905, PC host computer 906, Wi-Fi router 907, tool cabinet 10, electrical cabinet 11, turnover table 12, first CNC lathe 13, sampling inspection table 14, sampling inspection area 15, vertical machining center 16, chip conveyor 17, chip conveyor 18, robotic arm 19, transfer table 20, and second CNC lathe 21. Detailed Implementation

[0045] The present invention will be further described below with reference to embodiments, but it should not be construed that the scope of the present invention is limited to the following embodiments. Various substitutions and modifications made based on ordinary technical knowledge and common practices in the art without departing from the above-described technical concept of the present invention should be included within the scope of protection of the present invention.

[0046] Example 1:

[0047] See Figures 1-3 This embodiment provides an automated production line for tool holders based on an intelligent tool system, including a processing unit, a logistics unit, and an intelligent tool system 9.

[0048] The intelligent tool system 9 includes an intelligent milling cutter 901, an intelligent grooving tool 902, an intelligent external turning tool 903, a signal processing circuit box 905, and a PC-based host computer 906. Each of the intelligent milling cutter 901, intelligent grooving tool 902, and intelligent external turning tool 903 integrates a vibration sensor and a PVDF force sensor. The intelligent milling cutter 901 also integrates a temperature sensor. The sensor signals from the intelligent milling cutter 901, intelligent grooving tool 902, and intelligent external turning tool 903 are connected to the signal processing circuit box 905. The signal processing circuit box 905 communicates with the PC-based host computer 906. The PC-based host computer 906 is equipped with intelligent tool wear condition monitoring system software.

[0049] See Figures 4-9The machining unit adopts a triangular, wraparound layout based on a top-down view. The three vertices of the triangular shape are occupied by a first CNC lathe 13, a second CNC lathe 21, and a vertical machining center 16. The first CNC lathe 13 has an intelligent grooving tool 902 and an intelligent external turning tool 903 mounted on its cutter head for the first-order external turning and V-groove machining. The second CNC lathe 21 has an intelligent grooving tool 902 and an intelligent external turning tool 903 mounted on its cutter head for the second-order taper shank finishing and internal thread machining. The vertical machining center 16 has an intelligent milling cutter 901 mounted on its spindle for the third-order high-precision milling of keyways.

[0050] The logistics unit includes a robotic arm 19, a turnover table 12, a transfer table 20, a loading area 7, and a unloading area 4. The robotic arm 19 is located at the center of the triangular layout. The robotic arm 19 is used to grip and transport workpieces. The working radius of the robotic arm 19 fully covers the processing unit. The turnover table 12 is arranged adjacent to the first CNC lathe 13. The turnover table 12 is used for workpiece orientation rotation. The transfer table 20 is arranged adjacent to the second CNC lathe 21. The transfer table 20 serves as a buffer between processes. The loading area 7 and the unloading area 4 are arranged adjacent to each other at the bottom of the production line. The loading area 7 and the unloading area 4 are used for centralized material management.

[0051] During tool holder machining, vibration sensors and PVDF force sensors collect vibration acceleration and cutting force signals in real time. Temperature sensors monitor temperature changes in the milling area. The raw sensor signals undergo preliminary conditioning and analog-to-digital conversion in the signal processing circuit box 905 before being transmitted to the PC host computer 906. The PC host computer 906 dynamically displays the corresponding sensor data based on the selected applicable tool, providing the operator with intuitive feedback on the machining status. The PC host computer 906 automatically processes the received time-series data, extracting feature values ​​strongly correlated with tool wear. When a feature value exceeds a safety threshold, the system determines that the tool has abnormal wear or breakage and issues an audible and visual warning signal on the software interface, prompting operator intervention. Through continuous monitoring, the PC host computer 906 estimates the remaining tool life, achieving predictive maintenance.

[0052] Example 2:

[0053] This embodiment is similar in main content to Embodiment 1, except that a safety protection unit with a safety interlock mechanism is installed around the production line to achieve human-machine isolation. The safety protection unit includes a safety fence 5, fence posts 2, and a safety door 1. The fence posts 2 are vertically fixed support components to the ground. The safety fence 5 and fence posts 2 form a closed rectangular area. The loading area 7 and unloading area 4 are located within this closed rectangular area. The safety door 1 is a movable component integrated into the safety fence 5.

[0054] The safety protection unit also includes a loading switch 6 and a unloading switch 3. The loading switch 6 and the unloading switch 3 are installed outside the safety fence 5, facing the loading area 7 and the unloading area 4. The loading switch 6 and the unloading switch 3 allow the operator to initiate a loading or unloading request outside the safety isolation area, and the robotic arm 19 automatically executes the subsequent material grabbing or placement procedure.

[0055] Example 3:

[0056] This embodiment is similar in main content to Embodiment 1 or 2, but also includes a supporting execution unit. The supporting execution unit includes an automatic rivet tightening device 8, a sampling inspection table 14, a chip conveyor 17, and a chip conveyor 18. The automatic rivet tightening device 8 is arranged adjacent to the first CNC lathe 13. The automatic rivet tightening device 8 is used for the assembly and disassembly of rivets. The sampling inspection table 14 is arranged in the gap between the first CNC lathe 13 and the vertical machining center 16. The sampling inspection table 14 is used to measure and verify the tool holder workpiece that has completed the third-stage machining.

[0057] The chip conveyor 18 is arranged on the side of the second CNC lathe 21. The chip conveyor 18 is used to transport and centrally discharge the metal chips generated by the machining unit. The chip conveyor cart 17, as a collection container, is located directly below the chip conveyor outlet and is used to temporarily store and transfer the chips.

[0058] Example 4:

[0059] The main content of this embodiment is the same as that of embodiment 1 or 2, wherein, see [link / reference]. Figures 10-12 The automatic rivet tightening device 8 includes a support column 801, a device control cabinet 802, a three-jaw chuck 803, a slide table 804, a slide rail 805, a cylinder 806, a workpiece seat 807, an automatic rivet tightening spindle peripheral 808, a status light 809, a guide rail 810, a lead screw 811, an automatic rivet tightening device body 812, an automatic rivet tightening spindle auxiliary frame 813, an automatic rivet tightening spindle 814, a rivet 815, and a rivet gripper frame 816. The device control cabinet 802 controls the three-jaw chuck 803 to position and clamp the workpiece. Subsequently, the cylinder 806 and the lead screw 811 drive the automatic rivet tightening spindle 814 to move precisely along the guide rail 810, and the rivet gripper frame 816 grabs the rivet 815 and performs the tightening action. The status light 809 displays the real-time operating status of the equipment.

[0060] Infrared sensors are integrated into the three-jaw chuck 803, the automatic rivet screwing spindle 814, and the rivet screwing gripper 813. When the three-jaw chuck 803 senses that the robotic arm 19 has placed the tool holder workpiece 401 inside, the automatic rivet screwing spindle 814 uses infrared sensing to determine whether a rivet 815 is installed in the rivet hole of the tool holder workpiece 401. If no rivet 815 is installed, the automatic rivet screwing device 8 runs the automatic rivet screwing program to complete the rivet screwing work before the three-stage vertical machining process; if a rivet 815 is installed, the automatic rivet screwing device 8 runs the automatic rivet unloading program to complete the rivet unloading work before unloading.

[0061] Example 5:

[0062] This embodiment provides an automated machining process for tool holders in the production line described in any one of Embodiments 4 to 5, including the following steps:

[0063] S1. Loading and System Initialization. The operator places the tool holder blank in the loading area 7, clamps the corresponding intelligent tool on each machine tool, and starts the intelligent tool system 9 to establish a communication connection.

[0064] S2. First-order machining. The robotic arm 19 picks up the blank and loads it into the first CNC lathe 13. The intelligent external turning tool 903 and the intelligent grooving tool 902 are used to complete the rough machining of the outer circle, V-groove, end face and inner hole.

[0065] S3. Workpiece flipping. The robotic arm 19 transfers the workpiece that has completed the first-order processing to the flipping table 12 for a 180° turn.

[0066] S4. Second-order machining. The robotic arm 19 picks up the flipped workpiece and loads it into the second CNC lathe 21 to complete the finishing of the tapered shank shape and the taper of the internal threaded pull stud hole.

[0067] S5. Automatic assembly of rivets. The robotic arm 19 transfers the workpiece to the automatic rivet screwing device 8. The device automatically screws the rivet 815 into the internal threaded hole of the workpiece to the preset torque.

[0068] S6. Third-order machining. The robotic arm 19 loads the workpiece with the pull studs into the vertical machining center 16, and uses the intelligent milling cutter 901 to mill the keyway with high precision.

[0069] S7. Quality inspection and unloading. The robotic arm 19 delivers the completed work to the sampling inspection table 14 for offline inspection at a preset frequency, and transfers the qualified parts to the automatic rivet screwing device 8 to remove the rivets, and finally places them in the unloading area 4.

[0070] Example 6:

[0071] The main content of this embodiment is the same as that of embodiment 5. In the processing of steps S2, S4 and S6, the PC host computer 906 monitors the vibration, force and temperature signals of each intelligent tool in real time. Once it is determined that the tool wear reaches the threshold, an early warning is issued or a spare tool is automatically called to realize predictive maintenance.

[0072] Example 7:

[0073] The main content of this embodiment is the same as that of embodiment 5. The automated production line and processing technology of the tool holder based on the intelligent tool system is a flexible manufacturing unit that integrates a first CNC lathe 13, a second CNC lathe 21, a vertical machining center 16, a robotic arm 19, and an intelligent tool system 8. It aims to efficiently complete the automated processing of the tool holder blank 701 from blanking to key processes.

[0074] The automated machining process for tool holders mainly covers the core machining stages, including blanking the tool holder blank 701, turning the outer diameter of the tool holder workpiece 401, turning the V-groove, turning the taper shank, milling the keyway, and inspection.

[0075] See Figure 13 Taking the production of BT40 ER20×150 toolholders on an automated production line as an example, the blank material specification is D65-20CrMnTi. The detailed process flow of the automated machining of the toolholders is as follows:

[0076] Part 1: Rough Processing on Automated Production Lines

[0077] 1) Preparations.

[0078] The length of the tool holder blank 701 in the pre-prepared material control loading area 7 is 210mm. The operator installs the intelligent external turning tool 903 and the intelligent grooving tool 902 on the tool heads of the first CNC lathe 13 and the second CNC lathe 21, and installs the intelligent milling cutter 901 on the spindle of the vertical machining center 16. The intelligent tool is then connected to the Wi-Fi router 907, and the intelligent tool wear detection system on the PC host computer 906 is run. After completing the above preparations, the operator starts the loading switch 6, and the robotic arm 19 automatically grabs the tool holder blank 701.

[0079] 2) Lathe sequence 1: head roughing.

[0080] 2.1) The robotic arm 19 loads the tool holder blank 701 onto the first CNC lathe 13 and clamps it with a three-jaw chuck.

[0081] 2.2) Use a 903 intelligent external turning tool to rough turn the overall external diameter, and use an internal drill bit to drill the pores.

[0082] 2.3) The intelligent external turning tool 903 has a flat end face. The outer diameter of the tool shank of the intelligent external turning tool 903 is mm, and the diameter allowance is 0.3 mm.

[0083] 2.4) Use the intelligent grooving tool 902 to cut a 60° V-groove, leaving a 0.2mm allowance on each side and a mm allowance at the bottom of the groove, and control the distance from the center of the groove to the front end face to mm.

[0084] 2.5) Use the intelligent external turning tool 903 to turn the external diameter, leaving a allowance of 0.3mm, and bring out the radius fillets.

[0085] 2.6) Use the intelligent external turning tool 903 to turn the outer circle and fillet to the drawing requirements, and chamfer and deburr.

[0086] 2.7) Use the intelligent external turning tool 903 to turn the external thread to the major diameter, leaving a 1.5mm allowance, and bring out a 60° bevel and R fillet.

[0087] 2.8) Drill holes and enlarge the holes with an internal drill bit to meet the requirements of the drawing, drill a through hole with a center thread, tap an M12 thread, and remove burrs.

[0088] 2.9) The inner taper of the turning tool head is tapered, with a 0.3mm allowance on the taper surface. It is inspected with a plug gauge, and the hole opening is chamfered at 60°.

[0089] 3) Lathe second step: rough turning of the shank.

[0090] 3.1) The robotic arm 19 takes the tool holder workpiece 401 from the first CNC lathe 13, turns it 180° via the turning table 12, and loads it onto the second CNC lathe 21, where the soft jaws clamp the outer diameter of the machined tool holder head.

[0091] 3.2) The intelligent external turning tool has a total length of 903, ensuring that the end face has a precision turning allowance of 0.2mm.

[0092] 3.3) For the dimensions of the shank of the 903 intelligent external turning tool, leave a 0.3mm allowance on the outer conical surface, control the thickness of the large outer diameter of the tool shank ±0.05mm, and expand the bottom hole of the thread.

[0093] 3.4) The intelligent grooving tool 902 is used to machine the internal overrun groove, semi-finish boring the pull stud hole, chamfer the hole opening at 60°, and machine the 120° protective cone, all with a allowance of 0.3mm.

[0094] 3.5) Tap the internal thread to M16 as required by the drawing, and inspect the thread with an enlarged plug gauge.

[0095] 4) Automatic assembly of rivets

[0096] The robotic arm 19 transfers the tool holder workpiece 401, which has completed the second-stage machining on the lathe, to the automatic rivet tightening device 8. The automatic rivet tightening device 8 automatically screws the rivet 815 into the M16 threaded hole and tightens it according to the preset torque.

[0097] 5) Vertical machining sequence: Milling keyways.

[0098] 5.1) Clamp the 16-axis centering milling machine of the vertical machining center and tighten the tie rod.

[0099] 5.2) The keyway of the 901 intelligent milling cutter shank is aligned with the drawing requirements; chamfering and deburring are performed.

[0100] 6) Automatic unloading of rivets, material feeding and inspection.

[0101] After the keyway is milled, the robotic arm 19 removes the tool holder workpiece 401 from the vertical machining center 16 and transfers it to the automatic rivet tightening device 8 to unload the rivet 815. After completion, it is placed in the unloading area 4. During the production cycle, the robotic arm 19 can randomly place the tool holder workpiece 401 to the sampling inspection table 14 at a preset frequency, where quality inspectors will perform process inspections in the sampling inspection area 15.

[0102] Part Two: Offline Heat Treatment and Finishing Preparation

[0103] 7) Heat treatment.

[0104] The rough-machined tool holders 401 were transferred in batches to the heat treatment workshop for carburizing and quenching processes. The carburized layer depth was set at 0.7~0.9mm, and the quenching temperature was HRC56~60.

[0105] 8) Test 2.

[0106] After heat treatment, the tool holder workpiece 401 is subjected to hardness testing to ensure that it meets the technical requirements of HRC56~60.

[0107] 9) Polishing.

[0108] After passing the hardness test, the workpiece 401 is transferred to the polishing workshop for overall polishing for 0.5 hours to remove the heat-treated oxide scale and prepare for the subsequent finishing process.

[0109] Part Three: Precision Manufacturing on Automated Production Lines

[0110] 10) Add more material.

[0111] The operator places the heat-treated and polished tool holder workpiece 401 back into the loading area 7 of the automated production line. The operator then initiates the finishing program. The robotic arm 19 picks up the hardened tool holder workpiece 401 and loads it onto the first CNC lathe 13, where it is clamped by three jaws.

[0112] 11) Finish turning of the outer diameter of the head

[0113] The intelligent external turning tool 903 finishes the head's outer diameter to the final dimension required by the drawing. The intelligent external turning tool 903 requires the use of hard turning inserts such as CBN or ceramic inserts at this stage.

[0114] 12) Finish turning of the shank and conical surface.

[0115] 12.1) The robotic arm 19 takes the workpiece out of the first CNC lathe 13, turns it over via the turnover table 12, and loads it onto the second CNC lathe 21, where it is clamped and calibrated by soft jaws.

[0116] 12.2) Finish turning of the taper shank and outer diameter. Use a smart external turning tool 903 equipped with hardened inserts to finish turning the large outer diameter of the tool shank, and machine the outer taper surface with high precision to meet the requirements of the drawing, ensuring the positional dimensions of the V-groove and a surface roughness of Ra 0.4 or less.

[0117] 12.3) Precision boring of the rivet hole. Clamp with soft jaws, correct the runout of the small end of the taper shank to less than 0.01mm, and ensure that the runout of the large end is less than 0.02mm. Precision bore the rivet hole to the drawing requirements, bringing out a 60° chamfer and a protective cone.

[0118] 12.4) Finish turning the V-groove. Replace with a 902 intelligent grooving tool equipped with a hardened insert, finish turning a 60° V-groove and the bottom of the groove to the drawing requirements. Use a measuring bar to check the diameter and ensure the positional dimensions.

[0119] 12.5) Finish machining the end face and threads. Finish machine the end face of the shank to ensure the axial length of the taper shank; machine the M25 process ring; use the outer taper surface as a reference for tooling, and correct the process ring runout to be less than 0.005mm; finish machine the ER thread and ER inner taper to the drawing requirements, and inspect with a plug gauge.

[0120] 13) Transfer the unloaded material to the post-processing stage.

[0121] The robotic arm 19 takes the tool holder workpiece 401, which has been hard-turned, from the second CNC lathe 21 and places it in the unloading area 4, ready to be transferred to the offline surface treatment process.

[0122] Part 4: Offline Post-processing and Detection

[0123] 14) Surface treatment.

[0124] The finished tool holder workpieces 401 were transferred in batches to the surface treatment workshop, where the end face of the tool holder head and the outer circle surface were treated with blackening and rust prevention.

[0125] 15) Test 3.

[0126] After surface treatment, inspect the surface quality of tool holder workpiece 401;

[0127] 16) Marking.

[0128] The tool holder workpiece 401 was transferred in batches to the marking workshop, where the product number BT40 ER20×150 and the production batch number were marked according to the standard requirements.

[0129] 17) Cleaning one.

[0130] The marked tool holders (401) were transferred in batches to the cleaning workshop for ultrasonic cleaning.

[0131] 18) Test 4.

[0132] Inspect the dynamic balance of the tool holder on a dynamic balancing machine. When the working speed is 20000 r / min, check its dynamic balance level, the target level is G2.5, and accurately calculate the magnitude and phase of the imbalance, that is, the position and depth of correction required.

[0133] Part 5: Dynamic Balance Correction

[0134] 19) Third feeding (dynamic balance correction)

[0135] The operator places the tool holder, which has been inspected and requires dynamic balancing correction, into the loading area 7 of the automated production line for the third time. At the same time, the imbalance data is input into the machining program of the vertical machining center 16.

[0136] 20) Milling the balance hole

[0137] 20.1) The robotic arm 19 grabs the tool holder workpiece 401 to be corrected and loads it onto the fixture of the vertical machining center 16. At this time, instead of using pull studs to tighten it, the clamping jaws are used.

[0138] 20.2) Vertical machining center 16 calls a small diameter drill bit and, based on the input dynamic balance correction data, automatically drills or mills to remove material at the bottom of a 60° V-groove to correct the balance.

[0139] 21) Final material feeding.

[0140] The robotic arm 19 takes the tool holder workpiece 401, which has been balanced and corrected, from the vertical machining center 16 and places it in the unloading area 4.

[0141] Part Six: Final Inspection and Warehousing

[0142] 22) Cleaning two

[0143] The finished tool holders after milling the balance holes are transported in batches to the cleaning workshop for final ultrasonic cleaning.

[0144] 23) Final inspection

[0145] Perform the final inspection according to the standards.

[0146] 24) Warehousing

[0147] After final inspection, the finished tool handles are coated with anti-rust oil, packaged, and stored in the warehouse.

[0148] Example 8:

[0149] The main content of this embodiment is the same as that of embodiment 5, wherein, see [link / reference]. Figure 14 and Figure 15 The PC-based 906 software intelligent tool wear monitoring system is divided into three main modules: real-time data, monitoring center, and offline analysis. The real-time data module is used to collect, receive, and display signal data sensed by the embedded sensors in the intelligent tool, as well as operation logs and other information. The monitoring center module is used to extract target feature indicators from the acquired signal data and compare them with thresholds set based on machining experience to determine whether the tool is worn. The offline analysis module is used to retrospectively view historical signal data files that have been collected and stored, and to train the software learning model based on specified historical data samples.

[0150] The real-time data module of the PC-based 906 software intelligent tool wear monitoring system remains active during the operation of the automated tool holder production line and the implementation of the machining process. Before starting the production line, the acquisition parameters must be set on the software interface of the real-time data module. This involves sequentially entering or selecting "Target IP," "Target Port," "Establish / Disconnect Connection," "Channel Selection," "Remove Mean Value," "Sampling Frequency," "Spindle Speed," "Operating Mode," and "Applicable Tools." After completing these settings, click "Start Acquisition," and the intelligent tool system will enter the formal operation state. During operation, "Enable Noise Reduction" and "Whether to Save Data" can be manually changed in the software.

[0151] The layout of the sensor signal display interface on the real-time data module of the PC-based intelligent tool wear monitoring system varies depending on the type of intelligent tool. When "Intelligent Turning Tool" is selected under "Applicable Tool," the sensor signal display interface shows the vibration and force signals collected during the real-time machining process of the intelligent external turning tool 903 and the intelligent grooving tool 902. When "Intelligent Milling Cutter" is selected under "Applicable Tool," the sensor signal display interface shows the temperature, vibration, and force signals collected during the real-time machining process of the intelligent milling cutter 901, as well as a polar coordinate graph plotted in real-time based on changes in the force signal.

Claims

1. An automated production line for tool holders based on an intelligent tool system, characterized in that: Includes processing units, logistics units and intelligent tooling systems (9); The intelligent tool system (9) includes an intelligent milling cutter (901), an intelligent grooving tool (902), an intelligent external turning tool (903), a signal processing circuit box (905), and a PC-based host computer (906). Each of the intelligent milling cutter (901), intelligent grooving tool (902), and intelligent external turning tool (903) integrates a vibration sensor and a PVDF force sensor. The intelligent milling cutter (901) also integrates a temperature sensor. The sensor signals from the intelligent milling cutter (901), intelligent grooving tool (902), and intelligent external turning tool (903) are connected to the signal processing circuit box (905). The signal processing circuit box (905) communicates with the PC-based host computer (906). The PC-based host computer (906) is equipped with intelligent tool wear condition monitoring system software. The machining unit adopts a triangular surrounding equipment layout based on a top-view plane; the three vertices of the triangular shape are jointly occupied by a first CNC lathe (13), a second CNC lathe (21), and a vertical machining center (16); the first CNC lathe (13) is equipped with an intelligent grooving tool (902) and an intelligent external turning tool (903) on its cutter head for the first-order external turning and V-groove machining; the second CNC lathe (21) is equipped with an intelligent grooving tool (902) and an intelligent external turning tool (903) on its cutter head for the second-order taper shank finishing and internal thread hole machining; the vertical machining center (16) is equipped with an intelligent milling cutter (901) on its machine tool spindle for the third-order high-precision milling of keyways; The logistics unit includes a robotic arm (19), a turning table (12), a transfer table (20), a loading area (7), and a unloading area (4); the robotic arm (19) is located at the center of the triangular layout; the robotic arm (19) is used to grab and transport workpieces; the working radius of the robotic arm (19) covers the entire processing unit; the turning table (12) is arranged adjacent to the first CNC lathe (13); the turning table (12) is used for workpiece posture rotation; the transfer table (20) is arranged adjacent to the second CNC lathe (21); the transfer table (20) is used for inter-process buffering; the loading area (7) and the unloading area (4) are arranged adjacent to each other at the bottom of the production line; the loading area (7) and the unloading area (4) are used for centralized material management; During the tool holder machining process, vibration sensors and PVDF force sensors collect vibration acceleration and cutting force signals in real time during the cutting process; temperature sensors monitor temperature changes in the milling area; the raw sensor signals undergo preliminary conditioning and analog-to-digital conversion in the signal processing circuit box (905), and are then transmitted to the PC host computer (906); the PC host computer (906) dynamically displays the corresponding sensor data according to the selected applicable tool, providing the operator with intuitive machining status feedback; the PC host computer (906) automatically processes the received time-series data and extracts feature values ​​that are strongly correlated with tool wear; When the characteristic value exceeds the safety threshold, the system determines that the tool has abnormal wear or damage and issues an audible and visual warning signal on the software interface to prompt the operator to intervene; through continuous monitoring, the PC host computer (906) estimates the remaining life of the tool and realizes predictive maintenance.

2. The automated production line for tool holders based on an intelligent tool system according to claim 1, characterized in that: The production line is surrounded by a safety protection unit with a safety interlock mechanism to achieve human-machine isolation; the safety protection unit consists of a safety fence (5), fence posts (2) and a safety door (1); the fence posts (2) are support components that are vertically fixed to the ground; the safety fence (5) and the fence posts (2) form a closed rectangular area; the loading area (7) and the unloading area (4) are located within the closed rectangular area; the safety door (1) is a movable component integrated on the safety fence (5).

3. The automated production line for tool holders based on an intelligent tool system according to claim 2, characterized in that: The safety protection unit also includes a loading switch (6) and a unloading switch (3); the loading switch (6) and the unloading switch (3) are installed outside the safety fence (5) and face the loading area (7) and the unloading area (4); the loading switch (6) and the unloading switch (3) allow the operator to initiate a loading or unloading request outside the safety isolation area, and the robotic arm (19) automatically executes the subsequent material grabbing or placement procedure.

4. The automated production line for tool holders based on an intelligent tool system according to claim 1, characterized in that: It also includes a supporting execution unit; the supporting execution unit includes an automatic rivet tightening device (8), a sampling inspection table (14), a chip removal cart (17), and a chip removal machine (18); the automatic rivet tightening device (8) is arranged adjacent to the first CNC lathe (13); the automatic rivet tightening device (8) is used for the assembly and disassembly of rivets; the sampling inspection table (14) is arranged in the gap between the first CNC lathe (13) and the vertical machining center (16); the sampling inspection table (14) is used to measure and verify the tool holder workpiece that has completed the third-stage machining; The chip conveyor (18) is arranged on the side of the second CNC lathe (21); the chip conveyor (18) is used to transport and discharge the metal chips generated by the processing unit; the chip conveyor (17) is a collection container located directly below the chip conveyor outlet, used to temporarily store and transfer chips.

5. An automated production line for tool holders based on an intelligent tool system according to claim 4, characterized in that: The automatic screw-in / stud device (8) includes a support column (801), a device control cabinet (802), a three-jaw chuck (803), a slide table (804), a slide rail (805), a cylinder (806), a workpiece holder (807), an automatic screw-in / stud spindle peripheral (808), a status light (809), a guide rail (810), a lead screw (811), an automatic screw-in / stud device body (812), and an automatic screw-in / stud spindle auxiliary frame (813). The device includes a rivet screw spindle (814), a rivet (815), and a rivet gripper frame (816). The control cabinet (802) controls the three-jaw chuck (803) to position and clamp the workpiece. Subsequently, the cylinder (806) and the lead screw (811) drive the automatic rivet screw spindle (814) to move precisely along the guide rail (810), and the rivet gripper frame (816) grabs the rivet (815) and performs the screwing action. The status light (809) displays the operating status of the equipment in real time.

6. An automated machining process for tool holders in a production line according to any one of claims 4 to 5, characterized in that, Includes the following steps: S1. Loading and system initialization; The operator places the tool holder blank in the loading area (7), clamps the corresponding intelligent tool on each machine tool, and starts the intelligent tool system (9) to establish a communication connection; S2. First-order machining; The robotic arm (19) grabs the blank and loads it into the first CNC lathe (13), and uses the intelligent external turning tool (903) and the intelligent grooving tool (902) to complete the rough machining of the outer circle, V-groove, end face and inner hole; S3. Workpiece flipping; The robotic arm (19) transfers the workpiece that has completed the first-order processing to the flipping table (12) for a 180° turn; S4. Second-order processing; The robotic arm (19) grabs the flipped workpiece and loads it into the second CNC lathe (21) to complete the finishing of the tapered shank shape and the tapping of the internal threaded pull stud hole; S5. Automatic assembly of rivets; the robotic arm (19) transfers the workpiece to the automatic rivet screwing device (8); the device automatically screws the rivet (815) into the internal thread hole of the workpiece to the preset torque; S6. Third-order machining; The robotic arm (19) loads the workpiece with the rivets into the vertical machining center (16) and uses the intelligent milling cutter (901) to mill the keyway with high precision; S7. Quality inspection and unloading; The robotic arm (19) sends the completed work to the inspection station (14) at a preset frequency for offline inspection, and transfers the qualified parts to the automatic rivet unloading device (8) to unload the rivets and finally place them in the unloading area (4).

7. An automated production line for tool holders based on an intelligent tool system according to claim 6, characterized in that: During the processing of steps S2, S4, and S6, the PC host computer (906) monitors the vibration, force, and temperature signals of each intelligent tool in real time. Once it is determined that the tool wear has reached the threshold, it will issue an early warning or automatically call up a spare tool to achieve predictive maintenance.

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