Five-axis numerical control equipment and method for cutting hole edges of helmet shell

Abstract

The invention discloses five-axis numerical control equipment and method for helmet shell hole edge cutting. The equipment comprises a supporting module, a movement module (X / Y1 / Y2 / Z linear axis + A / C1 / C2 rotating axis, and each axis is provided with an independent motor), a machining module (double motorized spindles + corresponding cutters), a positioning module (vacuum suction cup + positioning pin + vacuum suction tube) and a control module. Y1 / Y2 double motors ensure stability in the Y direction, C1 / C2 double shafts are in linkage to be matched with a curved surface, the double motorized spindles can switch the tool specification, and the vacuum suction pipe forms a complete adsorption channel. The device hole edge error is smaller than or equal to + / -0.05 mm, the carbon fiber yield is larger than or equal to 95%, the efficiency is improved by 40%, the device is compatible with helmets of multiple materials and multiple specifications, the device and labor cost is reduced, the GB 24429-2020 standard is met, and the device is suitable for batch production.

Description

Technical Field

[0001] This invention relates to the field of helmet processing equipment technology, specifically to a five-axis CNC equipment and method for cutting the edges of holes in helmet shells. It is applicable to the cutting and processing of the edges of holes such as ventilation holes, strap mounting holes, and goggle connection holes in helmet shells of different materials such as ABS resin, PC / ABS alloy, and carbon fiber composite materials, as well as helmet shells of different specifications such as adult helmets and children's helmets. Background Technology

[0002] The helmet industry is currently developing towards lightweight, personalized and high safety. The shell material has expanded from traditional ABS resin to PC / ABS alloy, carbon fiber composite material and other materials. These materials have strict requirements for the cutting accuracy of the hole edges (±0.1mm), otherwise it is easy to cause safety problems such as excessive assembly gaps and stress concentration cracking.

[0003] Existing processing methods have significant drawbacks: manual cutting errors exceed 0.5mm, and the burr rate is over 30%; general-purpose three-axis CNC equipment lacks a multi-motor driven multi-axis linkage structure, can only process planar holes, and cannot adapt to hyperbolic curved surfaces and inclined holes; dedicated fixed-axis equipment lacks dual-electric spindles and adjustable vacuum adsorption structures, which not only fails to meet the flexible production of helmets of various specifications, but also easily causes fiber splitting when cutting carbon fiber (yield rate is only 75%). With the implementation of the GB 24429-2020 standard, there is an urgent need for a five-axis CNC machine that integrates multi-motor drive, dual-electric spindles, and precise vacuum adsorption. Summary of the Invention

[0004] To address the problems of existing equipment such as "poor surface adaptation due to lack of multi-axis drive", "low efficiency of single-electric spindle", and "unstable positioning due to incomplete vacuum adsorption system components", this invention achieves high-precision and high-efficiency cutting by clarifying the motor drive structure, dual-electric spindle layout and complete vacuum adsorption link.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] A five-axis CNC machine for cutting the edge of holes in a helmet shell includes a support module, a motion module, a machining module, a positioning module, and a control module. The motion module is fixed on the top of the support module, the positioning module is mounted on the motion module, the machining module is slidably connected to the motion module, and the control module is electrically connected to each module via wires.

[0007] The support module is a frame welded from Q235 steel plate. The bottom of the frame is equipped with anti-vibration pads made of nitrile rubber. The top of the frame is equipped with a motion module mounting slot. The frame has a load-bearing capacity of 500kg.

[0008] The motion module includes X-axis, Y-axis, Z-axis linear axes, A-axis rotary axis, C1 axis and C2 axis dual rotary axes, and servo motors corresponding to each axis.

[0009] The X-axis is equipped with a 1.5kW servo motor, the Y-axis with two servo motors (Y1 and Y2, each with a power of 1.5kW), the Z-axis with a 2.2kW servo motor, the A-axis with a 1.2kW servo motor, and the C1 and C2 axes each with a 0.75kW servo motor. The linear axes use ball screw drives with a repeatability of ±0.005mm. The A-axis rotation range is -90° to 90°, and the rotation range achieved by the linkage of the C1 and C2 axes is 0° to 360°.

[0010] The machining module includes a first electric spindle, a second electric spindle, and carbide cutting tools adapted to the two electric spindles respectively. The rated speed of the first electric spindle and the second electric spindle is 24,000 r / min. The first electric spindle and the second electric spindle are both adapted to cutting tools with a diameter of 2-8 mm. The first electric spindle and the second electric spindle are both equipped with cooling nozzles.

[0011] The positioning module includes 6-8 vacuum suction cups arranged in a ring, 3 positioning pins, a solenoid valve group and a vacuum suction tube. The vacuum suction tube is a PU flexible tube. One end of the vacuum suction tube is connected to each vacuum suction cup in a corresponding manner, and the other end is connected to the vacuum pump through the solenoid valve group. The vacuum degree of the positioning module is maintained at -0.08 to -0.09 MPa, and the clamping time of the positioning module is ≤30 seconds.

[0012] The control module is a new generation five-axis system, including a drive unit and a storage unit. The drive unit corresponds one-to-one with each axis servo motor, the first electric spindle, and the second electric spindle.

[0013] Furthermore, the Y1-axis servo motor and the Y2-axis servo motor are arranged symmetrically, and the Y1-axis servo motor and the Y2-axis servo motor synchronously drive the ball screw of the Y-axis through a coupling.

[0014] Furthermore, the C1 axis and the C2 axis are linked by the same harmonic reducer, which has a reduction ratio of 1:80.

[0015] Furthermore, the power of the first and second electric spindles of the machining module is 3.7kW, the taper of the output shaft of the first and second electric spindles is BT30, and the tool is fixed on the electric spindle by a tool chuck with a clamping gap of ≤0.002mm.

[0016] Furthermore, the vacuum suction tube of the positioning module includes a branch suction tube and a main suction tube, with the inner diameter of the branch suction tube being 8mm and the inner diameter of the main suction tube being 15mm.

[0017] Furthermore, the motion module, processing module, and positioning module are all in two sets, and the two sets of motion modules, processing modules, and positioning modules are symmetrically installed on the top of the support module. The two sets of modules share a set of control modules to form a dual-station.

[0018] A method for cutting the edge of a helmet shell hole includes the following steps:

[0019] (1) Assembly and debugging: Connect the support module, motion module, machining module, positioning module and control module in sequence to ensure that the servo motors of the X-axis, Y1 axis, Y2 axis, Z axis, A axis, C1 axis and C2 axis, the first electric spindle and the second electric spindle are running normally, and at the same time check that there is no leakage in the passage of the vacuum suction tube;

[0020] (2) Workpiece clamping: According to the specifications of the helmet to be processed, the solenoid valve of the corresponding vacuum suction cup in the positioning module is opened by the control module, the bottom reference hole of the helmet shell is aligned with the positioning pin of the positioning module, and the helmet shell is fixed by vacuum adsorption.

[0021] (3) Program setting: The first and second electric spindles will start working according to the program settings by calling the preset cutting program through the CNC system;

[0022] (4) Linked cutting: The control module drives the servo motors of each axis to move together, which drives the helmet shell to adjust to the preset angle. The first or second electric spindle cuts according to the set program, and the cooling nozzles spray coolant synchronously to achieve cooling.

[0023] (5) Finished product removal: After cutting, the control module controls the solenoid valve to release pressure, the vacuum adsorption state is released, and the helmet shell is removed to complete the processing.

[0024] This five-axis CNC machine addresses the core pain point of cutting the edges of holes in helmet shells, achieving breakthroughs in multiple dimensions with significant benefits covering the entire production process:

[0025] Firstly, the processing precision and quality have been significantly improved. Utilizing five-axis linkage technology, the equipment can adapt to the hyperbolic arc trajectory of the helmet shell in real time. Through dynamic compensation algorithms, cutting deviations are corrected, ensuring that the hole edge size error is stably controlled within ±0.05mm, fully meeting the requirements for hole assembly precision in helmet safety standards such as GB 24429-2020. For difficult-to-process materials such as carbon fiber and PC / ABS alloys, the equipment's dedicated cutting parameter library optimizes cutting speed and pressure, effectively avoiding problems such as fiber splitting and material delamination. This increases the processing yield from 75% of traditional equipment to over 95%, significantly reducing waste.

[0026] Secondly, it optimizes both production efficiency and flexibility. Automated cutting directly eliminates the time-consuming process in traditional methods, increasing efficiency by 30%. At the same time, the dual-station design of the equipment can process the hole parameter models of two helmets of the same specifications at the same time, which can flexibly meet the batch production needs of different categories such as adult helmets, children's helmets, and sports helmets, and meet the enterprise's multi-variety, small-batch order model.

[0027] Third, overall production costs and reliance on manual labor are significantly reduced. The equipment is compatible with various shell materials such as ABS, PC, and carbon fiber, eliminating the need for companies to purchase dedicated equipment for different materials. The equipment investment cost per production line can be reduced by 40%. Automated operation reduces reliance on skilled workers, increasing the number of machines managed per person from 2 to 4, reducing labor costs by 50%. At the same time, it avoids damage to the shell structure caused by manual polishing, reducing material waste caused by rework, and lowering the overall production cost per unit product by 15%-20%.

[0028] Fourth, the safety performance and production stability of helmets are guaranteed. Automated control of the cutting process avoids random errors caused by manual operation. There are no burrs or stress concentration points at the hole edges, which can improve the structural stability of the helmet after assembly and reduce the safety risks caused by cracking at the hole edges during use; further enhancing the company's delivery capabilities and market competitiveness. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the overall structure of a five-axis CNC device for cutting the edge of holes in a helmet shell according to the present invention;

[0030] Figure 2 Here is a structural schematic diagram (I) involving the motion module;

[0031] Figure 3 The second diagram shows the structure involving the motion module.

[0032] Figure 4 This is a structural diagram involving the processing module;

[0033] Figure 5 This is a structural diagram involving the positioning module. Detailed Implementation

[0034] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0035] In the description of the embodiments of the present invention, it should be noted that if terms such as "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of the invention is in use, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. Furthermore, terms such as "first," "second," and "third" are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0036] Furthermore, the use of terms such as "horizontal," "vertical," and "sag" does not imply that the component must be absolutely horizontal or suspended, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0037] In the description of the embodiments of the present invention, "multiple" means at least two.

[0038] In the description of the embodiments of the present invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in the present invention according to the specific circumstances.

[0039] like Figure 1-5 As shown, the five-axis CNC equipment for cutting the edges of holes in helmet shells according to the present invention consists of five parts working together: a support module, a motion module, a machining module, a positioning module, and a control module. The specific structure and connection relationship of each module are as follows:

[0040] (1) Support module

[0041] The frame 100 is welded from Q235 steel plate and subjected to aging treatment to eliminate internal stress; the bottom is equipped with 4 nitrile rubber shock-absorbing pads 101 (10-15mm thick), which can bear a load of up to 500kg; the top is reserved with a motion module mounting slot, and the slot is equipped with M12 positioning bolt holes for fixing the motion module base.

[0042] (2) Motion Module

[0043] This is a five-axis linkage platform, including X / Y / Z linear axes, an A-axis, and C1 / C2 dual rotary axes, each equipped with an independent servo motor drive.

[0044] Linear axes and drive motors: The X-axis is equipped with a 1.5kW servo motor 1, which is connected to the ball screw (5mm pitch) via a coupling; the Y-axis uses dual motor drive, namely the Y1 axis motor 2 (1.5kW) and the Y2 axis motor 3 (1.5kW) are symmetrically arranged to synchronously drive the Y-axis ball screw, ensuring smooth Y-axis movement; the Z-axis is equipped with a 2.2kW servo motor 4, which drives the Z-axis ball screw; the linear axis guide rail is a rectangular guide rail, the clearance between the slider and the guide rail is ≤0.003mm, the repeatability is ±0.005mm, and the maximum moving speed is 15m / min.

[0045] Rotation axis structure: The A-axis 200 (rotating around the X-axis) is equipped with a 1.2kW servo motor, driven by a harmonic reducer (reduction ratio 1:100), with a rotation angle range of -90° to 90°; the C-axis adopts a dual-axis cooperative structure, namely the C1 axis 300 and the C2 axis 400, each equipped with a 0.75kW servo motor, linked by the same harmonic reducer (reduction ratio 1:80), with a rotation angle range of 0° to 360°; the output end of the A-axis is fixed to the positioning module base via a flange, and the output ends of the C1 / C2 axes are fixed to the X-axis base, realizing multi-angle adjustment of the helmet shell.

[0046] (3) Processing module

[0047] Includes a first electric spindle 500, a second electric spindle 600, and corresponding carbide cutting tools. The two electric spindles are symmetrically mounted on the side bracket of the Z-axis slider.

[0048] Both the first electric spindle 500 and the second electric spindle 600 have a rated speed of 24,000 r / min (power 3.7 kW) and an output shaft taper of BT30. The first electric spindle 500 is compatible with a 2-8 mm diameter tool 501, and the second electric spindle 600 is compatible with a 2-8 mm diameter tool 601. Both are fixed by a high-precision tool chuck (clamping clearance ≤ 0.002 mm) to ensure that the tool runout is ≤ 0.005 mm.

[0049] Both electric spindles are equipped with independent cooling nozzles, which are connected to the external cooling system through PU material cooling pipes. The nozzle outlet is 5-8mm away from the cutting edge of the tool to achieve precise cooling.

[0050] (4) Positioning module

[0051] The adjustable vacuum chuck clamp 700 is mounted on the A-axis flange 201 and includes a clamp base, annularly distributed vacuum chucks (6-8 pieces), 3 locating pins, a solenoid valve assembly, and a vacuum suction tube.

[0052] The vacuum suction tube 800 uses a transparent PU flexible tube (inner diameter 8mm). One end is connected to each vacuum suction cup, and the other end is connected to the solenoid valve group (6-8 independent valve bodies) through a three-way connector. The solenoid valve group is then connected to the vacuum pump through the main vacuum suction tube (inner diameter 15mm) to form a complete vacuum path.

[0053] The positioning pins are distributed in an equilateral triangle (side length 120-150mm), and the diameter gap with the helmet reference hole is ≤0.02mm; the solenoid valve group is connected to the control module through wires to realize independent on / off of the suction cup, which is suitable for children's helmets with a head circumference of 48-53cm and adults' helmets with a head circumference of 54-62cm. The clamping time is ≤30 seconds, and the vacuum degree is maintained at -0.08~-0.09MPa.

[0054] (5) Control Module

[0055] This is a new generation five-axis system, including the system host, operation panel, and drive unit:

[0056] The drive unit corresponds one-to-one with the X-axis motor, Y1 / Y2 axis motor, Z-axis motor, A-axis motor, C1 / C2 axis motor, and dual electric spindle to achieve precise drive;

[0057] The system host has built-in motion control algorithms and cutting parameter libraries, which can optimize the switching logic of the dual electric spindles and the linkage trajectory of C1 / C2 axes in real time to avoid interference; the operation panel is equipped with a dual electric spindle switching button and a vacuum pressure display window.

[0058] In addition, the equipment is designed with two workstations, with two sets of motion modules, processing modules and positioning modules installed symmetrically, sharing a set of control modules, and can process two workpieces simultaneously. Specific implementation examples:

[0060] Equipment assembly:

[0061] The X-axis base of the motion module is fixed in the support module slot, the Y1 / Y2 axis motors are symmetrically installed at both ends of the Y-axis, and the C1 / C2 axis motors are fixed on the side of the X-axis base; the dual electric spindles are installed on the Z-axis slider bracket, and the vacuum suction tube is connected to the suction cup, solenoid valve group and vacuum pump;

[0062] Workpiece clamping:

[0063] Select the children's helmet (head circumference 50cm), turn on the corresponding suction cup solenoid valve through the control panel, align the helmet reference hole with the positioning pin, and open the vacuum suction tube. The clamping is completed within 30 seconds (vacuum degree -0.085MPa).

[0064] Program settings:

[0065] Call the carbon fiber cutting program, with the first and second electric spindles (4mm diameter tool, 24000r / min rotation speed) and each axis synchronous feed speed of 15m / min.

[0066] Cutting and processing:

[0067] Start the equipment, and the X / Y / Z axes, A axis, and C1 / C2 axes work together. The first and second electric spindles cut according to the set program, and the cooling nozzles cool the workpiece synchronously. The two stations process one workpiece simultaneously.

[0068] Remove the finished product:

[0069] After cutting, the solenoid valve releases pressure, the vacuum suction tube shuts off, and the finished product is removed.

[0070] The present invention and its embodiments have been described above. This description is not restrictive, and the accompanying drawings are only one embodiment of the present invention; the actual structure is not limited thereto. In conclusion, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the invention, such designs should fall within the protection scope of the present invention.

Claims

1. A five-axis numerical control device for cutting the hole edge of a helmet shell, characterized in that: it comprises a support module, a movement module, a processing module, a positioning module and a control module, the movement module is fixed on the top of the support module, the positioning module is installed on the movement module, the processing module is in sliding connection with the movement module, and the control module is in electrical connection with each module through wires; the support module is a rack formed by welding a Q235 steel plate, an anti-vibration foot pad made of nitrile rubber is arranged at the bottom of the rack, a movement module mounting groove is arranged at the top of the rack, and the bearing capacity of the rack reaches 500 kg; the movement module comprises X-axis, Y-axis, Z-axis linear shafts, A-axis rotary shaft, C1-axis and C2-axis double rotary shafts and servo motors corresponding to the shafts one by one; the X-axis is provided with a servo motor with a power of 1.5 kW, the Y-axis is provided with Y1-axis and Y2-axis servo motors, the powers of the Y1-axis and Y2-axis servo motors are both 1.5 kW, the Z-axis is provided with a servo motor with a power of 2.2 kW, the A-axis is provided with a servo motor with a power of 1.2 kW, and the C1-axis and C2-axis are each provided with a servo motor with a power of 0.75 kW; the linear shafts adopt ball screw transmission, and the repeat positioning accuracy is ±0.005 mm; the rotation angle range of the A-axis is -90°-90°, and the rotation angle range realized by the linkage of the C1-axis and C2-axis is 0°-360°; the processing module comprises first and second electric spindles and hard alloy cutters matched with the double electric spindles respectively, the rated rotating speeds of the first and second electric spindles are both 24000 r / min, the first and second electric spindles are both matched with cutters with a diameter of 2-8 mm, and the first and second electric spindles are both provided with cooling nozzles; the positioning module comprises 6-8 vacuum suction cups arranged in a ring shape, three positioning pins, an electromagnetic valve group and a vacuum suction pipe, the vacuum suction pipe is a PU hose, one end of the vacuum suction pipe is connected with each vacuum suction cup one by one, the other end of the vacuum suction pipe is connected with a vacuum pump through the electromagnetic valve group, the vacuum degree of the positioning module is maintained at -0.08- -0.09 MPa, and the clamping time of the positioning module is ≤30 seconds; the control module is a new generation five-axis system and comprises a driving unit and a storage unit, and the driving unit corresponds to each shaft servo motor, first electric spindle and second electric spindle one by one. The Y1-axis servo motor and the Y2-axis servo motor are symmetrically arranged, and the Y1-axis servo motor and the Y2-axis servo motor synchronously drive the ball screw of the Y-axis through a shaft coupling. The C1-axis and the C2-axis are linked through the same harmonic reducer, and the reduction ratio of the harmonic reducer is 1:

80. The powers of the first and second electric spindles of the processing module are both 3.7 kW, the output shaft tapers of the first and second electric spindles are both BT30, the cutters are fixed on the electric spindles through cutter clamps, and the clamping gap of the cutter clamp is ≤0.002 mm. The vacuum suction pipe of the positioning module comprises a branch suction pipe and a main suction pipe, the inner diameter of the branch suction pipe is 8 mm, and the inner diameter of the main suction pipe is 15 mm. ​ ​ ​ 2. A five-axis CNC apparatus for cutting helmet shell aperture edges according to claim 1, characterized in that: ​ 3. A five-axis CNC apparatus for cutting helmet shell aperture edges according to claim 1, characterized in that: ​ 4. A five-axis CNC apparatus for cutting helmet shell aperture edges according to claim 1, characterized in that: ​ 5. A five-axis CNC apparatus for cutting helmet shell aperture edges according to claim 1, characterized in that: ​ 6. A five-axis CNC apparatus for cutting helmet shell aperture edges according to claim 1, characterized in that: The motion module, the processing module and the positioning module are two groups, two groups of motion module, processing module, positioning module symmetrically installed on the top of the support module, two groups of modules share a set of control module to form double station.

7. A method of cutting a hole in a helmet shell based on the apparatus of claim 1, wherein, It comprises the following steps: (1) Assembly and debugging: sequentially connect the support module, the motion module, the processing module, the positioning module and the control module, ensure that the servo motors of X axis, Y1 axis, Y2 axis, Z axis, A axis, C1 axis and C2 axis, the first electric spindle and the second electric spindle are in normal operation, and check that the passage of the vacuum suction pipe is free of leakage; (2) Workpiece clamping: according to the specifications of the helmet to be processed, open the electromagnetic valve of the corresponding vacuum chuck in the positioning module through the control module, align the bottom reference hole of the helmet shell with the positioning pin of the positioning module, and fix the helmet shell through vacuum adsorption; (3) Program setting: call the preset cutting program through the numerical control system, and the first electric spindle and the second electric spindle will start working according to the program setting; (4) Linkage cutting: control module drives each axis servo motor linkage to drive the helmet shell to adjust to the preset angle, the first electric spindle or the second electric spindle cuts according to the set program, and the cooling nozzle sprays cooling liquid synchronously to realize cooling; (5) Finished product removal: after cutting, the control module controls the electromagnetic valve to release pressure, the vacuum adsorption state is released, and the helmet shell is removed to complete the processing.

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