Five-axis machining system and machining method for aluminum alloy machining

Abstract

The application belongs to the technical field of aluminum alloy processing. A five-axis machining system and method for aluminum alloy processing are provided, which include a bed body, a gantry, a multi-layer slide plate driving mechanism, a five-axis swing head, an integrated centralized tool magazine and an independent servo automatic clamp. The gantry moves along the bed body through a gear and rack transmission, and the multi-layer slide plate driving mechanism drives the five-axis swing head to realize Y and Z direction feeding. The five-axis swing head contains B and C shaft assemblies, is equipped with an encoder to realize angle closed-loop feedback, and is provided with a pneumatic brake disc to fix the angle. The integrated centralized tool magazine adopts a layered tool disc and a linkage automatic door, which can efficiently change tools and prevent flying debris pollution. The independent servo automatic clamp can be independently positioned, the position of the clamp jaw is adjustable, and it is suitable for different profiles. The application solves the problems of workpiece transfer, multiple positioning errors and special-shaped part clamping in traditional multi-device processing, improves the processing integration and precision, is suitable for door and window aluminum alloy profile processing, ensures operation safety and equipment stability, and effectively improves production efficiency.

Description

Technical Field

[0001] This invention relates to the field of aluminum alloy processing technology, and in particular to a five-axis machining system and method for aluminum alloy processing. Background Technology

[0002] The statements in this section are merely background information related to the present invention and do not necessarily constitute prior art.

[0003] In modern manufacturing, aluminum alloys are widely used in building applications such as doors, windows, and curtain walls due to their excellent properties, including lightweight, high strength, and corrosion resistance. Especially for aluminum alloy profiles used in doors and windows, the processing technology faces increasing challenges as the construction industry's requirements for product precision, appearance, and functionality continue to rise. Five-axis machining technology, with its multi-degree-of-freedom linkage advantage, can achieve high-precision machining of complex curved surfaces and irregular structures, becoming a core technological support for the precision machining of aluminum alloy profiles for doors and windows. Gantry machining centers, as an important form of five-axis machining equipment, are characterized by high rigidity and large machining stroke, making them suitable for batch processing of long profiles and meeting the needs of large-scale production of aluminum alloy profiles for doors and windows. In recent years, with the advancement of intelligent manufacturing, the industry's requirements for the integration, automation, and efficiency of processing equipment have been increasing. Traditional processing equipment can no longer meet the needs of processing complex structures, integrating multiple processes, and controlling high precision in aluminum alloy profiles for doors and windows, driving the development of five-axis gantry machining equipment towards integration and intelligence.

[0004] However, many technical problems still exist in the current processing of aluminum alloy profiles for doors and windows that urgently need to be solved. In traditional processing methods, processes such as cutting, end milling, drilling, and tapping of aluminum alloy profiles for doors and windows need to be completed on multiple machines, relying on manual workpiece handling. This is not only inefficient but also prone to workpiece damage. Furthermore, repeated positioning and clamping accumulates errors, severely affecting processing accuracy. For door and window profiles with complex structures such as curved or irregular shapes, traditional fixtures struggle to achieve precise positioning, resulting in poor processing consistency. Tool magazines are mostly laid out with a single type of tool, resulting in few tool change points and low efficiency in switching between different sizes and types of tools. They are also susceptible to dust contamination, affecting their lifespan. The layout of moving parts in processing equipment is unreasonable, leading to large space occupation and high risks of motion interference, thus hindering the improvement of processing efficiency. In addition, the lack of effective safety protection mechanisms during processing means that personnel accidentally entering the processing area can easily cause accidents. Insufficient coordination between the chip removal and cooling systems and the processing unit also affects processing stability and equipment lifespan. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a five-axis machining system and method for aluminum alloy processing, which enables multi-process centralized processing and significantly improves the processing efficiency and precision of aluminum alloys.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] In a first aspect, the present invention provides a five-axis machining system for aluminum alloy machining.

[0008] A five-axis machining system for aluminum alloy processing includes: a bed, a gantry, a multi-layer slide drive mechanism, a five-axis swivel head, an integrated centralized tool magazine, and an independent servo automatic fixture;

[0009] The gantry includes columns and crossbeams. The crossbeams are fixed to the top of the two columns. A gantry slider is provided at the lower end of the columns. The gantry slider slides with the gantry guide rail on the bed, so that the gantry can move along the length of the bed. A drive mechanism is installed on the columns. The gear of the drive mechanism meshes with the rack on the bed.

[0010] The multi-layer slide drive mechanism includes a slide saddle, an intermediate slide, and a spindle box. The slide saddle is fixed to the Y-axis lead screw nut on the gantry beam and can move along the length of the beam. The intermediate slide is mounted on one side of the slide saddle, and the spindle box slides in cooperation with the Z-axis guide rail of the intermediate slide.

[0011] The five-axis swivel head is rigidly connected to the end of the spindle box away from the slide saddle. The tool post of the integrated centralized tool magazine is fixed to the gantry beam. Independent servo automatic fixtures are arranged at intervals along the length of the bed. The bottom of the independent servo automatic fixture is equipped with a fixture gear and a fixture slider. The fixture gear meshes with the fixture rack on the side of the bed, and the fixture slider slides with the fixture guide rail on the bed.

[0012] In one implementation of the first aspect of the present invention, the five-axis oscillating head includes a B-axis assembly, a C-axis assembly, and an electric spindle; the C-axis assembly includes a C-axis housing, a C-axis servo motor, a C-axis drive wheel, a C-axis synchronous belt, a C-axis driven wheel, and a C-axis reducer. The C-axis housing is rigidly connected to the spindle box of the XYZ gantry via a flange. The fixed ends of the C-axis servo motor and the C-axis reducer are both fixedly mounted on the C-axis housing. The output end of the C-axis servo motor is connected to the C-axis drive wheel and is connected to the C-axis driven wheel via the C-axis synchronous belt. The C-axis driven wheel is fixedly connected to the input end of the C-axis reducer, and the output end of the C-axis reducer is rigidly connected to the B-axis housing of the B-axis assembly.

[0013] The B-axis assembly includes a B-axis housing, a B-axis servo motor, a B-axis drive pulley, a B-axis synchronous belt, a B-axis driven pulley, a B-axis reducer, a B-axis encoder, a reducer side support plate, and a swing arm.

[0014] The fixed ends of the B-axis servo motor and the B-axis reducer are fixed to the B-axis housing. The output end of the B-axis servo motor is connected to the B-axis drive wheel, which is connected to the B-axis driven wheel via the B-axis synchronous belt. The B-axis driven wheel is fixed to the input end of the B-axis reducer. The output end of the B-axis reducer is fixedly connected to the reducer side support plate. The reducer side support plate is fixedly connected to the swing arm. The electric spindle is fixed on the swing arm.

[0015] As a further limitation of the first aspect of the present invention, the C-axis assembly also includes a C-axis encoder, the C-axis encoder stator is fixedly mounted on the C-axis housing by a C-axis encoder bracket, the C-axis encoder rotor is coaxially fixedly connected to the C-axis driven wheel, and the C-axis assembly also includes a C-axis pneumatic brake disc, which is assembled between the output end of the C-axis reducer and the B-axis housing.

[0016] The B-axis assembly also includes a B-axis encoder. The rotor of the B-axis encoder is fixed on a second encoder bracket, which is mounted on a swing arm and rotates with it. The stator of the B-axis encoder is mounted on a first encoder bracket, which is installed together with a support sleeve and fixed to the B-axis housing.

[0017] As a further limitation of the first aspect of the present invention, the B-axis assembly also includes a B-axis pneumatic brake disc, which is mounted between the output end of the B-axis reducer and the side support plate of the reducer.

[0018] In one implementation of the first aspect of the present invention, the integrated centralized tool magazine further includes a tool disc, an extension drive mechanism, and an automatic door;

[0019] The extension drive mechanism includes an electromechanical integrated base, a servo motor, a coupling, a lead screw, and a lead screw nut. The electromechanical integrated base is fixed to the tool post, the servo motor is installed inside the electromechanical integrated base, the output end is connected to the lead screw through the coupling, the lead screw nut is threadedly engaged with the lead screw, and is fixed to the gantry fixed bracket through the lead screw nut fixing plate.

[0020] The cutter head has a layered structure with multiple tool changing zero points. The cutter head is connected to the reducer rotor through the lower connecting sleeve. The reducer stator is fixed to the receiving plate. The receiving plate is also connected to the upper connecting sleeve and the cutter head servo motor. The upper connecting sleeve is fixed to the tool holder. The automatic door is hinged to the tool holder. A U-shaped rod and a pull rod are provided between the automatic door and the tool holder. When the tool holder is fed, it drives the automatic door to open and close synchronously.

[0021] In one implementation of the first aspect of the present invention, the independent servo automatic fixture further includes a servo motor, a reducer, a positioning gripper, a free gripper, a clamp, a positioning plate, and a cylinder; the servo motor is connected to the reducer, the output end of the reducer is fixedly connected to a gear, and the gear meshes with a rack on the bed; the positioning gripper is fixed to the side of the fixture body by a positioning bar and a self-locking knob plunger, and the free gripper is slidably connected to the guide rail on the fixture body;

[0022] The button is located on the side of the free gripper. Pressing the button allows adjustment of the relative position between the free gripper and the fixture rack. The cylinder is connected to the fixture rack, and the piston rod extends to drive the free gripper to move towards the positioning gripper. The clamp is located on the side of the fixture body and cooperates with the guide rail on the bed. The positioning plate is connected to the fixture body through primary and secondary lifting cylinders.

[0023] In one implementation of the first aspect of the present invention, the multi-layer slide drive mechanism further includes a servo motor, a synchronous belt drive mechanism, and a Z-axis lead screw; the synchronous belt drive mechanism includes a driving pulley, a synchronous belt, and a driven pulley; the servo motor is mounted on the slide saddle and its output end is connected to the driving pulley; the synchronous belt is sleeved between the driving pulley and the driven pulley; and the driven pulley is fixedly connected to one end of the Z-axis lead screw through a tensioning sleeve.

[0024] The other end of the Z-axis lead screw is fixed to the slide saddle via a bearing seat, and the nut of the Z-axis lead screw is fixed to the spindle box; sprockets are installed at the lower ends of both sides of the middle slide plate, the chain meshes with the sprockets, one end of the chain is connected to the connecting screw and chain fixing block assembly on the slide saddle, and the other end is connected to the fixing blocks on both sides of the spindle box.

[0025] In one implementation of the first aspect of the present invention, the gantry drive mechanism includes a servo motor, a reducer, and a gear; the servo motor is fixed to the column via a flange, its output end is connected to the input end of the reducer, the output end of the reducer is fixed to the gear, the gear meshes with a rack on the side of the bed, and a lubrication assembly is provided on the meshing surface of the gear and the rack.

[0026] In one implementation of the first aspect of the present invention, a water chiller is also included. The water chiller is fixed on a bracket on one side of the bed and includes a water tank, a water pump, a cooling pipe and a temperature sensor. One end of the cooling pipe is connected to the water tank, and the other end is connected to the cooling channel of the electric spindle of the five-axis oscillating head through a rotary joint. The water pump is connected in series with the cooling pipe, and the temperature sensor is installed at the outlet of the cooling pipe.

[0027] It also includes a chip conveyor and a radar sensor. The chip conveyor is installed in the chip removal trough at the bottom of the bed and includes a motor, chain, scraper and discharge port. The motor drives the chain to rotate through a reducer. The scraper is fixed to the chain and scrapes off aluminum chips as the chain moves. The radar sensor is installed below the gantry beam.

[0028] Secondly, the present invention provides a five-axis machining method for aluminum alloy processing.

[0029] A five-axis machining method for aluminum alloy processing, utilizing the five-axis machining system for aluminum alloy processing of the first aspect of the present invention, includes the following processes:

[0030] The control system receives the processing task of aluminum alloy profiles for doors and windows, and generates a processing program according to the processing requirements of the profiles. The processing program includes the action instructions and processing parameters of each component.

[0031] The servo motor of the independent servo automatic fixture is started, and through the meshing transmission between its bottom gear and the rack on the side of the bed, and in conjunction with the sliding engagement between the bottom slider of the fixture and the top guide rail of the bed, each independent servo automatic fixture is driven to move along the length of the bed to the set processing position.

[0032] The aluminum alloy profile blank for doors and windows is placed in the positioning area of ​​the independent servo automatic fixture, and the independent servo automatic fixture performs a clamping action to fix the profile blank.

[0033] The gantry's drive mechanism starts, and its gears mesh with the rack on the bed, driving the gantry to move along the top guide rail of the bed, so that the multi-layer sliding plate drive and the five-axis oscillating head on the gantry approach the blank of the profile to be processed.

[0034] The extension drive mechanism of the integrated centralized tool magazine is activated, driving the tool post to feed in the set direction. At the same time, the tool disc rotates, rotating the target machining tool to the tool change position, completing the docking of the tool with the five-axis tilting head.

[0035] The servo motor driven by the multi-layer slide plate starts, driving the Z-axis lead screw to rotate, which in turn drives the spindle box and the five-axis swivel head to adjust their height along the Z-axis guide rail of the middle slide plate. At the same time, the Y-axis lead screw on the gantry beam drives the slide saddle, which in turn drives the multi-layer slide plate to move along the length of the beam, so that the five-axis swivel head is aligned with the machining start position. The five-axis swivel head starts and adjusts the electric spindle angle to the required machining posture.

[0036] The electric spindle of the five-axis swivel head starts, driving the tool to rotate; the gantry drive mechanism drives the gantry to feed along the X-axis of the bed, and the multi-layer slide drive cooperates to achieve Y-axis and Z-axis feed. The five-axis swivel head maintains the set machining posture and cooperates with the multi-axis feed to perform machining on the aluminum alloy profile blank for doors and windows.

[0037] After the profile processing is completed, the electric spindle stops rotating, the five-axis oscillating head resets, the independent servo automatic fixture releases, and the processed aluminum alloy profile for doors and windows is removed, completing a single processing cycle.

[0038] Compared with the prior art, the beneficial effects of the present invention are:

[0039] This invention innovatively proposes a five-axis machining system for aluminum alloy processing. The core components include a machine bed, a gantry, a multi-layer sliding plate drive mechanism, a five-axis swivel head, an integrated centralized tool magazine, and independent servo automatic fixtures. These components are connected according to a specific logic: the gantry moves in the X-axis direction through the cooperation of a slider and the machine bed guide rails; the multi-layer sliding plate drive mechanism drives the five-axis swivel head to complete Y-axis and Z-axis feeds; the integrated centralized tool magazine is fixed to the gantry beam; and the independent servo automatic fixtures are arranged along the machine bed and positioned via gear and rack transmission. This system solves the problem of traditional aluminum alloy profile processing for doors and windows relying on multiple stand-alone machines, overcoming the cumbersome process of multiple workpiece transfers and the accuracy loss caused by multiple positioning. Through integrated design, multiple processes such as cutting, milling, and drilling are completed in a single system, significantly improving processing integration and overall production efficiency. Simultaneously, it avoids workpiece damage during transfer and the accumulation of errors from multiple clamping operations, providing a stable equipment foundation for high-precision processing of complex and irregularly shaped aluminum alloy profiles.

[0040] This invention optimizes the structure of a five-axis swivel head, which includes a B-axis assembly, a C-axis assembly, and an electric spindle. The C-axis assembly, based on the C-axis housing, drives the B-axis housing to rotate via a servo motor-synchronous belt-reducer transmission chain. The B-axis assembly, using the B-axis housing as a carrier, also drives the swivel arm and electric spindle to swing via a servo motor-synchronous belt-reducer transmission chain. The electric spindle is fixed to the front end of the swivel arm for tool mounting. This invention solves the problems of loose transmission layout and poor multi-axis coordination in traditional five-axis swivel heads, and overcomes the defects of low transmission efficiency and inaccurate tool posture control. Through a compact "motor-synchronous belt-reducer" transmission logic, it ensures stable and precise power transmission between the B-axis and C-axis, improving the coordination of five-axis linkage and the accuracy of machining posture control. At the same time, it avoids tool posture deviation caused by transmission gaps or loose layout during machining, providing reliable transmission guarantee for the machining of complex curved surfaces of aluminum alloy profiles for doors and windows (such as curved fan frames and irregular shaped pressure lines), ensuring that the machining contour of complex structures meets design requirements.

[0041] This invention adds a C-axis encoder and a C-axis pneumatic brake disc to the C-axis assembly of a five-axis swivel head, and a B-axis encoder to the B-axis assembly. The C-axis encoder stator is fixed to the C-axis housing, and the rotor is coaxially linked with the C-axis driven wheel to provide real-time angle feedback. The C-axis pneumatic brake disc is mounted between the C-axis reducer and the B-axis housing to fix the angle. The B-axis encoder stator is fixed to the B-axis housing, and the rotor rotates with the swivel arm to dynamically capture the swing angle. This solves the problems of low angle detection accuracy and lack of a reliable braking mechanism in traditional five-axis swivel heads, overcomes the cumulative deviation caused by single angle detection feedback, and the defect of easy loosening of the swivel head angle during processing. The encoder realizes closed-loop feedback of the angle throughout the entire stroke, which can correct the angle deviation in time and improve the real-time performance and accuracy of angle detection. The pneumatic brake disc can provide stable braking force after the angle is adjusted to the correct position, avoiding angle deviation caused by cutting force during processing, further ensuring the accuracy of angle processing of aluminum alloy profiles for doors and windows (such as bevel angles and slot angles), and reducing scrap caused by angle errors.

[0042] This invention, in the B-axis assembly of a five-axis swivel head, assembles a B-axis pneumatic brake disc between the output end of the B-axis reducer and the side support plate of the reducer, forming a dedicated braking structure for the B-axis. This solves the problem of insufficient braking torque on the B-axis in traditional five-axis swivel heads and overcomes the defect that the B-axis is prone to angle deviation due to insufficient torque in the high-cutting-force machining of aluminum alloy profiles. The B-axis pneumatic brake disc can quickly tighten after the B-axis is adjusted to the target angle, providing a stable braking torque for the B-axis and effectively preventing displacement of the swivel components due to inertia or cutting force, thus improving the stability of maintaining the B-axis angle. At the same time, it avoids changes in tool posture caused by loosening of the B-axis angle, ensuring that the tool always maintains the set posture during the machining of aluminum alloy profiles for doors and windows (such as arc contours and sealing grooves), guaranteeing the consistency of machining dimensions and surface quality.

[0043] This invention optimizes the structure of an integrated centralized tool magazine, comprising a tool holder, a layered tool disc, an extension drive mechanism, and a linked automatic door. The extension drive mechanism drives the tool holder to feed via a servo motor-screw transmission. The tool disc has multiple tool changing zero points and is driven to rotate by a reducer. The automatic door is linked to the tool holder via a U-shaped rod, a pull rod, and a pull rod, opening and closing synchronously during tool holder feed. This solves the problems of low tool changing efficiency and susceptibility to contamination from machining debris in traditional tool magazines, and overcomes the shortcomings of long tool changing times and difficult cleaning of the tool magazine interior in single-tool positions. The layered tool disc and multiple tool changing zero point design can simultaneously accommodate various tools such as saw blades, milling cutters, and drill bits, significantly shortening tool changing time and improving tool changing efficiency. The linked automatic door opens synchronously when the tool disc extends and closes synchronously when it retracts, effectively preventing debris from entering the tool magazine interior, avoiding wear on tools or tool magazine components, extending the service life of tools and the tool magazine, and adapting to the needs of multi-process tool switching in aluminum alloy door and window processing.

[0044] This invention optimizes the structure of a multi-layer slide plate drive mechanism, comprising a servo motor, a synchronous belt drive mechanism, a Z-axis lead screw, and a chain balancing assembly. The servo motor drives the Z-axis lead screw to rotate via the synchronous belt drive, driving the spindle box to feed along the Z-axis guide rail. The sprockets on both sides of the middle slide plate cooperate with the chain, with one end fixed to the slide saddle and the other end connected to the spindle box, balancing the weight of the middle slide plate. This solves the problems of large Z-axis feed load and excessive space occupation in traditional multi-layer slide plate drives, and overcomes the defects of slide plate lifting and tilting deviation caused by gravity and low Z-axis feed accuracy. The synchronous belt drive has buffering and vibration reduction characteristics, which can reduce vibration during power transmission and improve Z-axis feed accuracy. The chain balancing assembly can counteract the weight of the middle slide plate, reduce the load on the Z-axis lead screw, and avoid lead screw wear or feed deviation caused by gravity. At the same time, the compact multi-layer structure makes full use of space, avoids excessive length of the equipment in the Z-axis direction, improves space utilization, and ensures that the five-axis oscillating head can stably adjust the height, adapting to the processing of aluminum alloy profiles for doors and windows of different thicknesses.

[0045] This invention optimizes the gantry drive mechanism, comprising a servo motor, a reducer, gears, and a lubrication assembly for the gear-rack meshing surface. The servo motor is fixed to the gantry column via a flange, and after being reduced in speed by the reducer, it drives the gears to rotate. The gears mesh with the rack on the machine bed to achieve X-axis feed of the gantry. The lubrication assembly on the meshing surface continuously provides lubrication, solving the problems of rapid wear and uneven feed in traditional gantry drive mechanisms with gear-rack transmissions, and overcoming the defects of high resistance and easy wear of components during transmission. The cooperation between the servo motor and the reducer ensures stable and controllable power output, improving the smoothness and positioning accuracy of the gantry's X-axis feed. The lubrication assembly reduces friction during gear-rack meshing, lowers the wear rate of components, extends the service life of the drive mechanism, and avoids transmission jamming or abnormal noise caused by insufficient lubrication. This ensures smooth feed of the gantry during long-stroke processing of aluminum alloy profiles for doors and windows (such as long-size sash frames), reducing the risk of processing interruption.

[0046] This invention innovatively proposes an aluminum alloy machining method utilizing the aforementioned five-axis machining system. The process follows a workflow of "program generation - fixture positioning - loading and clamping - gantry movement - tool recall - posture adjustment - five-axis machining - unloading." In each step, system components work collaboratively, such as independent servo automatic fixture synchronous positioning, integrated centralized tool magazine automatic tool changing, and five-axis tilting head precise posture adjustment. This solves the problems of disordered traditional aluminum alloy machining processes and poor coordination between equipment components, overcoming the shortcomings of easy errors in manual operation and inefficient connection between machining stages. By uniformly generating machining programs and coordinating the actions of each component through the control system, the machining process is ensured to be coherent and orderly, improving overall machining efficiency. Precise coordination of each stage (such as synchronous fixture positioning and gantry movement, and seamless connection between tool recall and tilting head posture adjustment) avoids machining defects caused by operational errors or poor component linkage, while also ensuring dimensional consistency when batch-processing aluminum alloy profiles for doors and windows, reducing scrap rates and lowering production costs.

[0047] Advantages of additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0048] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0049] Figure 1 A schematic diagram of a five-axis machining system for aluminum alloy machining, provided as an exemplary embodiment of the present invention. Figure 1 ;

[0050] Figure 2 A schematic diagram of a five-axis machining system for aluminum alloy machining, provided as an exemplary embodiment of the present invention. Figure 2 ;

[0051] Figure 3 A schematic diagram of a five-axis machining system for aluminum alloy machining, provided as an exemplary embodiment of the present invention. Figure 3 ;

[0052] Figure 4 A schematic diagram of a five-axis machining system for aluminum alloy machining, provided as an exemplary embodiment of the present invention. Figure 4 ;

[0053] Figure 5 A schematic diagram of a multi-layer sliding plate transmission structure provided as an exemplary embodiment of the present invention. Figure 1 ;

[0054] Figure 6 A schematic diagram of a multi-layer sliding plate transmission structure provided as an exemplary embodiment of the present invention. Figure 2 ;

[0055] Figure 7 A schematic diagram of a multi-layer sliding plate transmission structure provided as an exemplary embodiment of the present invention. Figure 3 ;

[0056] Figure 8 A schematic diagram of a multi-layer skateboard transmission structure library provided as an exemplary embodiment of the present invention. Figure 4 ;

[0057] Figure 9 A schematic diagram of a multi-layer sliding plate transmission structure provided as an exemplary embodiment of the present invention. Figure 5 ;

[0058] Figure 10 A schematic diagram of a multi-layer sliding plate transmission structure provided as an exemplary embodiment of the present invention. Figure 6 ;

[0059] Figure 11 A schematic diagram of a multi-layer sliding plate transmission structure provided as an exemplary embodiment of the present invention. Figure 7 ;

[0060] Figure 12 A schematic diagram of a five-axis oscillating head provided for an exemplary embodiment of the present invention. Figure 1 ;

[0061] Figure 13 A schematic diagram of a five-axis oscillating head provided for an exemplary embodiment of the present invention. Figure 2 ;

[0062] Figure 14 A schematic diagram of a five-axis oscillating head provided for an exemplary embodiment of the present invention. Figure 3 ;

[0063] Figure 15 A schematic diagram of an integrated centralized tool magazine provided as an exemplary embodiment of the present invention. Figure 1 ;

[0064] Figure 16 A schematic diagram of an integrated centralized tool magazine provided as an exemplary embodiment of the present invention. Figure 2 ;

[0065] Figure 17 A schematic diagram of an integrated centralized tool magazine provided as an exemplary embodiment of the present invention. Figure 3 ;

[0066] Figure 18 A schematic diagram of an integrated centralized tool magazine provided as an exemplary embodiment of the present invention. Figure 4 ;

[0067] Figure 19A schematic diagram of an independent servo-controlled automatic gripper provided as an exemplary embodiment of the present invention. Figure 1 ;

[0068] Figure 20 A schematic diagram of an independent servo-controlled automatic gripper provided as an exemplary embodiment of the present invention. Figure 2 ;

[0069] Figure 21 A schematic diagram of an independent servo-controlled automatic gripper provided as an exemplary embodiment of the present invention. Figure 3 ;

[0070] Figure 22 A schematic diagram of an independent servo-controlled automatic gripper provided as an exemplary embodiment of the present invention. Figure 4 ;

[0071] 1. C-axis housing; 2. C-axis servo motor; 3. C-axis drive pulley; 4. C-axis synchronous belt; 5. C-axis driven pulley; 6. C-axis RV reducer; 7. C-axis encoder; 8. C-axis pneumatic brake disc; 9. B-axis housing; 10. Electric spindle; 11. B-axis servo motor; 12. B-axis drive pulley; 13. B-axis synchronous belt; 14. B-axis driven pulley; 15. B-axis RV reducer; 16. B-axis encoder; 17. B-axis pneumatic brake disc; 18. Reducer side support plate; 19. Swing arm; 20. Support sleeve; 21. First encoder bracket; 22. Second encoder bracket; 23. C-axis encoder bracket;

[0072] 24. Bed; 25. Gantry; 26. Multi-layer slide structure; 27. Integrated centralized tool magazine; 28. Independent servo automatic fixture; 29. ​​Five-axis swivel head; 30. Power distribution box; 31. Water chiller; 32. Chip conveyor; 33. Radar detection and control system; 34. Gantry drive rack; 35. Gantry slide rail; 36. Fixture drive rack; 37. Fixture slide rail;

[0073] 38. Tool holder; 39. Gantry fixing bracket; 40. Slider; 41. Automatic door; 42. Tool disc; 43. Hinge; 44. U-shaped rod; 45. Pull rod; 46. Servo motor; 47. Coupling; 48. Lead screw; 49. Lead screw nut seat; 50. Lead screw nut fixing plate; 51. Electromechanical integrated base; 52. Tool holder; 53. Tool disc servo motor; 54. Reducer; 55. Upper connecting sleeve; 56. Lower connecting sleeve; 57. Receiving plate; 58. Cutting tool;

[0074] 59. Servo motor; 60. Saddle; 61. Intermediate slide plate; 62. Z-axis lead screw; 63. Chain fixing block; 64. Fixing block; 65. Sprocket; 66. Spindle box; 67. Pointer; 68. Chain; 69. Drive wheel tensioning sleeve; 70. Drive wheel; 71. Synchronous belt; 72. Driven wheel; 73. Driven wheel tensioning sleeve;

[0075] 74. Servo motor; 75. Clamping device; 76. Positioning gripper; 77. Positioning bar; 78. Self-locking rotary plunger; 79. Free gripper; 80. Button; 81. Cylinder; 82. Fixture rack; 83. Fixture guide rail; 84. Intermediate support; 85. Anti-collision block; 86. First-stage lifting cylinder; 87. Second-stage lifting cylinder; 88. Positioning plate; 89. Profile. Detailed Implementation

[0076] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0077] It should be noted that the following detailed descriptions are exemplary and intended to provide further illustration of the invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0078] This implementation proposes a five-axis gantry machining system, such as... Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, the core lies in the coordinated operation of the bed 24, gantry 25, multi-layer slide structure 26, five-axis swivel head 29, integrated centralized tool magazine 27 and independent servo automatic fixture 28 to achieve centralized and high-precision machining of complex processes.

[0079] In this implementation, the bed 24 serves as the overall load-bearing foundation of the system. It is welded from Q345 low-alloy high-strength steel and undergoes overall stress-relief annealing treatment at 600-650℃ for 4 hours after welding to eliminate residual welding stress and prevent deformation after long-term processing. The length of the bed 24 can be adjusted according to customer needs (typically 6-16m). Two parallel rectangular guide rails are machined on the top, with a surface hardness of ≥HRC58 and a straightness of ≤0.01mm / m, providing high-precision X-axis guidance for the gantry 25. A module 3 rack is fixed along the length of the side of the bed 24. The rack teeth are carburized and quenched to a hardness of ≥HRC60, meshing with the gears of the gantry 25 drive mechanism to transmit power. A U-shaped chip removal groove with a width of 200mm and a depth of 150mm is opened at the bottom of the bed 24 for installing the chip conveyor 32. A power distribution box 30 is reserved on one side of the bed 24, and a water-cooled machine 31 is fixed on the right side to ensure stable assembly of auxiliary equipment.

[0080] In this implementation, the gantry 25 is equipped with a gantry drive rack 34, a gantry slide rail 35, a fixture drive rack 36, and a fixture slide rail 37. The gantry 25 is a rigid portal frame consisting of two columns and a crossbeam. The crossbeam is forged from 45# steel and precision machined. It is rigidly connected to the top of the two columns by 12 sets of M24 high-strength bolts. The flatness of the connection surface is ≤0.01mm / 100mm, and the perpendicularity is ≤0.015mm, ensuring that the overall first-order natural frequency of the gantry 25 is ≥450Hz, meeting the rigidity requirements of high-speed machining. A slider 40 is fixed on the inner side of the lower end of the column. The slider 40 is made of HT300 wear-resistant cast iron with a surface hardening hardness ≥HRC50. It slides with the guide rail on the top of the bed 24, and the clearance is controlled by adjusting shims with a thickness of 0.005-0.01mm. A drive mechanism mounting plate is welded to the outer side of the column to fix the gantry drive mechanism. The top of the crossbeam is machined with mounting holes for the Y-axis guide rail and the Y-axis lead screw. The Y-axis guide rail is a hardened linear guide rail that mates with the slide saddle 60 of the multi-layer slide structure 26. The Y-axis lead screw is a precision ball screw (accuracy grade C3) that is fixed to the mounting holes by angular contact ball bearings at both ends. The lead screw 48 nut is fixed to the slide saddle 60 of the multi-layer slide structure 26 to provide power for Y-axis feed.

[0081] Two or more areas can be used as loading / unloading and processing areas. For extra-long materials, no zoning is required; the entire bed and all fixtures are used to serve a single workpiece. For example... Figure 3 As shown, a machine bed can be temporarily divided into a processing area (area A in the diagram) and a loading area (area B in the diagram). In the loading area, loading can be done manually, but not limited to manual loading. In the processing area, a gantry moves in and automatically completes tool changes for autonomous processing. When processing in area A is completed and loading in area B is also completed, the gantry moves to area B for processing, and area A becomes the unloading area. After unloading, it can become the loading area, and this process repeats.

[0082] The gantry drive mechanism includes a servo motor, a planetary reducer, and gears. Optionally, the servo motor is an A6 series 7.5kW motor with a rated speed of 3000r / min, fixed to the column mounting plate via a flange. The output shaft is connected to the input end of the planetary reducer via a shrink sleeve. The reducer is of precision class 3 with a reduction ratio of 1:20, and its output end is connected to the gear via a flat key. The gear has a module of 3, 25 teeth, and a tooth surface hardening hardness ≥HRC60. It meshes with the rack on the 24th side of the bed, and the meshing backlash is controlled at 0.02-0.03mm via an eccentric adjustment mechanism to ensure no axial movement during X-axis feed.

[0083] In this implementation, such as Figure 5 , Figure 6 , Figure 7 , Figure 8 , Figure 9 , Figure 10 and Figure 11As shown, the multi-layer slide structure 26 is the core for achieving precise Y-axis and Z-axis feed of the five-axis oscillating head 29. It includes a slide saddle 60, an intermediate slide 61, a spindle box 66, a servo motor 59, a synchronous belt 71 transmission mechanism, a Z-axis lead screw 62, a chain 68, and a sprocket 65. When the chain 68 moves, the pointer 67 can be used as a reference point for easy adjustment.

[0084] The slide saddle 60 is a QT450 ductile iron box-type structure. A slider 40, matching the Y-axis guide rail of the crossbeam, is fixed at the bottom. A screw 48 nut mounting hole is machined on the right side of the slide saddle 60, securing it to the nut of the Y-axis screw. Rotation of the Y-axis screw drives the slide saddle 60 to move along the Y-axis guide rail, with a feed accuracy of ±0.008mm. The intermediate slide plate 61 is a 50mm thick 6061-T6 aluminum alloy rectangular plate, fixed to the left side of the slide saddle 60. Z-axis guide rails are fixed on both sides, with a straightness of ≤0.005mm / m. The spindle box 66 is a ZG270-500 cast steel part. A slider 40 matching the Z-axis guide rail is fixed on the right side, and a flange surface is machined on the left side. It is rigidly connected to the C-axis housing 1 of the five-axis oscillating head 29 via eight sets of M16 bolts. The flange surface flatness is ≤0.005mm, and the perpendicularity is ≤0.008mm, ensuring the installation accuracy of the five-axis oscillating head 29. Servo motor 59 is a 1FL6 series 5.5kW motor, fixed to the slide saddle 60 by a bracket, and its output end is connected to the drive pulley 70 of the synchronous belt 71 transmission mechanism (the drive pulley 70 is equipped with a drive pulley tensioning sleeve 69); the synchronous belt 71 transmission mechanism includes the drive pulley 70, polyurethane synchronous belt 71 and driven pulley 72, the synchronous belt 71 has an embedded amide tensile layer, and the gear ratio of the drive pulley 70 to the driven pulley 72 is 1:1.5; the driven pulley 72 is connected to the upper end of the Z-axis lead screw 62 through the driven pulley tensioning sleeve 73, the Z-axis lead screw 62 is a precision ball screw (accuracy grade C3), and its lower end is fixed to the bearing seat at the bottom of the slide saddle 60 by an angular contact ball bearing, the lead screw 48 nut is connected to the spindle box 66, the servo motor drives the synchronous belt 71 transmission mechanism to drive the Z-axis lead screw 62 to rotate, and drives the spindle box 66 to feed along the Z guide rail, with a feed accuracy of ±0.005mm.

[0085] In this implementation, sprockets 65 are installed at the lower ends of both sides of the middle slide plate 61, and a chain 68 meshes with the sprockets 65. One end of the chain 68 is connected to the fixed end at the top of the slide saddle 60, and the other end is connected to the follower ends on both sides of the spindle box 66. More specifically, one end of the chain 68 is connected to the connecting screw and chain fixing block 63 on the slide saddle 60, and the other end is connected to the fixing blocks 64 on both sides of the spindle box. Under the action of gravity, the chain 68 always presses the sprockets 65, offsetting about 60% of the gravity of the middle slide plate 61 and reducing the load on the Z-axis lead screw 62.

[0086] In this implementation, such as Figure 12 , Figure 13 and Figure 14As shown, the C-axis assembly is a "static support unit" that provides a fixed connection to the gantry and outputs C-axis rotational driving force; the B-axis assembly is a "rotation-oscillation composite unit" that rotates with the C-axis using the B-axis housing as a carrier, while independently achieving B-axis oscillation; the electric spindle is a "cutting execution unit" that is fixed to the front end of the B-axis swing arm and completes cutting with the movement of the B / C axes and the XYZ-axis feed. The overall layout of this invention is compact, with no interference between the strokes of each motion axis. The C-axis rotation range is 0°~360°, and the B-axis oscillation range is -90°~+90°, meeting the posture adjustment requirements for complex curved surface machining.

[0087] In this implementation, the C-axis assembly is the core connection between the oscillating head and the gantry frame, and also provides rotational power around the vertical C-axis. Its structural features are "stationary housing + rotational transmission chain", and the connection relationships of each component are as follows:

[0088] The C-axis housing 1, serving as the fundamental support for the C-axis assembly, is welded from low-alloy high-strength steel, possessing excellent rigidity and resistance to deformation. After welding, it undergoes overall stress-relief annealing to eliminate residual welding stress and prevent deformation during long-term use. Optionally, the top of the C-axis housing 1 is machined with a flange connection surface, rigidly connected to the gantry spindle box via high-strength bolts. The bolts are evenly distributed, and the preload torque is calibrated to ensure no relative displacement at the connection point. The first-order natural frequency is ≥500Hz, meeting the rigidity requirements of high-speed machining. The internal design of the C-axis housing 1 includes mounting bases for the C-axis servo motor 2, the C-axis RV reducer 6, and the C-axis encoder 7. Each mounting surface is precision milled, with a flatness ≤0.01mm / 100mm and a perpendicularity ≤0.015mm, providing a high-precision mounting reference for internal components.

[0089] In this implementation, the fixed ends of the C-axis servo motor 2 and the C-axis RV reducer 6 are rigidly fixed to the C-axis housing 1, forming a static support foundation. The output end of the C-axis servo motor 2 is connected to the C-axis drive pulley 3 via a flat key, and the power is transmitted to the C-axis driven pulley 5 via the C-axis synchronous belt 4. The C-axis driven pulley 5 is fixedly connected to the input end of the C-axis RV reducer 6, and the output end of the C-axis RV reducer 6 is rigidly connected to the B-axis housing 9. This transmission chain adopts a combination of "servo motor-synchronous belt-RV reducer". The C-axis synchronous belt 4 has buffering and vibration reduction characteristics, while the C-axis RV reducer 6 ensures high transmission accuracy and high torque output. The two work together to achieve a power transmission effect of "high-speed response + high precision + high torque".

[0090] In this implementation, the stator of the C-axis encoder 7 is fixed to the stationary end of the C-axis housing 1, and the rotor of the C-axis encoder 7 is coaxially fixed to the C-axis driven wheel 5 through the C-axis encoder bracket 23. The rotation angle signal of the transmission chain is collected in real time to provide closed-loop feedback for the CNC system, ensuring that the C-axis rotation angle accuracy is ≤0.005°. The C-axis pneumatic brake disc 8 is assembled between the output end of the C-axis RV reducer 6 and the B-axis housing 9. It is a normally closed structure. After the angle is adjusted to the correct position, it is vented and braked. The braking torque is ≥1500 N·m, the response time is ≤0.1s, effectively preventing inertial rotation, and the angle holding accuracy is ≤0.002°.

[0091] In this implementation, the B-axis assembly uses the B-axis housing 9 as its core carrier, rotates around the C-axis along with the output end of the C-axis assembly, and simultaneously independently oscillates around the horizontal axis of the B-axis. Its structural features are "rotating carrier + oscillating transmission chain," and the connection relationships of each component are as follows:

[0092] The B-axis housing 9, serving as the integrated carrier for the B-axis assembly, is die-cast from ZL201 aluminum alloy. The die-casting process ensures a dense structure and lightweight design. After die-casting, it undergoes T6 heat treatment for solution treatment and artificial aging, achieving a tensile strength ≥320MPa and a yield strength ≥280MPa. This reduces overall weight while maintaining rigidity, thus minimizing the rotational load on the C-axis. The left side of the B-axis housing 9 has a flange surface machined to mate with the output end of the C-axis RV reducer 6, with a clearance ≤0.01mm to ensure smooth power transmission. Inside the housing are mounting bases for the B-axis servo motor 11 and the B-axis RV reducer 15, as well as wiring channels. The parallelism of each mounting surface is ≤0.015mm / total length, and the channel diameter is ≥30mm, facilitating wiring integration and cable avoidance during movement.

[0093] The fixed ends of the B-axis servo motor 11 and the B-axis RV reducer 15 are fixedly mounted on the B-axis housing 9 and rotate synchronously with the B-axis housing 9. The output end of the B-axis servo motor 11 is connected to the B-axis drive pulley 12 via a flat key, and the power is transmitted to the B-axis driven pulley 14 via the B-axis synchronous belt 13. The B-axis driven pulley 14 is fixedly connected to the input end of the B-axis RV reducer 15. The output end of the B-axis RV reducer 15 is welded to the reducer side support plate 18, and the reducer side support plate 18 is then connected to the B-axis swing arm 19 by bolts. The output torque of the B-axis RV reducer 15 is ≥1400N. m, to meet the swing load requirements of the B swing arm 19 and the electric spindle 10.

[0094] In this implementation, the rotor of the B-axis encoder 16 is fixed to the moving end of the B-axis swing arm 19 via the second encoder bracket 22, and the stator of the B-axis encoder 16 is fixed to the carrier end of the B-axis housing 9 via the first encoder bracket 21 and the support sleeve 20. During the swing, the angle signal is collected in real time to form a closed-loop control. The swing angle accuracy is ≤0.005°. The B-axis pneumatic brake disc 17 is assembled between the output end of the B-axis RV reducer 15 and the reducer side support plate 18. It has the same structure as the C-axis pneumatic brake disc 8. After the swing is in place, it is braked and fixed. The angle maintenance accuracy is ≤0.002°, ensuring the stability of the tool posture during the cutting process.

[0095] The B-arm swing arm 19 is made of 6061-T6 aluminum alloy forging. The forging process ensures that the component has a dense structure and uniform mechanical properties. After T6 heat treatment, the tensile strength is ≥300MPa. The front end of the swing arm is machined with a mounting flange for the electric spindle 10. The flatness of the flange surface is ≤0.005mm, and the perpendicularity is ≤0.008mm. The electric spindle 10 is rigidly fixed to the B-arm swing arm 19 through the front flange. The pre-tightening torque of the connecting bolts has been calibrated to ensure that there is no relative displacement between the electric spindle 10 and the B-arm swing arm 19, and the radial runout of the mating surface is ≤0.005mm.

[0096] In this implementation, a dedicated wiring channel is designed inside the B-axis housing 9, integrating the power cable of the electric spindle 10, the cable of the C-axis servo motor 2, the cable of the B-axis servo motor 11, the signal cable of the C-axis encoder 7, the signal cable of the B-axis encoder 16, and the air pipes of the C-axis pneumatic brake disc 8 and the B-axis pneumatic brake disc 17. The cables are high-flexibility drag chain cables, with a bending resistance of ≥10 million cycles. The air pipes are made of PU material, possessing wear-resistant and aging-resistant properties. All lines and pipes are centrally laid through PA66 nylon conduits, arranged according to functional zones: power cable conduits, signal cable conduits, and pneumatic pipe conduits. The minimum spacing between conduits is ≥5mm to avoid electromagnetic interference from power cables to signal cables and to prevent pipe entanglement or wear during movement. After the wiring exits from the B-axis housing 9, it connects to the fixed wiring in the C-axis housing 1 via a rotary joint. The rotary joint supports 360° unlimited rotation with a leakage rate ≤0.1L / min, ensuring the reliability of the wiring connection and the flexibility of movement.

[0097] In this implementation, the C-axis housing 1 is rigidly connected to the XYZ gantry spindle box via a top flange. The gantry spindle box is the core actuator for XYZ axis feed: the X-axis feeds along the length of the gantry beam, the Y-axis feeds along the width of the beam, and the Z-axis feeds vertically. All three axes use precision ball screw drives, with a positioning accuracy of ±0.01mm and a repeatability of ±0.008mm. After the five-axis tilting head is fixed, it achieves linear feed in the XYZ directions along with the spindle box. Simultaneously, angle adjustment is achieved through C-axis rotation and B-axis oscillation, ultimately forming a five-axis linkage of X / Y / Z / B / C, meeting the multi-pose machining requirements of complex aluminum alloy components.

[0098] The specific working principle is as follows:

[0099] After the CNC system issues a C-axis rotation command, the C-axis servo motor 2 starts, and its output torque is transmitted to the C-axis drive wheel 3 via a flat key, and then to the C-axis driven wheel 5 via the C-axis synchronous belt 4. The C-axis driven wheel 5 drives the input end of the C-axis RV reducer 6 to rotate. The C-axis RV reducer 6 reduces the speed and amplifies the torque, then drives the B-axis housing 9 and the B-axis assembly and electric spindle 10 to rotate around the C-axis via its output end. During the rotation, the C-axis encoder 7 collects angle signals in real time and transmits them to the CNC system. The system calculates the position deviation using a PID algorithm and dynamically adjusts the output of the C-axis servo motor 2 to form a closed-loop control. When the target angle is reached, the system issues a braking command, the C-axis pneumatic brake disc 8 is vented and tightened, fixing the position of the B-axis housing 9 and completing the C-axis angle adjustment. The C-axis rotation speed range is 0~30 r / min, which can be steplessly adjusted by the CNC system according to machining requirements.

[0100] After the CNC system issues a B-axis swing command, the B-axis servo motor 11 starts, and the output torque is transmitted to the B-axis RV reducer 15 via the B-axis drive wheel 12, B-axis synchronous belt 13, and B-axis driven wheel 14. The output end of the B-axis RV reducer 15 drives the reducer side support plate 18 and the B-axis swing arm 19 to swing around the B-axis. During the swing, the B-axis encoder 16 collects the swing angle signal in real time and feeds it back to the CNC system for deviation correction to ensure swing accuracy. After swinging to the target angle, the B-axis pneumatic brake disc 17 is vented and braked to fix the position of the B-axis swing arm 19. The B-axis swing speed range is 0~20° / s, and the swing angle range is -90°~+90°, which can cover the processing posture requirements of most complex aluminum alloy components.

[0101] The five-axis oscillating head is fixed to the gantry spindle box via the C-axis housing 1. It achieves linear feed in the XYZ directions along the spindle box. The X-axis feeds along the gantry beam, the Y-axis feeds laterally along the spindle box, and the Z-axis moves up and down vertically. All three axes are driven by servo motors with precision ball screws. The maximum feed speeds can reach 20m / min, 15m / min, and 10m / min respectively, with a positioning accuracy of ±0.01mm, providing a high-precision linear feed foundation for five-axis linkage.

[0102] To achieve high-precision machining of complex curved surfaces of aluminum alloys, this invention may optionally employ a five-axis linkage kinematic model based on a homogeneous transformation matrix to establish a mapping relationship between the machine tool coordinate system and the workpiece coordinate system, as follows:

[0103] Coordinate system definition: The origin of the machine tool coordinate system O-XYZ is located at the center of the gantry worktable. The X-axis is along the length of the bed, the Y-axis is along the length of the crossbeam (perpendicular to the length of the bed), and the Z-axis is vertically upward. The C-axis rotary coordinate system O1-X1Y1Z1 rotates around the Z-axis with a rotation angle of γ. The B-axis oscillating coordinate system O2-X2Y2Z2 oscillates around the X1 axis with an oscillation angle of β. The origin of the tool coordinate system O3-X3Y3Z3 is located at the tool tip, and the Z3 axis coincides with the axis of the electric spindle 10 along the tool axis.

[0104] Homogeneous transformation matrix: The homogeneous transformation matrix of a five-axis linkage is the product of the transformation matrices of each axis, i.e.:

[0105] ;

[0106] in, The XYZ axis translation transformation matrix. Associating the C-axis rotation transformation matrix with the drive angle of the C-axis servo motor 2, Associating the B-axis rotation transformation matrix with the drive angle of B-axis servo motor 11, This is the tool offset transformation matrix. This matrix can be used to realize the coordinate transformation from any point in the workpiece coordinate system to the machine tool coordinate system, providing a theoretical basis for interpolation calculation in CNC systems.

[0107] Interpolation and Control: The CNC system employs the NURBS non-uniform rational B-spline interpolation algorithm to discretize the complex surface of the CAD model into minute line segments. Through look-ahead processing, the curvature of these segments is analyzed, and the feed rate is dynamically adjusted to ensure smooth cutting. The system uses inverse kinematics to decompose the surface machining path into displacements along the XYZ axes and angular changes along the B / C axes. The interpolation cycle is 0.1 ms, the interpolation accuracy is ≤0.001 mm, and the synchronization error of each axis is ≤0.01 mm.

[0108] Optionally, the five-axis linkage control of the present invention adopts a "master-slave control + closed-loop feedback" architecture, with the following core components:

[0109] Main controller: It adopts an industrial-grade high-end CNC system, equipped with a high-performance processor and large-capacity storage, and supports functions such as multi-axis synchronous control, 3D graphics simulation, and parametric programming. It can process machining data of complex curved surfaces in real time.

[0110] Servo drive module: It adopts a vector control type servo driver, which is matched with the C-axis servo motor 2, the B-axis servo motor 11 and the XYZ-axis servo motors respectively. The control cycles of the current loop, speed loop and position loop are 0.02ms, 0.1ms and 0.1ms respectively, ensuring that the motor responds quickly and runs smoothly.

[0111] Feedback module: The signals from the C-axis encoder 7, B-axis encoder 16, and XYZ-axis grating ruler are transmitted to the main controller in real time via a high-speed industrial bus with a transmission rate ≥100Mbps and a delay ≤1ms, ensuring the real-time performance and accuracy of angle and position feedback.

[0112] Safety control module: Integrates safety functions such as safety torque shutdown (STO) and safety stop (SS1). When overload, overtravel, emergency stop or other abnormalities occur, the torque of C-axis servo motor 2, B-axis servo motor 11 and XYZ-axis servo motors is immediately cut off, and C-axis pneumatic brake disc 8 and B-axis pneumatic brake disc 17 are simultaneously tightened to prevent equipment damage and personnel injury.

[0113] In this implementation, such as Figure 15 , Figure 16 , Figure 17 and Figure 18 As shown, the integrated centralized tool magazine 27 is fixed to the crossbeam of the gantry 25 by four sets of M20 bolts and is located on the right side of the five-axis swivel head 29. It includes a tool holder 38, a tool disc 42, an extension drive mechanism, and an automatic door 41.

[0114] In this implementation, the tool holder 38 is a welded frame of Q235 steel, measuring 800mm × 600mm × 300mm, with linear guides welded to both sides. The extension drive mechanism includes an integrated electromechanical base 51, a tool head servo motor 53, a coupling 47, a lead screw 48, and a lead screw nut 49. The integrated electromechanical base 51 is a ZL102 cast aluminum part, fixed to the tool holder 38, and has a motor cavity and a lead screw cavity 48 inside. The tool head servo motor 53 is a J4 series 2kW motor, fixed to the integrated electromechanical base 51. The output end of the machine cavity is connected to the lead screw 48 via a coupling 47. The lead screw 48 is a precision ball screw (accuracy grade C3), and both ends are fixed to the electromechanical integrated base 51 via deep groove ball bearings. The lead screw nut 49 is threadedly engaged with the lead screw 48 and is fixed to the gantry fixed bracket 39 via the lead screw nut fixing plate 50. The gantry fixed bracket 39 is connected to the crossbeam. When the cutter head servo motor 53 drives the lead screw 48 to rotate, it drives the electromechanical integrated base 51 and the cutter post 38 to feed along the guide rail with a feed accuracy of ±0.01mm.

[0115] In this implementation, the cutter head 42 is a 6061-T6 aluminum alloy layered disc with a diameter of 600mm and a 3-layer design: the upper layer installs 3 saw blades (φ100-600mm), the middle layer installs 12 milling cutters / drills (φ4-20mm), and the lower layer installs 2 angle heads; the cutter head 42 has 17 tool 58 mounting positions uniformly machined around its circumference, each mounting position corresponding to an independent tool changing zero point, with a tool changing accuracy of ±0.005mm; the cutter head 42 is connected to the rotor of the reducer 54 through the lower connecting sleeve 56, the reducer 54 is a planetary reducer (reduction ratio 1:10), the stator is fixed to the receiving plate 57, the receiving plate 57 is also connected to the upper connecting sleeve 55 and the cutter head servo motor 53, and the upper connecting sleeve 55 is fixed to the tool holder 38; the cutter head servo motor 53 drives the rotor of the reducer 54 to rotate, which drives the lower connecting sleeve 56 and the cutter head 42 to rotate synchronously, realizing the tool 58 switching, with a tool changing time ≤2s.

[0116] The automatic door 41 is made of Q235 arc-shaped steel plate and is hinged to the tool holder 38 via hinge 43. A U-shaped rod 44 is welded to the inside, and the U-shaped rod 44 is connected to the tool holder 38 via a pull rod 45. When the tool holder 38 feeds outward, the pull rod 45 pulls the U-shaped rod 44 through the action of the servo motor 46, which drives the automatic door 41 to open. When the tool holder 38 retracts, the pull rod 45 pushes the U-shaped rod 44, which drives the automatic door 41 to close. A nylon brush is attached to the inside of the automatic door 41 to prevent flying chips from entering the tool disc 42 during processing.

[0117] In this implementation, such as Figure 19 , Figure 20 , Figure 21 and Figure 22 As shown, independent servo automatic fixtures 28 are arranged along the length of the bed 24 (e.g., 8-16). Each fixture is an independent control unit, including a fixture body, a servo motor 74, a reducer, gears, a fixture rack 82, a positioning gripper 76, a free gripper 79, a clamp 75, a positioning plate 88, a first-stage lifting cylinder 86 and a second-stage lifting cylinder 87. The fixture body is equipped with anti-collision blocks 85.

[0118] In this implementation, the fixture body is a ZL201 cast aluminum box, and the bottom of the fixture body is fixed with a slider and gear mounting seat that match the bed guide rail; the servo motor 74 is preferably an A6 series 1.5kW motor, which is fixed to the side of the fixture body by a bracket, and the output end is connected to a reducer (reduction ratio 1:30). The output end of the reducer is connected to a gear through a flat key. The gear has a module of 2 and 20 teeth, and meshes with the fixture drive rack 36 on the bed 24 to drive the fixture to move along the bed, with a positioning accuracy of ±0.01mm.

[0119] The clamp rack 82 is a 45# steel rack with a module of 2, fixed to the side of the clamp body. The positioning jaw 76 is an L-shaped Q235 steel plate, fixed to the side of the clamp body by a positioning strip 77 and a self-locking knob plunger 78. Pressing the self-locking knob plunger 78 can adjust the position of the positioning jaw 76, and releasing it will automatically lock it. The free jaw 79 slides with the jaw guide rail 83 on the side of the clamp body. A button 80 is provided on the side. Pressing the button 80 can release the free jaw 79 and move it to the target position along the jaw guide rail 83. Releasing the button 80 will result in initial positioning (the button is connected to the movable positioning part, which has teeth that mesh and fix with the clamp rack 82). The clamping cylinder 81 is an SMCCDQ2B32-50D type, with the cylinder body fixed to the clamp body and the piston rod connected to the clamp rack 82. The clamping force is adjustable from 500 to 1000N.

[0120] In this implementation, the clamp 75 is an NBKMPS20 type, fixed to the side of the clamping body and cooperating with the bed guide rail. When power is lost, the clamping force is ≥5kN. The positioning plate 88 is a Q235 steel plate, fixed to the clamping body by a two-stage lifting cylinder 81. The first-stage cylinder 81 has a stroke of 170mm, the second-stage cylinder 81 has a stroke of 170mm, and the total stroke is 340mm. The height of the positioning plate 88 can be adjusted according to the profile height to assist in profile positioning. The positioning accuracy is ±0.02mm.

[0121] When processing extra-long profiles, such as Figure 22 As shown, the profile 89 has a large volume and length. An intermediate support 84 is installed between adjacent clamps. The slider of the intermediate support 84 cooperates with the gripper guide rail 83. An adjustable support block is provided at the top. The height can be adjusted by handwheel to prevent the profile from bending due to its own weight.

[0122] In this implementation, the distribution box 30 is fixed to the left side mounting position of the bed 24 by M8 bolts. It is a cold-rolled steel plate powder-coated structure (IP54 protection), with dimensions of 800mm×600mm×400mm. It contains a power supply module, a control module, and wiring terminals. The power supply module is a Mean Well SE-1000-24 type switching power supply, which converts 380V AC power to 220V / 24V DC power and supplies power to various components through the wiring terminals. The control module is an S7-1200CPU1214C type PLC, which communicates with the radar detection and control system 33 through the Profinet bus, receives control commands and feeds back the status of components, and also has overload, short circuit, and leakage protection functions.

[0123] In this implementation, the water chiller 31 is fixed to the right side bracket of the bed 24. It is a CW-6000 industrial chiller (6kW cooling capacity), which includes a water tank, a water pump, cooling pipes, and a temperature sensor. The water tank has a volume of 50L and is filled with deionized water. The water pump is a CDL2-12 type with a flow rate of 15L / min, connected in series with the cooling pipes. The cooling pipes are made of PU tubing (16mm inner diameter, 22mm outer diameter), with one end connected to the water tank and the other end connected to the cooling channel of the electric spindle 10 through a rotary joint, forming a closed loop. The temperature sensor is a PT100 type (accuracy class A), installed at the outlet of the cooling pipes, which monitors the coolant temperature in real time. When the temperature exceeds 25℃, the water chiller 31 is triggered to increase the cooling power to ensure that the temperature is stable at 20-25℃.

[0124] In this implementation, the chip conveyor 32 is installed in the chip removal trough at the bottom of the machine bed 24. It is a scraper chain structure, including a motor, chain, scraper, and discharge port. The motor has a power of 1.5kW and a speed of 1450r / min, and drives the chain through a reducer with a reduction ratio of 1:50. The chain is made of 304 stainless steel with a pitch of 25.4mm. The scraper is made of NM400 wear-resistant steel plate (5mm thick), fixed to the chain, with a spacing of 150mm, and fits against the bottom of the chip removal trough. The aluminum chips generated during processing are scraped and sent to the discharge port by the scraper. A 500L chip collection box is provided below the discharge port. The chip conveyor 32 is electrically connected to the radar detection and control system 33, and can automatically start and stop according to the processing rhythm. The chip removal capacity is ≥50L / h.

[0125] In this implementation, the radar detection and control system 33 is mounted on a bracket below the crossbeam of the gantry 25, facing the processing area of ​​the independent servo automatic fixture 28. It includes a radar sensor and a signal processor. The radar sensor is a Pepperl+Fuchs R2000 24GHz millimeter-wave radar with a detection range of 0.5-5m and a detection angle of 120°, and is fixed to the bracket with bolts. The signal processor is an STM32F103RCT6, which is connected to the radar sensor via an RS485 bus and communicates with the radar detection and control system 33 via an industrial Ethernet. When personnel or foreign objects are detected entering the processing area (distance ≤1m), the signal processor sends a stop signal to the radar detection and control system 33 within 1 second, triggering an emergency stop of the equipment.

[0126] In this implementation, the radar detection and control system 33 is a CX2030 five-axis CNC system, installed on the cold-rolled steel plate operation console. The console is equipped with a 15-inch touch screen and operation buttons 80 on the outside, and a cooling fan inside. The radar detection and control system 33 integrates order splitting software and software, which can import ERP order information (Excel format), automatically split orders and generate machining programs. It is electrically connected to each component through an EtherCAT bus (control cycle 0.1ms) to achieve multi-axis synchronous control. It also has a status monitoring function, which displays machining progress, component temperature, fault information, etc. in real time, and supports remote diagnosis and data export.

[0127] This system uses radar detection and control system 33 to coordinate the operation of each component according to the five-step logic of "processing preparation - loading and clamping - tool 58 calling - five-axis machining - unloading and cleaning", realizing the fully automated processing of aluminum alloy profiles for doors and windows. The actions at each stage are precisely coordinated, as follows:

[0128] (a) Processing preparation stage (program and component pre-positioning).

[0129] Program generation: Operators input ERP order information (such as the quantity and size of irregular sash frames for casement windows) through the touch screen of the control console. The order splitting software of the radar detection and control system 33 splits the batch orders into individual processing tasks. The software imports the profile 3D model (STEP / IGES format), plans processes such as cutting, milling, and drilling, sets processing parameters (such as roughing speed of 6000r / min, feed rate of 8m / min, and depth of cut of 2mm), assigns tools 58 (such as φ12mm carbide end mills for roughing), and automatically stores the generated processing program in memory.

[0130] Fixture positioning: The radar detection and control system 33 sends positioning commands to the servo motors of each independent servo automatic fixture 28. The servo motors start, and the output torque is reduced by the reducer and then transmitted to the gears. The gears mesh with the bed rack, driving the fixtures to move along the bed guide rail to the set position (e.g., when machining an 1800mm long fan frame, the distance between adjacent fixtures is 150mm). After the fixtures are in place, the radar detection and control system 33 commands the clamp 75 to de-energize, and the clamp 75 clamps the guide rail to fix the fixture position. At the same time, the piston rod of the lifting cylinder 81 extends, driving the positioning plate 88 to a height of 20mm to form a profile positioning reference surface.

[0131] Tool magazine and auxiliary preparation: The servo motor of the tool head 42 of the integrated centralized tool magazine 27 starts, driving the reducer rotor to rotate, which in turn drives the tool head 42 to rotate the tool 58 (such as a φ12mm end mill) required for the first process to the tool change zero point; the servo motor of the extended drive mechanism is in standby mode; the water chiller 31 starts, the water pump runs, the coolant circulates in the cooling pipes, the temperature sensor monitors the temperature and stabilizes it at 22℃; the chip conveyor 32 and the radar detection and control system 33 are powered on and enter the working state.

[0132] (II) Material loading and clamping stage (profile fixing and status confirmation)

[0133] Loading operation: The 6063-T5 aluminum alloy blank (e.g., 6m long, 60mm×45mm cross section) is hoisted by a six-axis robot between the positioning jaw 76 and the free jaw 79 of the independent servo automatic fixture 28; the two ends of the profile are aligned with the reference surface of the positioning plate 88. Profiles longer than 6m are supported by the support block of the middle support 84. The handwheel is adjusted to make the support block fit with the bottom of the profile to prevent the profile from bending.

[0134] Workpiece clamping: When the operator presses the "Clamp" button 80 on the control panel, the radar detection and control system 33 commands the solenoid valve at the air inlet of the clamping cylinder 81 to be energized, the piston rod extends, and drives the free gripper 79 to move along the clamp rack 82 to the positioning gripper 76 for clamping; the pressure sensor installed at the air inlet of the cylinder 81 collects the clamping force signal in real time. When the clamping force reaches 800N, the pressure sensor sends a "clamping normal" signal back to the radar detection and control system 33; if the clamping force is insufficient (<500N) or overloaded (>1200N), the touch screen displays an alarm message, and the position of the free gripper 79 needs to be adjusted or the clamping force needs to be corrected by the pressure regulating valve before the clamping action is re-executed.

[0135] (III) Tool calling stage (tool magazine and five-axis oscillating head 29 docking).

[0136] Gantry movement: The radar detection and control system 33 commands the servo motor of the gantry 25 drive mechanism to start, and the output torque is transmitted to the gear through the reducer. The gear meshes with the rack of the bed 24, driving the gantry 25 to move along the bed guide rail to the starting processing position of the profile to be processed (50mm away from the end of the profile). During the movement, the Y-axis lead screw of the crossbeam is finely adjusted to the position of the sliding saddle 60 to ensure that the axis of the electric spindle 10 of the five-axis swivel head 29 is aligned with the center of the profile, and the positioning accuracy is controlled within ±0.01mm.

[0137] Tool magazine feed and tool change: The extension drive mechanism of the integrated centralized tool magazine 27 receives the tool change command, the tool head servo motor 53 starts, and drives the lead screw 48 to rotate through the coupling 47; since the lead screw nut 49 is fixed, the rotation of the lead screw 48 drives the electromechanical integrated base 51 and the tool holder 38 to feed outward along the guide rail; at the same time, the tool holder 38 pulls the U-shaped rod 44 through the pull rod 45, which drives the automatic door 41 to open slowly until the tool head 42 is fully extended from the tool holder 38. When the tool holder 38 is fed to the tool changing position (the distance between the target tool 58 on the tool holder 42 and the tool shank 52 interface of the electric spindle 10 is 100mm), the tool holder servo motor 53 stops; the tool holder servo motor 53 restarts, finely adjusts the angle of the tool holder 42, so that the tool shank 52 of the target tool 58 is aligned with the tool shank 52 interface of the electric spindle 10; the drawbar mechanism inside the electric spindle 10 is activated, and the tool shank 52 is tightened through the drawbar 45, with a clamping force ≥15kN, to complete the installation of the tool 58; after the tool change, the tool holder servo motor 53 reverses, the tool holder 38 retracts, the automatic door 41 closes synchronously, and the brush cleans the residual flying debris on the surface of the tool holder 42.

[0138] (iv) Five-axis linkage machining stage (multi-axis collaboration and precision control).

[0139] Head tilting posture adjustment: The radar detection and control system 33 sends angle adjustment commands to the B-axis servo motor 11 and C-axis servo motor 2 of the five-axis tilting head 29. The B-axis servo motor 11 starts, and the output torque is transmitted to the B-axis driven wheel 14 through the B-axis drive wheel 12 and the B-axis synchronous belt 13. The B-axis driven wheel 14 drives the input end of the B-axis RV reducer 15 to rotate. After deceleration, the B-axis RV reducer 15 drives the output end to drive the reducer side support plate 18 and the tilting arm 19 to swing around the B-axis to the target angle (such as 0°, so that the axis of the tool 58 is perpendicular to the profile surface). The C-axis servo motor 2 starts, and the output torque is transmitted to the C-axis driven wheel 5 through the C-axis drive wheel 3 and the C-axis synchronous belt 4. The C-axis driven wheel 5 drives the input end of the C-axis RV reducer 6 to rotate. After deceleration, the reducer 6 drives the output end to drive the B-axis housing 9 and the electric spindle 10 to rotate around the C-axis to the target angle (such as 0°, so that the tool 58 is aligned with the machining start point). The B-axis encoder 16 and C-axis encoder 7 acquire swing angle and rotation angle signals in real time, and feed them back to the radar detection and control system 33 via the Profinet bus. The radar detection and control system 33 uses a PID algorithm to calculate the position deviation and dynamically adjusts the output of the servo motor to ensure that the angle deviation is ≤0.002°. When the angle is adjusted to the correct position, the B-axis pneumatic brake disc 17 and C-axis pneumatic brake disc 8 are vented, the brake pads clamp the brake discs, and fix the posture of the electric spindle 10 to prevent angle deviation during machining.

[0140] Multi-axis feed machining: The servo motor of the multi-layer slide structure 26 starts, and the output torque is transmitted to the driven wheel 72 via the driving wheel 70 and the synchronous belt 71 of the synchronous belt transmission mechanism. The driven wheel 72 drives the Z-axis lead screw 62 to rotate. The lead screw 48 cooperates with the nut to drive the spindle box 66 to descend along the Z-axis guide rail of the middle slide 61, so that the tool 58 contacts the profile surface and the depth of cut reaches the set value (such as a roughing depth of cut of 2mm). The gantry 25 drive mechanism drives the gantry 25 to feed in the X direction (feed speed 8m / min), while the Y-axis lead screw of the crossbeam drives the saddle 60 to feed in the Y direction (feed speed 5m / min), which cooperates with the Z-axis feed (feed speed 3m / min) to realize the X / Y / Z three-axis linkage. The electric spindle 10 starts, driving the tool 58 to rotate at high speed (6000r / min), and processes the profile according to the tool path generated by the software (such as rough milling the rectangular section outline of the casement window irregular fan frame).

[0141] Process Coordination Control: During machining, the water chiller 31 continuously cools the electric spindle 10. The coolant enters the cooling channel of the electric spindle 10 through the rotary joint, carrying away the heat generated by the high-speed rotation of the electric spindle 10. The temperature sensor monitors the coolant temperature in real time to ensure it remains stable at 22-23℃. The chip conveyor 32 operates synchronously, with scrapers scraping the aluminum chips generated during machining from the chip conveying groove to the chip collection box, preventing aluminum chips from accumulating and scratching the profile surface or affecting the life of the tool 58. The radar sensor of the radar detection and control system 33 continuously scans the machining area. If personnel are detected approaching, a stop signal is immediately sent to the radar detection and control system 33 through the signal processor to ensure operational safety. After a process (such as roughing) is completed, the radar detection and control system 33 instructs the tool magazine 27 to change the tool 58 (such as changing to a φ8mm carbide ball end mill for semi-finishing), repeats the head adjustment steps, and proceeds to the next process.

[0142] (v) Unloading and cleaning stage (finished product removal and equipment reset).

[0143] Material unloading: After all processes are completed, the electric spindle 10 stops rotating, the five-axis oscillating head 29 resets (B-axis 0°, C-axis 0°), and the B-axis pneumatic brake disc 17 and C-axis pneumatic brake disc 8 are released; the tool holder 38 of the integrated centralized tool magazine 27 extends, the tool disc 42 rotates to retract the tool 58, the tool holder 38 retracts, and the automatic door 41 closes; the piston rod of the clamping cylinder 81 of the independent servo automatic fixture 28 retracts, the free gripper 79 is released, and the positioning plate 88 and the intermediate support 84 descend; the six-axis robot lifts the processed profile (such as the irregular fan frame of a casement window) to the finished product area and places it on a rubber buffer pad to prevent bumps.

[0144] Cleaning: Chip conveyor 32 continues to run for 5 minutes to clean the residual aluminum chips in the chip conveying groove; water chiller 31 stops running after the temperature of electric spindle 10 drops to 25℃; the operator uses a compressed air gun to clean the aluminum chips on the surface of the five-axis oscillating head 29, tool magazine 27, and fixture 28, and checks the wear of tool 58 (if the wear of the milling cutter edge is >0.1mm, tool 58 should be replaced); radar detection and control system 33 automatically saves the processing data (processing time, accuracy detection results, equipment operating parameters), generates a production report, and waits for the next batch of processing tasks.

[0145] In this implementation, optionally, a casement window frame with an irregular shape (arc structure, requiring machining on all six sides) is used as an example to explain the machining process in detail and verify the system performance, as follows:

[0146] (a) Profile parameters and processing requirements.

[0147] Profile parameters: Material: 6063-T5 aluminum alloy, total length: 1800mm, rectangular section: 60mm×45mm, both ends are 1 / 4 arc (radius of curvature R200mm), two sealing grooves are machined on the inner side (5mm wide, 8mm deep, groove spacing: 30mm), and the four outer corners are R5mm rounded.

[0148] Accuracy requirements: dimensional tolerance ±0.03mm, arc profile ≤0.05mm, bevel perpendicularity ≤0.02mm, surface roughness Ra≤0.8μm, batch processing 500 pieces.

[0149] (ii) Processing preparation.

[0150] Program and parameter settings: The radar detection and control system 33 generates a three-level machining program with the following parameters:

[0151] Roughing: Use a φ12mm carbide end mill with an integrated centralized tool magazine 27, an electric spindle speed of 6000r / min, X / Y feed rate of 8m / min, Z-axis depth of cut of 2mm, and leave 0.3mm finishing allowance;

[0152] Semi-finishing: Replace with a φ8mm carbide ball end mill, electric spindle 10 with a speed of 9000r / min, feed rate of 5m / min, Z-axis depth of cut of 0.3mm, and leave a finishing allowance of 0.1mm;

[0153] Finishing: Use a φ6mm diamond-coated ball end mill, with an electric spindle speed of 15000r / min, a feed rate of 3m / min, and a Z-axis depth of cut of 0.1mm; for machining the sealing groove, use a φ5mm solid carbide slot end mill, with an electric spindle speed of 10000r / min and a feed rate of 3m / min; for deburring, use a φ5mm nylon brush, with an electric spindle speed of 3000r / min and a feed rate of 1m / min.

[0154] Fixture and tool magazine preparation: 12 independent servo automatic fixtures 28 are positioned along the bed 24 at 150mm intervals, and clamps 75 clamp the guide rails; positioning plates 88 are raised to a height of 20mm; the integrated centralized tool magazine 27 rotates the φ12mm end mill to the tool change zero point; the water chiller 31 is started, and the coolant temperature is stabilized at 22℃; the chip conveyor 32 and the radar detection and control system 33 enter the working state.

[0155] (iii) Processing procedure.

[0156] Material loading and clamping: The six-axis robot hoists a 6m long 6063-T5 aluminum alloy blank to the positioning jaw 76 and free jaw 79 of the fixture 28, with intermediate support 84 providing auxiliary support; the clamping cylinder 81 clamps the blank with a clamping force of 800N, and the pressure sensor confirms that the clamping status is normal.

[0157] Rough processing, specifically, includes:

[0158] The gantry 25 moves along the X direction to the starting end of the profile, the tool holder 38 of the integrated centralized tool magazine 27 feeds, the automatic door 41 opens, the cutter head 42 aligns the φ12mm end mill with the electric spindle 10, the tool puller mechanism clamps the tool 58, the tool holder 38 retracts, and the automatic door 41 closes.

[0159] The B-axis of the five-axis oscillating head 29 swings 0°, the C-axis rotates 0°, and the pneumatic brake disc is engaged.

[0160] The electric spindle 10 starts, the multi-layer slide structure 26 drives the Z-axis feed (2mm depth of cut), the gantry 25 feeds along the X-axis (8m / min), the layer milling removes the blank allowance, the chip conveyor 32 removes chips synchronously, after roughing the rectangular section cross-section size is 60.3mm×45.3mm, the arc section leaves a 0.3mm allowance.

[0161] Semi-finishing, specifically, includes:

[0162] The integrated centralized tool magazine 27 allows for the replacement of φ8mm ball end mills, the tool head 42 provides rotational positioning, and the electric spindle 10 clamps the tool 58.

[0163] The B-axis of the five-axis oscillating head 29 is dynamically adjusted according to the arc tangent angle (0°-±15°), the C-axis rotates in coordination, and the encoder feeds back the angle deviation and corrects it.

[0164] The electric spindle 10 operates at 9000 r / min with a feed rate of 5 m / min. It fits and mills along the profile contour, corrects roughing errors, and after semi-finishing, the rectangular section has a cross-sectional size of 60.1 mm × 45.1 mm, a circular arc profile of ≤ 0.06 mm, and a 0.1 mm finishing allowance.

[0165] Finishing, specifically, includes:

[0166] Replace with a φ6mm diamond-coated end mill, electric spindle 10 with a speed of 15000r / min and a feed rate of 3m / min, use NURBS interpolation algorithm to fine mill the contour, the rectangular section size reaches 60±0.02mm×45±0.02mm, and the arc contour accuracy is 0.04mm;

[0167] Use a φ10mm carbide end mill, an electric spindle with a speed of 12000r / min and a feed rate of 4m / min, to machine 45° bevel angles at both ends. The perpendicularity test result is 0.015mm.

[0168] Use a φ5mm slot end mill, an electric spindle with a speed of 10000r / min and a feed rate of 3m / min to machine a sealing groove along the inner side of the profile. The groove width is 5±0.01mm and the depth is 8±0.02mm.

[0169] Replace with φ5mm nylon brush, electric spindle 10 speed 3000r / min, feed speed 1m / min, remove burrs from the four outer corners to form R5mm rounded corners, surface roughness Ra0.6μm.

[0170] In summary, this system precisely addresses the industry pain points of "low efficiency, poor precision, and weak versatility" in the processing of aluminum alloy profiles for doors and windows. It can be widely applied to the processing of profiles for building door and window products such as casement windows, sliding doors, and curtain walls, promoting the industry's transformation from decentralized processing to integrated, precise, and intelligent production, and possessing significant economic and social value.

[0171] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A five-axis machining system for aluminum alloy processing, characterized in that, include: Bed, gantry, multi-layer slide drive mechanism, five-axis swivel head, integrated centralized tool magazine and independent servo automatic fixture; The gantry includes columns and crossbeams. The crossbeams are fixed to the top of the two columns. A gantry slider is provided at the lower end of the columns. The gantry slider slides with the gantry guide rail on the bed, so that the gantry can move along the length of the bed. A drive mechanism is installed on the columns. The gear of the drive mechanism meshes with the rack on the bed. The multi-layer slide drive mechanism includes a slide saddle, an intermediate slide, and a spindle box. The slide saddle is fixed to the Y-axis lead screw nut on the gantry beam and can move along the length of the beam. The intermediate slide is mounted on one side of the slide saddle, and the spindle box slides in cooperation with the Z-axis guide rail of the intermediate slide. The five-axis swivel head is rigidly connected to the end of the spindle box away from the slide saddle. The tool post of the integrated centralized tool magazine is fixed to the gantry beam. Independent servo automatic fixtures are arranged at intervals along the length of the bed. The bottom of the independent servo automatic fixture is equipped with a fixture gear and a fixture slider. The fixture gear meshes with the fixture rack on the side of the bed, and the fixture slider slides with the fixture guide rail on the bed. The integrated centralized tool magazine also includes a tool disc, an extension drive mechanism, and an automatic door; The extension drive mechanism includes an electromechanical integrated base, a servo motor, a coupling, a lead screw, and a lead screw nut. The electromechanical integrated base is fixed to the tool post, the servo motor is installed inside the electromechanical integrated base, the output end is connected to the lead screw through the coupling, the lead screw nut is threadedly engaged with the lead screw, and is fixed to the gantry fixed bracket through the lead screw nut fixing plate. The cutter head has a layered structure with multiple tool changing zero points. The cutter head is connected to the reducer rotor through the lower connecting sleeve. The reducer stator is fixed to the receiving plate. The receiving plate is also connected to the upper connecting sleeve and the cutter head servo motor. The upper connecting sleeve is fixed to the tool holder. The automatic door is hinged to the tool holder. A U-shaped rod and a pull rod are provided between the automatic door and the tool holder. When the tool holder is fed, it drives the automatic door to open and close synchronously. The independent servo automatic fixture also includes a servo motor, a reducer, a fixture rack, a positioning gripper, a free gripper, a clamp, a positioning plate, and a cylinder; the servo motor is connected to the reducer, the output end of the reducer is fixed to the gear, and the gear meshes with the rack on the bed; the positioning gripper is fixed to the side of the fixture body by a positioning bar and a self-locking knob plunger, and the free gripper is slidably connected to the guide rail on the fixture body; A button is mounted on the side of the free gripper; pressing the button adjusts the relative position of the free gripper and the fixture rack. The cylinder is connected to the fixture rack, and the piston rod extends to drive the free gripper to move toward the positioning gripper. The clamp is mounted on the side of the fixture body and cooperates with the guide rail on the bed. The positioning plate is connected to the fixture body through primary and secondary lifting cylinders. The multi-layer slide drive mechanism also includes a servo motor, a synchronous belt drive mechanism, and a Z-axis lead screw; the synchronous belt drive mechanism includes a driving pulley, a synchronous belt, and a driven pulley; the servo motor is mounted on the slide saddle and its output end is connected to the driving pulley; the synchronous belt is sleeved between the driving pulley and the driven pulley; and the driven pulley is fixedly connected to one end of the Z-axis lead screw through a tensioning sleeve. The other end of the Z-axis lead screw is fixed to the slide saddle via a bearing seat, and the nut of the Z-axis lead screw is fixed to the spindle box; sprockets are installed at the lower ends of both sides of the middle slide plate, the chain meshes with the sprockets, one end of the chain is connected to the connecting screw and chain fixing block assembly on the slide saddle, and the other end is connected to the fixing blocks on both sides of the spindle box.

2. The five-axis machining system for aluminum alloy machining as described in claim 1, characterized in that, The five-axis oscillating head includes a B-axis assembly, a C-axis assembly, and an electric spindle. The C-axis assembly includes a C-axis housing, a C-axis servo motor, a C-axis drive pulley, a C-axis synchronous belt, a C-axis driven pulley, and a C-axis reducer. The C-axis housing is rigidly connected to the spindle box of the XYZ gantry via a flange. The fixed ends of the C-axis servo motor and the C-axis reducer are both fixedly mounted on the C-axis housing. The output end of the C-axis servo motor is connected to the C-axis drive pulley, which is connected to the C-axis driven pulley via the C-axis synchronous belt. The C-axis driven pulley is fixedly connected to the input end of the C-axis reducer. The output end of the C-axis reducer is rigidly connected to the B-axis housing of the B-axis assembly. The B-axis assembly includes a B-axis housing, a B-axis servo motor, a B-axis drive pulley, a B-axis synchronous belt, a B-axis driven pulley, a B-axis reducer, a B-axis encoder, a reducer side support plate, and a swing arm. The fixed ends of the B-axis servo motor and the B-axis reducer are fixed to the B-axis housing. The output end of the B-axis servo motor is connected to the B-axis drive wheel, which is connected to the B-axis driven wheel via the B-axis synchronous belt. The B-axis driven wheel is fixed to the input end of the B-axis reducer. The output end of the B-axis reducer is fixedly connected to the reducer side support plate. The reducer side support plate is fixedly connected to the swing arm. The electric spindle is fixed on the swing arm.

3. The five-axis machining system for aluminum alloy machining as described in claim 2, characterized in that, The C-axis assembly also includes a C-axis encoder. The C-axis encoder stator is fixedly mounted on the C-axis housing via a C-axis encoder bracket. The C-axis encoder rotor is coaxially fixedly connected to the C-axis driven wheel. The C-axis assembly also includes a C-axis pneumatic brake disc, which is assembled between the output end of the C-axis reducer and the B-axis housing. The B-axis assembly also includes a B-axis encoder. The rotor of the B-axis encoder is fixed on a second encoder bracket, which is mounted on a swing arm and rotates with it. The stator of the B-axis encoder is mounted on a first encoder bracket, which is installed together with a support sleeve and fixed to the B-axis housing.

4. The five-axis machining system for aluminum alloy machining as described in claim 2, characterized in that, The B-axis assembly also includes a B-axis pneumatic brake disc, which is mounted between the output end of the B-axis reducer and the side support plate of the reducer.

5. The five-axis machining system for aluminum alloy machining as described in claim 1, characterized in that, The gantry's drive mechanism includes a servo motor, a reducer, and gears. The servo motor is fixed to the column via a flange, and its output end is connected to the input end of the reducer. The output end of the reducer is fixed to the gears, and the gears mesh with a rack on the side of the bed. A lubrication assembly is provided on the meshing surface of the gears and racks.

6. The five-axis machining system for aluminum alloy machining as described in claim 1, characterized in that, It also includes a water chiller, which is fixed on a bracket on one side of the bed and includes a water tank, a water pump, cooling pipes and a temperature sensor; one end of the cooling pipe is connected to the water tank and the other end is connected to the cooling channel of the electric spindle of the five-axis oscillating head through a rotary joint; the water pump is connected in series with the cooling pipes and the temperature sensor is installed at the outlet of the cooling pipes. It also includes a chip conveyor and a radar sensor. The chip conveyor is installed in the chip removal trough at the bottom of the bed and includes a motor, chain, scraper and discharge port. The motor drives the chain to rotate through a reducer. The scraper is fixed to the chain and scrapes off aluminum chips as the chain moves. The radar sensor is installed below the gantry beam.

7. A five-axis machining method for aluminum alloy processing, characterized in that, The five-axis machining system for aluminum alloy machining according to any one of claims 1-6 includes the following process: The control system receives the processing task of aluminum alloy profiles for doors and windows, and generates a processing program according to the processing requirements of the profiles. The processing program includes the action instructions and processing parameters of each component. The servo motor of the independent servo automatic fixture is started, and through the meshing transmission between its bottom gear and the rack on the side of the bed, and in conjunction with the sliding engagement between the bottom slider of the fixture and the top guide rail of the bed, each independent servo automatic fixture is driven to move along the length of the bed to the set processing position. The aluminum alloy profile blank for doors and windows is placed in the positioning area of ​​the independent servo automatic fixture, and the independent servo automatic fixture performs a clamping action to fix the profile blank. The gantry's drive mechanism starts, and its gears mesh with the rack on the bed, driving the gantry to move along the top guide rail of the bed, so that the multi-layer sliding plate drive and the five-axis oscillating head on the gantry approach the blank of the profile to be processed. The extension drive mechanism of the integrated centralized tool magazine is activated, driving the tool post to feed in the set direction. At the same time, the tool disc rotates, rotating the target machining tool to the tool change position, completing the docking of the tool with the five-axis tilting head. The servo motor driven by the multi-layer slide plate starts, driving the Z-axis lead screw to rotate, which in turn drives the spindle box and the five-axis swivel head to adjust their height along the Z-axis guide rail of the middle slide plate. At the same time, the Y-axis lead screw on the gantry beam drives the slide saddle, which in turn drives the multi-layer slide plate to move along the length of the beam, so that the five-axis swivel head is aligned with the machining start position. The five-axis swivel head starts and adjusts the electric spindle angle to the required machining posture. The electric spindle of the five-axis swivel head starts, driving the tool to rotate; the gantry drive mechanism drives the gantry to feed along the X-axis of the bed, and the multi-layer slide drive cooperates to achieve Y-axis and Z-axis feed. The five-axis swivel head maintains the set machining posture and cooperates with the multi-axis feed to perform machining on the aluminum alloy profile blank for doors and windows. After the profile processing is completed, the electric spindle stops rotating, the five-axis oscillating head resets, the independent servo automatic fixture releases, and the processed aluminum alloy profile for doors and windows is removed, completing a single processing cycle.

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