A mobile counterbore geometry error measuring device and cost prediction method for large centrifuge manufacturing process

Abstract

A mobile stop port geometry error measuring device and cost prediction method for large centrifuge manufacturing process. It relates to the field of centrifuge processing and manufacturing. In the existing large centrifuge stop port measurement, large size parts cannot be measured, the cost is high, the dependence on manual is strong, and the precision is insufficient. The present application comprises a line laser sensor, a measuring support, a precision turntable, an A-direction pitching motion assembly, a B-direction pitching motion assembly, a lifting motion assembly, a horizontal motion assembly and a mobile trolley. The measuring support is connected with the precision turntable rotor table surface. The precision turntable base is fixedly connected with the B-direction pitching motion assembly table surface through an adapter disc. The concentricity installation error between the center of the pitching motion assembly composed of the precision turntable, the A-direction pitching motion assembly and the B-direction pitching motion assembly and the center of the precision turntable is less than or equal to 30 microns. The center position of the mobile trolley table surface is fixedly connected with a double-axis inclination sensor through a mounting seat. The detection surface of the double-axis inclination sensor is parallel to the table surface.

Description

Technical Field

[0001] This invention relates to the field of centrifuge manufacturing, and specifically to a mobile stop geometry error measuring device and cost prediction method for the manufacturing process of large centrifuges. Background Technology

[0002] In the manufacturing and maintenance of large centrifuges, the machining accuracy of the geometric errors of the end face and radial face of the stop, such as flatness and roundness, directly determines the overall performance and operational stability of the equipment. If the actual values ​​of these dimensions deviate significantly from the design values, it will lead to imbalance and increased vibration when the centrifuge rotates at high speed, severely shortening the service life of the equipment and reducing work efficiency. Therefore, accurate measurement of the geometric errors of the stop is a core link in ensuring product quality.

[0003] Currently, there are many limitations in the methods for measuring the geometric shape error of the stop edge of large centrifuges:

[0004] Firstly, when using a coordinate measuring machine or a cylindricity tester for measurement, the hoisting and handling process of large centrifuges is cumbersome, and some large parts that exceed the stroke cannot be measured. Custom-made special instruments with large stroke and large load capacity are extremely expensive.

[0005] Secondly, traditional dial indicator measurement methods rely heavily on the operator's experience, have complex operating procedures, and are inefficient.

[0006] Third, the measurement accuracy of handheld scanners is only 20-50μm, which makes it difficult to capture the tiny dimensional errors of the stop and cannot meet the requirements of high-precision detection.

[0007] Meanwhile, the quality of edge machining is directly related to machine tool blade wear and machine wear, but companies lack scientific cost forecasting methods to support their decisions when dealing with equipment wear. Production costs are affected by a combination of factors, including raw material prices, labor costs, energy consumption, and machine wear. Simply considering the cost-saving effect of equipment wear cannot comprehensively assess the economics of repairing, replacing parts, or replacing equipment, which can easily lead to uncontrolled production costs or unstable product quality.

[0008] Therefore, existing technologies lack both convenient and efficient means of measuring the geometric shape error of the stop surface, and a multi-dimensional cost prediction system linked to the measurement data, making it difficult to achieve synergy between processing quality control and production cost optimization. Developing a high-precision mobile stop surface geometric shape error measuring device and establishing a corresponding cost prediction method to achieve a deep integration of accurate geometric shape error detection and scientific production cost control is of significant practical importance for improving the manufacturing quality of large centrifuges, reducing production losses, and optimizing decision-making efficiency. Summary of the Invention

[0009] To address the problems in existing methods for measuring the geometrical error of large centrifuge stop surfaces, such as cumbersome handling of traditional equipment, inability to measure large-sized parts, high cost, heavy reliance on manual labor, insufficient accuracy, and difficulty in correlating geometrical errors with machine wear and tear to scientifically predict production costs and make decisions on equipment maintenance and replacement, this invention provides a mobile geometrical error measuring device and cost prediction method for the manufacturing process of large centrifuges.

[0010] The technical solution of this invention is:

[0011] A mobile stop geometry error measuring device for the manufacturing process of large centrifuges includes a line laser sensor, a measuring bracket, a precision turntable, an A-direction pitch motion component, a B-direction pitch motion component, a lifting motion component, a traverse motion component, a mobile trolley, and an electric lifting support leg.

[0012] The line laser sensor is detachably connected to the measuring bracket through the bolt holes of the line laser sensor connector. The bottom of the measuring bracket is fixedly connected to the rotor surface of the precision turntable through the measuring bracket adapter. The base of the precision turntable is fixedly connected to the B-direction pitch motion component platform through the circumferentially distributed bolt holes of the adapter plate, ensuring that the concentricity installation error between the center of the pitch motion component composed of the precision turntable, the A-direction pitch motion component, and the B-direction pitch motion component and the center of the precision turntable is ≤30μm.

[0013] The pitch motion component in direction A and the pitch motion component in direction B are fixedly connected by bolts on the upper and lower mounting surfaces of the pitch motion component, and the pitch motion component in direction A and the pitch motion component in direction B are arranged at a 90-degree angle. The bottom of the pitch motion component in direction A is fixed to the upper surface of the slider of the traverse motion component by bolts. The base of the traverse motion component is fastened to the slider of the lifting motion component by T-bolts. The bottom mounting plate of the lifting motion component is fixed to the platform of the moving trolley by expansion bolts. The traverse motion component and the lifting motion component are installed at a 90-degree angle to achieve bidirectional displacement adjustment of the precision turntable in both vertical and horizontal directions.

[0014] The mobile trolley has rubber wheels with brakes bolted to its four corners. Four electric lifting legs are fixedly installed at the four corners of the mobile trolley. The electric lifting legs are composed of electric push rods and circular support feet connected by threads. A dual-axis tilt sensor is fixedly connected to the center of the mobile trolley platform through a mounting base. The detection surface of the dual-axis tilt sensor is parallel to the platform.

[0015] Furthermore, this also includes electrical control systems;

[0016] The electrical control system includes a controller, an industrial computer, a tablet computer, a precision turntable servo driver, a precision turntable torque motor, a pitch / lift / traverse motion component servo driver, a pitch / lift / traverse motion component servo motor, a line laser sensor, a power supply battery, a pitch / lift / traverse motion component grating system, a precision turntable grating system, and a dual-axis tilt sensor.

[0017] The controller, industrial computer, tablet computer, precision turntable servo driver, precision turntable torque motor, pitch / lift / traverse motion component servo driver, pitch / lift / traverse motion component servo motor, power supply battery, pitch / lift / traverse motion component grating system, and precision turntable grating system are all centrally installed in the electrical control cabinet of the mobile trolley.

[0018] The controller is connected to the industrial computer via an RJ45 network cable, the industrial computer is wirelessly connected to the tablet computer via a WiFi module, and the controller is connected to the precision turntable servo driver and the pitch / lift / traverse motion component servo driver via an EtherCAT bus cable.

[0019] The precision turntable servo driver is connected to the precision turntable torque motor terminal via the motor power line, and the pitch / lift / traverse motion component servo driver is connected to the corresponding terminal of the pitch / lift / traverse motion component servo motor via the motor power line.

[0020] The precision turntable grating system is connected to the precision turntable servo driver via an RS485 serial cable, and the pitch / lift / traverse motion component grating system is connected to the corresponding pitch / lift / traverse motion component servo driver via an RS485 serial cable.

[0021] The dual-axis tilt sensor is connected to the industrial control computer via an RS485 serial cable, and the line laser sensor is connected to the industrial control computer via an RJ45 network cable.

[0022] Furthermore, the measuring bracket is integrally machined, and its length is customized within the range of 500mm-2000mm according to the diameter of the stop of the centrifuge being measured. Both ends of the measuring bracket are equipped with standardized bolt holes. By manually disassembling the bolts connecting the measuring bracket adapter to the precision turntable, measuring brackets of different lengths can be replaced to adapt to different models of centrifuges with diameters of 500mm-5000mm.

[0023] Furthermore, the mobile vehicle is powered by a high-power lithium battery with a rated voltage of 24V and a capacity of 100Ah. The battery integrates a power detection module and an alarm module, and is connected to the industrial control computer through wires. The remaining power is displayed in real time on the tablet computer interface, and an audible and visual alarm is automatically issued when the power is below 20%.

[0024] The precision turntable uses closely spaced ball bearings, and the lifting and traversing motion components use standard electric modules. A line laser sensor is used in conjunction with the precision turntable to rotate 360 ​​degrees.

[0025] Furthermore, the laser emitting surface of the line laser sensor is perpendicular to the end face of the measuring bracket. The line laser sensor rotates once with the precision turntable, scanning the end face or radial surface of the stop to be measured. It can complete the flatness measurement of the end face of the stop and the roundness measurement of the radial surface, and display the three-dimensional contour of the measured cross section in real time on the measurement software interface.

[0026] Furthermore, the dual-axis tilt sensor collects the tilt angle data of the mobile trolley platform in real time and transmits it to the industrial control computer for processing. The controller then drives and adjusts the extension and retraction stroke of each electric push rod to ensure that the mobile trolley platform is level with the ground.

[0027] Furthermore, the controller communicates with the industrial computer using the Modbus TCP protocol, the industrial computer communicates with the tablet computer using the TCP-IP wireless communication protocol, the controller communicates with the servo driver using the EtherCAT industrial bus, and the grating system communicates with the servo driver using the Modbus-RTU serial communication protocol, thereby realizing closed-loop control and precise positioning of each motion axis.

[0028] Furthermore, a cost prediction method for a mobile stop geometry error measuring device for large centrifuge manufacturing processes is provided, comprising the following steps:

[0029] Step 1: The mobile stop geometry error measurement device for the manufacturing process of large centrifuges collects runout data from both ends of the same batch of centrifuge products. Each end of the stop is collected 3 times. The collected data is fitted using the least squares method to evaluate 8 key parameters, including eccentricity, eccentricity angle, maximum runout and its corresponding angle, minimum runout and its corresponding angle, tilt, tilt angle, highest point and its corresponding angle, and lowest point and its corresponding angle. After removing abnormal data, a runout data sample is formed.

[0030] Step 2: Use a 5th-order Gaussian filter algorithm to decompose the fluctuating data samples into frequency bands, extracting feature parameters for three frequency bands: 0-10Hz, 10-50Hz, and 50-100Hz, including amplitude, frequency, and phase. Establish a mapping relationship between the feature parameters and the wear of machine tool blades and the degree of machine wear through a radial basis function neural network, forming a complete associated sample containing ≥1000 sets of data, with a neural network training error ≤3%.

[0031] Step 3: Obtain raw material data, labor cost data, energy consumption cost data, and machine wear data within the same time period through the industrial internet platform, calculate the daily, weekly, and monthly change rates of the four types of data, and statistically analyze the degree of change;

[0032] The raw material data includes spot and futures price indices for steel and alloys.

[0033] Labor cost data includes industry average wages and overtime rates;

[0034] Energy cost data includes the electricity consumption of the machine per unit time and the allocated costs of water and electricity in the factory.

[0035] Machine wear data includes quantified values ​​of associated samples based on step two;

[0036] Step 4: Using the monthly change rate of the four types of data in Step 3 as the independent variable and the unit production cost of centrifuges as the dependent variable, construct a multiple linear regression model;

[0037] The model expression is: y = a1x1 + a2x2 + a3x3 + a4x4 + b;

[0038] Where y is the unit production cost, x1 is the rate of change of raw material prices, x2 is the rate of change of labor costs, x3 is the rate of change of energy consumption costs, x4 is the rate of change of machine wear, a1, a2, a3, and a4 are regression coefficients, and b is a constant term. The model parameters are solved by multiple linear regression analysis to predict the unit production cost of centrifuges under different production scales.

[0039] Step 5: Develop a machine processing strategy based on cost forecasts.

[0040] When the predicted increase in unit production cost is ≤1.5%, replace the easily worn parts of the machine tool blades;

[0041] When the increase is less than 1.5% and less than or equal to 5%, the machine tool should be overhauled and the severely worn core components should be replaced.

[0042] When the increase is greater than 5%, assess the economics of replacing the machine tool with a new one, and give priority to replacing the machine tool with a new one.

[0043] Furthermore, in step two, the input layer of the radial basis function neural network contains 9 neurons, including amplitude, frequency, and phase in 3 frequency bands; the hidden layer contains 20 neurons; and the output layer contains 2 neurons, including the wear amount of the machine tool blade and the degree of machine wear. The gradient descent method is used to optimize the network weights, with ≥1000 iterations, to ensure that the deviation between the output quantitative data and the actual detection data is ≤5%.

[0044] Furthermore, in step four, the independent variable data of the multiple linear regression model are standardized to eliminate the influence of dimensions. The model fit R² ≥ 0.9, and the significance of the model is verified by the F test with a significance level of α = 0.05, ensuring the reliability and accuracy of the prediction results.

[0045] Compared with the prior art, the present invention has the following advantages:

[0046] This invention allows for easy and convenient measurement of the geometric errors of the centrifuge's end face and radial surface, such as flatness and roundness, without the need to transport the centrifuge. This improves measurement efficiency and accuracy, reduces measurement costs, and enables flexible measurement at centrifuges in different locations, eliminating the need to transport the centrifuge to a specific measurement site and significantly saving time and labor costs.

[0047] This invention enables rapid and accurate positioning and leveling of a precision turntable via a pitch motion component and a lifting and traversing motion component. This adjustment process is automatic, ensuring the accuracy of the line laser sensor measurements and reducing the workload of operators. Simultaneously, the line laser sensor, combined with the rotational measurement method of the precision turntable, can comprehensively and accurately acquire geometrical error data of the end face and radial surface of the centrifuge stop, improving measurement accuracy.

[0048] This invention utilizes a line laser sensor in conjunction with a precision turntable featuring closely spaced ball bearings for 360-degree rotational measurement, achieving a measurement accuracy of ±1μm. This allows for precise capture of minute dimensional errors in the stop, solving the problem of insufficient accuracy in handheld scanners. The pitch motion component in direction A is linked with the pitch motion component in direction B, along with the lifting and traversing motion components, enabling automatic positioning and leveling of the precision turntable. This reduces reliance on manual operation and improves measurement efficiency.

[0049] This invention boasts strong adaptability and operational flexibility. The measuring bracket length can be customized within the range of 500mm-2000mm, and by changing the bracket, it can be adapted to different models of centrifuges with diameters ranging from 500mm to 5000mm. The electrical control system supports wireless operation via tablet computer, allowing real-time viewing of measurement data, 3D profiles, and battery levels, providing convenient operation and a high degree of visualization. Simultaneously, by correlating measurement data with machine tool blade wear and machine depreciation parameters, and combining multi-dimensional cost data on raw materials, labor, and energy consumption, a predictive model is constructed with a goodness of fit R² ≥ 0.9, accurately predicting unit production costs. Differentiated machine handling strategies are formulated based on cost increases, achieving synergy between quality control and cost optimization, preventing uncontrolled production costs or excessive equipment wear. Attached Figure Description

[0050] Figure 1 This is a schematic diagram of the invention's structure;

[0051] Figure 2 This is a schematic diagram of the installation structure of the device above the trolley platform;

[0052] Figure 3 This is a schematic diagram of the installation structure of the lifting and translating motion components;

[0053] Figure 4This is a schematic diagram of the installation structure of the pitch motion component itself;

[0054] Figure 5 This is a schematic diagram of the installation structure of the pitch assembly and the precision turntable;

[0055] Figure 6 This is a schematic diagram of the installation structure of the precision turntable, measuring bracket, and line laser sensor;

[0056] Figure 7 This is a schematic diagram of the electric support leg installation structure at the bottom of the vehicle;

[0057] Figure 8 This is a schematic diagram of the electronic control system of the present invention;

[0058] In the diagram: 1. Mobile trolley, 2. Rubber wheels, 3. Electric lifting outriggers, 4. Lifting motion assembly, 5. Lateral motion assembly, 6. A-direction pitch motion assembly, 7. B-direction pitch motion assembly, 8. Precision turntable, 9. Measuring bracket, 10. Line laser sensor connector, 11. Line laser sensor, 12. Dual-axis tilt sensor.

[0059] 3a. Electric actuator; 3b. Circular support feet;

[0060] 5a. Slider; 6a. Pitch motion component adapter.

[0061] 8a. Adapter plate; 8b. Measuring bracket adapter;

[0062] 1-1. Controller; 1-2. Industrial PC; 1-3. Tablet PC; 1-4. Precision turntable servo driver; 1-5. Precision turntable torque motor; 1-6. Pitch / lift / traverse motion component servo driver; 1-7. Pitch / lift / traverse motion component servo motor; 1-9. Power supply battery; 1-10. Pitch / lift / traverse motion component grating system; 1-11. Precision turntable grating system. Detailed Implementation

[0063] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments will be clearly and completely described below with reference to the accompanying drawings. The following embodiments are used to illustrate the present invention, but are not intended to limit the scope of the present invention. Specific implementation method one:

[0065] Combination Figure 1 and Figure 2This embodiment describes a mobile stop geometry error measuring device for the manufacturing process of large centrifuges, which includes a line laser sensor 11, a measuring bracket 9, a precision turntable 8, an A-direction pitch motion component 6, a B-direction pitch motion component 7, a lifting motion component 4, a lateral movement component 5, a mobile trolley 1, and an electric lifting support leg 3.

[0066] The line laser sensor 11 is detachably connected to the measuring bracket 9 through the bolt holes of the line laser sensor connector 10. The bottom of the measuring bracket 9 is fixedly connected to the rotor surface of the precision turntable 8 through the measuring bracket adapter 8b. The base of the precision turntable 8 is fixedly connected to the surface of the B-direction pitch motion component 7 through the circumferentially distributed bolt holes of the adapter plate 8a, ensuring that the concentricity installation error between the center of the pitch motion component composed of the precision turntable 8, the A-direction pitch motion component 6, and the B-direction pitch motion component 7 and the center of the precision turntable 8 is ≤30μm.

[0067] To achieve high-precision coaxiality, a precision-machined positioning boss and positioning groove mating structure is provided on the mating surface of the precision turntable 8 base and the adapter plate. The initial precise positioning is achieved through this mating structure, and then the bolts are tightened to ensure that the concentricity installation error between the center of the pitch motion assembly composed of the precision turntable 8 and the pitch motion assembly 6 in the A direction and the pitch motion assembly 7 in the B direction and the center of the precision turntable is ≤30μm.

[0068] The pitch motion component 6 in the A direction and the pitch motion component 7 in the B direction are fixedly connected by bolts on the upper and lower mounting surfaces of the pitch motion component adapter 6a. The pitch motion component 6 in the A direction and the pitch motion component 7 in the B direction are arranged at a 90-degree angle. The bottom of the pitch motion component 6 in the A direction is fixed to the upper surface of the slider 5a of the transverse motion component 5 by bolts. The base of the transverse motion component 5 is fastened to the slider of the lifting motion component 4 by T-bolts. The bottom mounting plate of the lifting motion component 4 is fixed to the platform of the moving trolley 1 by expansion bolts. The transverse motion component 5 and the lifting motion component 4 are stacked at a 90-degree angle to realize the bidirectional displacement adjustment of the precision turntable 8 in the up and down and left and right directions.

[0069] The mobile trolley 1 has rubber wheels 2 with brakes bolted to the four corners of its bottom. Four electric lifting legs 3 are fixedly installed at the four corners of the mobile trolley 1. The electric lifting legs 3 are composed of electric push rods 3a and circular support feet 3b connected by threads. A dual-axis tilt sensor 12 is fixedly connected to the center of the platform of the mobile trolley 1 through a mounting base. The detection surface of the dual-axis tilt sensor 12 is parallel to the platform.

[0070] The line laser sensor 11 is mounted on the measuring bracket 9, which is customized according to the workpiece size. The measuring bracket 9 of the corresponding length is installed according to the diameter specification of the workpiece being measured, and the measuring bracket is fixed on the precision turntable 8. The line laser sensor 11 emits a linear laser beam to measure the contour of the stop. The line laser sensor 11 illuminates the cross-section (end face or radial face) of the stop being measured. Then, the precision turntable 8 rotates one revolution, measuring the eccentricity and tilt of the cross-section relative to the precision turntable 8. The position of the precision turntable 8 is then adjusted by the lifting, translation, and pitch motion components. After the position adjustment is completed, the precision turntable 8 rotates another revolution, thereby measuring the flatness and roundness geometric shape error information of the stop, with an accuracy of ±1μm. The precision turntable 8 uses a closely packed ball bearing turntable, which is not limited by air source and air pipes, enhancing the mobility of the device. The radial rotation error of the precision turntable 8 is within 0.2μm, increasing the flexibility of the device. The precision turntable 8 is mounted on the platform of the pitch motion component 7 in the B direction, and both the precision turntable 8 and the tilt adjustment platform are placed horizontally. At this time, the centrifuge is also placed horizontally. The lifting and traversing motion components can control the lifting and traversing motion of the pitch motion component. The lifting and traversing motion components use standard electric modules. The electric modules use motors as power sources and convert motion into linear or rotational displacement through a transmission structure. Precise positioning is achieved by relying on guide and control components, with a positioning accuracy of 1μm.

[0071] The A-direction pitch motion assembly 6 and the B-direction pitch motion assembly 7 use standard electric angle displacement stages. Powered by a motor, these stages are converted into precise rotation of the worktable via a transmission mechanism. Combined with feedback elements, closed-loop angle positioning is achieved. The A-direction pitch motion assembly 6 and the B-direction pitch motion assembly 7 are installed at a 90-degree angle. The A-direction pitch assembly 6 enables the precision turntable 8 to pitch along direction A, and the B-direction pitch motion assembly 7 enables it to pitch along direction B. This allows the precision turntable 8 to pitch in any direction. Working simultaneously with the lifting motion assembly 4 and the traversing motion assembly 5, they allow for fine-tuning of the precision turntable 8's attitude. To ensure that the rotation axis of the precision turntable 8 in the measuring device coincides with the axis of the centrifuge, the following steps are taken: First, a line laser probe is used to measure the end face of the centrifuge stop. The data collected by the line laser sensor 11 is used to evaluate the fitting plane, and the parallelism between the surface of the precision turntable 8 and the fitting plane is adjusted to within 5μm. The flatness of the surface of the precision turntable 8 can be guaranteed to be within 2μm through machining. Then, the line laser probe is adjusted to measure the diameter surface of the centrifuge stop, and the concentricity between the diameter surface of the centrifuge stop and the diameter surface turntable is adjusted to within 5μm. Since parts are machined based on a section and a diameter, this method can adjust the rotation axis of the diameter surface turntable to be highly coincident with the axis of the centrifuge.

[0072] After the precision turntable 8 is properly positioned, the device begins measuring the geometric shape error of the centrifuge stop. The line laser sensor 11 rotates horizontally one revolution under the drive of the precision turntable 8, thus measuring the end face and radial surface geometric shape errors of the centrifuge stop. This allows for the assessment of the runout, roundness, and flatness of the centrifuge stops at both ends, and the three-dimensional profile of the measured cross-section can be displayed on the software interface. The above process is repeated to measure the stop at the other end of the centrifuge, assessing its runout, roundness, and flatness, and again displaying the three-dimensional profile of the measured cross-section on the software interface.

[0073] In this device, the mobile trolley is the main body, and all working units are installed on the mobile trolley 1. The lifting motion component 4 is installed on the upper surface of the mobile trolley 1. The translation motion component 5 is installed in a 90-degree superposition manner with the lifting motion component 4, so that the precision turntable 8 can move up and down as well as left and right. The purpose is to make the center of the precision turntable 8 coincide with the center of the part being measured.

[0074] The A-direction pitch motion component 6 is mounted on the slider 5a of the lateral motion component 5. The B-direction pitch motion component 7 is mounted on the platform of the A-direction pitch motion component 6. The base of the precision turntable 8 is mounted on the platform of the B-direction pitch motion component 7. The measuring bracket 9 is mounted on the precision turntable 8. The line laser sensor 11 is fixed to the measuring bracket 9 via the sensor-to-measuring bracket connector 10. The moving trolley 1 has four wheels 2 underneath, which can move the trolley to the vicinity of the workpiece. The trolley has four lifting legs 3 underneath. The lifting legs move downward to stabilize the moving trolley 1. At the same time, based on the data fed back by the dual-axis tilt sensor 12, the movement of the lifting legs is controlled by software to keep the platform of the trolley level with the ground. Specific Implementation Method Two:

[0076] Combination Figure 8 This embodiment describes a mobile stop geometry error measuring device for the manufacturing process of large centrifuges, which also includes an electrical control system.

[0077] The electrical control system includes a controller 1-1, an industrial computer 1-2, a tablet computer 1-3, a precision turntable servo driver 1-4, a precision turntable torque motor 1-5, a pitch / lift / traverse motion component servo driver 1-6, a pitch / lift / traverse motion component servo motor 1-7, a line laser sensor 11, a power supply battery 1-9, a pitch / lift / traverse motion component grating system 1-10, a precision turntable grating system 1-11, and a dual-axis tilt sensor 12.

[0078] Among them, the controller 1-1, industrial computer 1-2, tablet computer 1-3, precision turntable servo driver 1-4, precision turntable torque motor 1-5, pitch / lift / traverse motion component servo driver 1-6, pitch / lift / traverse motion component servo motor 1-7, power supply battery 1-9, pitch / lift / traverse motion component grating system 1-10, and precision turntable grating system 1-11 are centrally installed in the electrical control cabinet of the mobile trolley 1;

[0079] Controller 1-1 is connected to industrial computer 1-2 via RJ45 network cable. Industrial computer 1-2 is wirelessly connected to tablet computer 1-3 via WiFi module. Controller 1-1 is connected to precision turntable servo driver 1-4 and pitch / lift / traverse motion component servo driver 1-6 via EtherCAT bus cable.

[0080] The precision turntable servo driver 1-4 is connected to the terminal of the precision turntable torque motor 1-5 via the motor power line, and the pitch / lift / traverse motion component servo driver 1-6 is connected to the corresponding terminal of the pitch / lift / traverse motion component servo motor 1-7 via the motor power line.

[0081] The precision turntable grating system 1-11 is connected to the precision turntable servo driver 1-4 via an RS485 serial cable, and the pitch / lift / traverse motion component grating system 1-10 is connected to the corresponding pitch / lift / traverse motion component servo driver 1-6 via an RS485 serial cable.

[0082] The dual-axis tilt sensor 12 is connected to the industrial computer 1-2 via an RS485 serial cable, and the line laser sensor 11 is connected to the industrial computer 1-2 via an RJ45 network cable.

[0083] The controller 1-1 communicates with the industrial computer 1-2 via the Modbus TCP protocol, while the industrial computer 1-2 communicates wirelessly with the tablet computer 1-3 using the TCP-IP protocol. The controller 1-1 communicates with the servo driver via the EtherCAT industrial bus, achieving efficient data transmission and control response. The attitude of each axis, sensor data acquisition, and measurement result evaluation can all be operated and viewed on the tablet computer. The movement of the mobile carriage 1 can also be controlled on the tablet computer 1-3, facilitating user operation. All electrical components are centrally installed in the electrical control cabinet of the mobile carriage 1. Specific implementation method three:

[0085] Combination Figure 3This embodiment describes a mobile stop geometry error measuring device for the manufacturing process of large centrifuges. The measuring bracket 9 is integrally machined, and its length is customized within the range of 500mm-2000mm according to the stop diameter of the centrifuge being measured. Both ends of the measuring bracket 9 are provided with standardized bolt holes. By manually disassembling the bolts connecting the measuring bracket adapter 8b to the precision turntable 8, measuring brackets of different lengths can be replaced. The base of the transverse motion component 5 is fastened to the slider of the lifting motion component 4 by T-bolts. The bottom mounting plate of the lifting motion component 4 is fixed to the platform of the mobile trolley 1 by expansion bolts. The transverse motion component 5 and the lifting motion component 4 are installed at a 90-degree angle to achieve bidirectional displacement adjustment of the precision turntable 8 in both vertical and horizontal directions. This allows the precision turntable 8 to move in both vertical and horizontal directions, aligning the center of the precision turntable 8 with the center of the measured part. The transverse motion component 5 and the lifting motion component 4 are made of high-precision motion modules. Specific implementation method four:

[0087] Combination Figure 4 This embodiment describes a mobile stop geometry error measuring device for the manufacturing process of large centrifuges. The mobile trolley 1 is powered by a high-power lithium battery 1-9 with a rated voltage of 24V and a capacity of 100Ah. The battery 1-9 integrates a power detection module and an alarm module, and is connected to an industrial control computer 1-2 through wires. The remaining power is displayed in real time on the interface of the tablet computer 1-3. When the power is lower than 20%, an audible and visual alarm is automatically issued.

[0088] The precision turntable 8 uses closely spaced ball bearings, the lifting motion component 4 and the transverse motion component 5 use standard electric modules, and the line laser sensor 11 works with the precision turntable 8 to rotate 360 ​​degrees in the circumferential direction.

[0089] The mobile trolley 1 includes wheels with rubber wheels that are equipped with brakes for gripping. The electric lifting outriggers 3 can move downwards independently to make close contact with the ground. At the same time, a dual-axis tilt sensor 12 is installed on the upper surface of the mobile trolley 1 (not shown in the figure). The length of the four electric lifting outriggers 3 is adjusted in real time to keep the mobile trolley 1 in a horizontal position. This allows the measuring device to adapt to different ground conditions and maintain stability, ensuring the validity of the measurement results.

[0090] The mobile trolley 1 is powered by a high-power battery, featuring a battery level display and low battery alarm, freeing it from the constraints of a power cord and further improving its mobility. Meanwhile, the main shaft of the precision turntable 8 uses closely spaced ball bearings, with radial runout essentially identical to that of an air bearing. This eliminates the need for an air supply to the device, freeing it from dependence on an air source. Specific implementation method five:

[0092] Combination Figure 5 This embodiment describes a mobile stop geometry error measuring device for the manufacturing process of large centrifuges. The laser emitting surface of the line laser sensor 11 is perpendicular to the end face of the measuring bracket 9. The line laser sensor 11 rotates one revolution with the precision turntable 8 to scan the end face or radial surface of the stop being measured. It can complete the flatness measurement of the end face of the stop and the roundness measurement of the radial surface, and display the three-dimensional contour of the measured section in real time on the measurement software interface.

[0093] The precision turntable 8 is mounted on the platform of the pitch motion component 7 in the B direction. The two are fixedly connected by an adapter plate 8a screw, so that the base of the precision turntable 8 is fixedly connected to the platform of the pitch motion component 7. There is a measuring bracket adapter 8b on the platform of the precision turntable 8 for connecting the platform of the precision turntable 8 to the measuring bracket. The purpose of the precision turntable is to drive the measuring bracket and the line laser sensor to rotate, so that the line laser sensor scans along the stop of the measured part and collects the surface data of the part. Specific implementation method six:

[0095] Combination Figure 6 and Figure 7 This embodiment describes a mobile stop geometry error measuring device for the manufacturing process of large centrifuges. The dual-axis tilt sensor 12 collects real-time tilt angle data of the moving trolley 1 platform and transmits it to the industrial control computer 1-2 for processing. The controller 1-1 then drives the extension and retraction of each electric push rod 3a to ensure the moving trolley 1 platform is level with the ground. The line laser sensor 11 is detachably connected to the measuring bracket 9 via bolt holes in the line laser sensor connector 10. The bottom of the measuring bracket 9 is fixedly connected to the rotor surface of the precision turntable 8 via a measuring bracket adapter 8b. The measuring bracket 9 is made of high-strength aluminum alloy to ensure that the line laser sensor does not vibrate during the movement of the precision turntable, guaranteeing the accuracy of the measurement data. The measuring bracket 9 is customized according to the diameter of the workpiece being measured; the length of the measuring bracket 9 varies for different diameter workpieces. The measuring bracket can be manually installed and disassembled, making it suitable for a wide range of part types. Specific implementation method seven:

[0097] Combination Figure 8 This embodiment describes a mobile stop geometry error measuring device for the manufacturing process of large centrifuges. The controller 1-1 communicates with the industrial computer 1-2 using the Modbus TCP protocol, the industrial computer 1-2 communicates with the tablet computer 1-3 using the TCP-IP wireless communication protocol, the controller 1-1 communicates with the servo driver using the EtherCAT industrial bus, and the grating system communicates with the servo driver using the Modbus-RTU serial communication protocol, thereby realizing closed-loop control and precise positioning of each motion axis.

[0098] First, move the mobile large centrifuge stop geometry error measuring device to the appropriate measurement position of the large centrifuge to be measured, at which point the centrifuge is placed horizontally. Tighten the rubber wheels 2 of the mobile trolley 1 to bring it to a stable stop, then control the electric lifting support legs 3 of the mobile trolley 1 to descend and contact the ground, increasing the stability of the trolley. Simultaneously, perform preliminary leveling of the upper surface of the mobile trolley 1.

[0099] Adjust the length of the measuring bracket 9. A wired laser sensor 11 is installed at the end of the measuring bracket 9. First, use the wired laser sensor 11 to measure the end face of the centrifuge stop. After the laser line from the wired laser sensor 11 covers the measured surface, fix the measuring bracket 9 to the precision turntable 8. Then, press the start button. The precision turntable 8 rotates, thereby rotating the wired laser sensor 11. After one rotation, the host computer evaluates a fitting plane based on the data collected by the wired laser sensor. At this time, the fitting plane has a parallelism value with the turntable surface. The host computer sends instructions to the motion control system based on the data measured by the wired laser sensor 11, automatically controlling the pitch motion component to move, driving the precision turntable 8 to adjust the pitch attitude of the precision turntable, so that the parallelism between the centrifuge stop end face and the precision turntable surface is adjusted to within 5μm. Repeat the above process 2-4 times to achieve this. Then, the wired laser sensor 11 rotates. After one rotation, the host computer evaluates the fitting plane based on the data collected by the wired laser sensor. A fitting annular surface is defined, and the center of the fitting annular surface has a concentricity value with the center of the precision turntable. The host computer sends instructions to the motion control system based on the data measured by the line laser sensor 11, automatically controlling the movement of the lifting motion component 4 and the lateral movement component 5, driving the precision turntable 8 to move and adjust the position and posture of the precision turntable, so that the concentricity between the centrifuge stop diameter surface and the precision turntable 8 is adjusted to within 5μm. This process is repeated 2-4 times to achieve the desired result. At this point, the rotation axis of the precision turntable is highly coincident with the rotation axis of the centrifuge component. Then, the measurement button is clicked to rotate the precision turntable 8. After one rotation, the roundness and radial runout information of the centrifuge stop can be obtained. The irradiation direction of the line laser sensor is adjusted so that the line laser sensor irradiates the end face of the stop. Then, the measurement button is activated, and the precision turntable 8 drives the line laser sensor 11 to rotate, measuring the runout data of the centrifuge end face stop. The end face runout and flatness information of the measured section are further evaluated, a measurement report is generated, and displayed through the software interface.

[0100] After the measurement is completed, the measuring bracket 9 is disassembled manually. Select the measuring bracket according to the diameter of the measured part, place it on the moving trolley 1, click the zero return button, and all moving components return to their initial positions. Raise the electric lifting support leg 3, release the wheel clamping device, move the measuring device to a suitable position for storage, and turn off the battery power for the next use. Detailed implementation method eight:

[0102] Combination Figures 1-8 This embodiment describes a cost prediction method for a mobile stop geometry error measuring device for the manufacturing process of large centrifuges. The method includes the following steps:

[0103] Step 1: Using the mobile stop geometry error measuring device for the manufacturing process of large centrifuges as described in claim 1, runout data is collected from both ends of the same batch of centrifuge products. Each end of the stop is collected 3 times. The collected data is fitted using the least squares method to evaluate 8 key parameters, including eccentricity, eccentricity angle, maximum runout and its corresponding angle, minimum runout and its corresponding angle, tilt, tilt angle, highest point and its corresponding angle, and lowest point and its corresponding angle. After removing abnormal data, a runout data sample is formed.

[0104] Step 2: Use a 5th-order Gaussian filter algorithm to decompose the fluctuating data samples into frequency bands, extracting feature parameters for three frequency bands: 0-10Hz, 10-50Hz, and 50-100Hz, including amplitude, frequency, and phase. Establish a mapping relationship between the feature parameters and the wear of machine tool blades and the degree of machine wear through a radial basis function neural network, forming a complete associated sample containing ≥1000 sets of data, with a neural network training error ≤3%.

[0105] Step 3: Obtain raw material data, labor cost data, energy consumption cost data, and machine wear data within the same time period through the industrial internet platform, calculate the daily, weekly, and monthly change rates of the four types of data, and statistically analyze the degree of change;

[0106] The raw material data includes spot and futures price indices for steel and alloys.

[0107] Labor cost data includes industry average wages and overtime rates;

[0108] Energy cost data includes the electricity consumption of the machine per unit time and the allocated costs of water and electricity in the factory.

[0109] Machine wear data includes quantified values ​​of associated samples based on step two;

[0110] Step 4: Using the monthly change rate of the four types of data in Step 3 as the independent variable and the unit production cost of centrifuges as the dependent variable, construct a multiple linear regression model;

[0111] The model expression is: y = a1x1 + a2x2 + a3x3 + a4x4 + b;

[0112] Where y is the unit production cost, x1 is the rate of change of raw material prices, x2 is the rate of change of labor costs, x3 is the rate of change of energy consumption costs, x4 is the rate of change of machine wear, a1, a2, a3, and a4 are regression coefficients, and b is a constant term. The model parameters are solved by multiple linear regression analysis to predict the unit production cost of centrifuges under different production scales.

[0113] Step 5: Develop a machine processing strategy based on cost forecasts.

[0114] When the predicted increase in unit production cost is ≤1.5%, replace the easily worn parts of the machine tool blades;

[0115] When the increase is less than 1.5% and less than or equal to 5%, the machine tool should be overhauled and the severely worn core components should be replaced.

[0116] When the increase is greater than 5%, assess the economics of replacing the machine tool with a new one, and give priority to replacing the machine tool with a new one. Specific implementation method nine:

[0118] Combination Figure 1 and Figure 2 This embodiment describes a cost prediction method for a mobile stop geometry error measuring device for the manufacturing process of large centrifuges. In step two, the input layer of the radial basis function neural network contains 9 neurons, including amplitude, frequency, and phase in 3 frequency bands. The hidden layer contains 20 neurons, and the output layer contains 2 neurons, including machine tool blade wear and machine wear degree. The gradient descent method is used to optimize the network weights, with ≥1000 iterations, to ensure that the deviation between the output quantitative data and the actual detection data is ≤5%. Specific Implementation Method Ten:

[0120] Combination Figure 1 and Figure 2 This embodiment describes a cost prediction method for a mobile stop geometry error measuring device for the manufacturing process of large centrifuges. In step four, the independent variable data of the multiple linear regression model are standardized to eliminate the influence of dimensions. The model fit R² ≥ 0.9, and the significance of the model is verified by the F test with a significance level of α = 0.05, ensuring the reliability and accuracy of the prediction results.

[0121] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create similar embodiments without departing from the scope of the present invention. Any simple modifications, substitutions, and improvements made to the above embodiments without departing from the scope of the present invention, based on the technical essence of the present invention, and within the spirit and principles of the present invention, shall still fall within the protection scope of the present invention.

Claims

1. A mobile stop geometry error measuring device for the manufacturing process of large centrifuges, characterized in that, It includes a line laser sensor (11), a measuring bracket (9), a precision turntable (8), an A-direction pitch motion assembly (6), a B-direction pitch motion assembly (7), a lifting motion assembly (4), a lateral movement assembly (5), a moving trolley (1), and an electric lifting outrigger (3). The line laser sensor (11) is detachably connected to the measuring bracket (9) through the bolt holes of the line laser sensor connector (10). The bottom of the measuring bracket (9) is fixedly connected to the rotor table of the precision turntable (8) through the measuring bracket adapter (8b). The base of the precision turntable (8) is fixedly connected to the table of the B-direction pitch motion component (7) through the circumferentially distributed bolt holes of the adapter plate (8a). This ensures that the center of the pitch motion component composed of the precision turntable (8), the A-direction pitch motion component (6), and the B-direction pitch motion component (7) is concentric with the center of the precision turntable (8) with an installation error ≤30μm. The pitch motion component (6) in the A direction and the pitch motion component (7) in the B direction are fixedly connected by bolts on the upper and lower mounting surfaces of the pitch motion component adapter (6a). The pitch motion component (6) in the A direction and the pitch motion component (7) in the B direction are arranged at a 90-degree angle. The bottom of the pitch motion component (6) in the A direction is fixed to the upper surface of the slider (5a) of the transverse motion component (5). The base of the transverse motion component (5) is fastened to the slider of the lifting motion component (4) by T-bolts. The bottom mounting plate of the lifting motion component (4) is bolted to the table surface of the moving trolley (1). The transverse motion component (5) and the lifting motion component (4) are installed at a 90-degree angle to realize the up-down and left-right bidirectional displacement adjustment of the precision turntable (8). The bottom of the mobile trolley (1) is equipped with rubber wheels (2) with brakes. Four electric lifting legs (3) are installed at the four corners of the mobile trolley (1). The electric lifting legs (3) are composed of an electric push rod (3a) and a circular support foot (3b) connected by threads. A dual-axis tilt sensor (12) is fixedly connected to the center of the platform of the mobile trolley (1) through a mounting seat. The detection surface of the dual-axis tilt sensor (12) is parallel to the platform. The electrical control system includes a controller (1-1), an industrial computer (1-2), a tablet computer (1-3), a precision turntable servo driver (1-4), a precision turntable torque motor (1-5), a pitch / lift / traverse motion component servo driver (1-6), a pitch / lift / traverse motion component servo motor (1-7), a line laser sensor (11), a power supply battery (1-9), a pitch / lift / traverse motion component grating system (1-10), a precision turntable grating system (1-11), and a dual-axis tilt sensor (12). Among them, the controller (1-1), industrial computer (1-2), tablet computer (1-3), precision turntable servo driver (1-4), precision turntable torque motor (1-5), pitch / lift / traverse motion component servo driver (1-6), pitch / lift / traverse motion component servo motor (1-7), power supply battery (1-9), pitch / lift / traverse motion component grating system (1-10), and precision turntable grating system (1-11) are centrally installed in the electrical control cabinet of the mobile trolley (1); The controller (1-1) is connected to the industrial computer (1-2) via a network cable. The industrial computer (1-2) is connected to the tablet computer (1-3) via a WiFi module. The controller (1-1) is connected to the precision turntable servo driver (1-4) and the pitch / lift / traverse motion component servo driver (1-6) via a cable. The precision turntable servo driver (1-4) is connected to the terminal of the precision turntable torque motor (1-5) via the motor power line, and the pitch / lift / traverse motion component servo driver (1-6) is connected to the corresponding terminal of the pitch / lift / traverse motion component servo motor (1-7) via the motor power line. The precision turntable grating system (1-11) and the precision turntable servo driver (1-4) are connected via a serial cable, and the pitch / lift / traverse motion component grating system (1-10) and the corresponding pitch / lift / traverse motion component servo driver (1-6) are connected via a serial cable. The dual-axis tilt sensor (12) is connected to the industrial computer (1-2) via an RS485 serial cable, and the line laser sensor (11) is connected to the industrial computer (1-2) via a network cable. The laser emitting surface of the line laser sensor (11) is perpendicular to the end face of the measuring bracket (9). The line laser sensor (11) rotates once with the precision turntable (8) to scan the end face or radial surface of the stop to be measured. It can complete the flatness measurement of the end face of the stop and the roundness measurement of the radial surface, and display the three-dimensional contour of the measured section in real time on the measurement software interface. The dual-axis tilt sensor (12) collects the tilt angle data of the platform of the mobile trolley (1) in real time and transmits it to the industrial control computer (1-2) for processing. Then, the controller (1-1) drives and adjusts the extension and retraction stroke of each electric push rod (3a) to ensure that the platform of the mobile trolley (1) is level with the ground.

2. The mobile stop geometry error measuring device for the manufacturing process of large centrifuges according to claim 1, characterized in that, The measuring bracket (9) is integrally machined and its length is customized within the range of 500mm-2000mm according to the diameter of the stop of the centrifuge being measured. Both ends of the measuring bracket (9) are provided with standardized bolt holes. By manually disassembling the bolts connecting the measuring bracket adapter (8b) and the precision turntable (8), measuring brackets (9) of different lengths can be replaced to adapt to different models of centrifuges with diameters of 500mm-5000mm.

3. The mobile stop geometry error measuring device for the manufacturing process of large centrifuges according to claim 1, characterized in that, The mobile vehicle (1) is powered by a high-power lithium battery (1-9) with a rated voltage of 24V and a capacity of 100Ah. The battery (1-9) integrates a power detection module and an alarm module, and is connected to the industrial control computer (1-2) through wires. The remaining power is displayed in real time on the tablet computer (1-3) interface. When the power is lower than 20%, an audible and visual alarm is automatically issued. The precision turntable (8) uses closely spaced ball bearings, the lifting motion component (4) and the transverse motion component (5) use standard electric modules, and the line laser sensor (11) works with the precision turntable (8) to rotate 360 ​​degrees in the circumferential direction.

4. The mobile stop geometry error measuring device for the manufacturing process of large centrifuges according to claim 1, characterized in that, The controller (1-1) communicates with the industrial computer (1-2) using the Modbus TCP protocol, the industrial computer (1-2) communicates with the tablet computer (1-3) using the TCP-IP wireless communication protocol, the controller (1-1) communicates with the servo driver using the EtherCAT industrial bus, and the grating system communicates with the servo driver using the Modbus-RTU serial communication protocol, thereby realizing closed-loop control and precise positioning of each motion axis.

5. The cost prediction method for a mobile stop geometry error measuring device for large centrifuge manufacturing processes according to any one of claims 1-4, characterized in that, The method includes the following steps: Step 1: Using the mobile stop geometry error measuring device for the manufacturing process of large centrifuges as described in claim 1, runout data is collected from both ends of the same batch of centrifuge products. Each end of the stop is collected 3 times. The collected data is fitted using the least squares method to evaluate 8 key parameters, including eccentricity, eccentricity angle, maximum runout and its corresponding angle, minimum runout and its corresponding angle, tilt, tilt angle, highest point and its corresponding angle, and lowest point and its corresponding angle. After removing abnormal data, a runout data sample is formed. Step 2: Use a 5th-order Gaussian filter algorithm to decompose the fluctuating data samples into frequency bands, extracting feature parameters for three frequency bands: 0-10Hz, 10-50Hz, and 50-100Hz, including amplitude, frequency, and phase. Establish a mapping relationship between the feature parameters and the wear of machine tool blades and the degree of machine wear through a radial basis function neural network, forming a complete associated sample containing ≥1000 sets of data, with a neural network training error ≤3%. Step 3: Obtain raw material data, labor cost data, energy consumption cost data, and machine wear data within the same time period through the industrial internet platform, calculate the daily, weekly, and monthly change rates of the four types of data, and statistically analyze the degree of change; The raw material data includes spot and futures price indices for steel and alloys. Labor cost data includes industry average wages and overtime rates; Energy cost data includes the electricity consumption of the machine per unit time and the allocated costs of water and electricity in the factory. Machine wear data includes quantified values ​​of associated samples based on step two; Step 4: Using the monthly change rate of the four types of data in Step 3 as the independent variable and the unit production cost of centrifuges as the dependent variable, construct a multiple linear regression model; The model expression is: y = a1x1 + a2x2 + a3x3 + a4x4 + b; Where y is the unit production cost, x1 is the rate of change of raw material prices, x2 is the rate of change of labor costs, x3 is the rate of change of energy consumption costs, x4 is the rate of change of machine wear, a1, a2, a3, and a4 are regression coefficients, and b is a constant term. The model parameters are solved by multiple linear regression analysis to predict the unit production cost of centrifuges under different production scales. Step 5: Develop a machine processing strategy based on cost forecasts. When the predicted increase in unit production cost is ≤1.5%, replace the easily worn parts of the machine tool blades; When the increase is less than 1.5% and less than or equal to 5%, the machine tool should be overhauled and the severely worn core components should be replaced. When the increase is greater than 5%, assess the economics of replacing the machine tool with a new one, and give priority to replacing the machine tool with a new one.

6. The cost prediction method for the mobile stop geometry error measuring device for the manufacturing process of large centrifuges according to claim 5, characterized in that, In step two, the input layer of the radial basis function neural network contains 9 neurons, including amplitude, frequency, and phase of 3 frequency bands. The hidden layer contains 20 neurons, and the output layer contains 2 neurons, including the wear amount of machine tool blades and the degree of machine wear. The gradient descent method is used to optimize the network weights, with ≥1000 iterations, to ensure that the deviation between the output quantitative data and the actual detection data is ≤5%.

7. The cost prediction method for the mobile stop geometry error measuring device for the manufacturing process of large centrifuges according to claim 5, characterized in that, In step four, the independent variable data of the multiple linear regression model are standardized to eliminate the influence of dimensions. The model fit R² ≥ 0.9, and the significance of the model is verified by the F test with a significance level of α = 0.05, ensuring the reliability and accuracy of the prediction results.

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