Efficient intelligent control system for center hole grinding and positioning

Abstract

The invention discloses a center hole grinding and positioning efficient intelligent control system, and relates to the technical field of machining, the system comprises a positioning module, a parameter regulation and control module, a tool clamping module, an overload protection module, a quality control module and a PLC controller; through a positioning deviation dynamic compensation algorithm, a position detection unit is combined to collect deviation in real time and calculate the compensation amount, a tailstock fine adjustment mechanism is driven to achieve accurate alignment, it is ensured that the coaxiality of a main shaft grinding head and a tailstock power head always meets the preset requirement, and the target rotating speed is dynamically calculated through a grinding rotating speed self-adaption algorithm; meanwhile, deviation is corrected in real time by means of the detection unit, and the problems of excessive hard workpiece grinding and insufficient soft workpiece grinding caused by the fixed rotating speed are solved; grinding time is set according to the specification of a center hole, machining consistency is guaranteed, adaptive clamping force is calculated through a tool clamping force self-adaptive algorithm, and universal clamping of workpieces of multiple specifications is achieved by linkage of a spring adjusting assembly and a measuring ball adjusting bolt.

Description

Technical Field

[0001] This invention relates to the field of machining technology, specifically to a high-efficiency intelligent control system for center hole grinding and positioning. Background Technology

[0002] In the field of machining, gear shafts are core components of transmission equipment such as gearboxes and reducers. Their machining accuracy directly determines the stability and service life of the transmission system. The center hole serves as the reference for subsequent grinding of the outer diameter and gear teeth of the gear shaft. Its grinding quality is a key link in ensuring the overall machining accuracy. Currently, center hole grinding is mostly carried out using ordinary lathes as the basic machining equipment, in conjunction with a spindle grinding head and a tailstock power head to achieve basic grinding actions. At the same time, with the increasing demand for gear shafts from industries such as automobile manufacturing and mining machinery, mass standardized production and customized high-precision production coexist, which puts forward higher requirements for the reference coaxiality, machining parameter adaptability, and tooling versatility of center hole grinding.

[0003] However, traditional center hole grinding positioning technology has some limitations in practical applications. First, the positioning process relies on manual operation, requiring manual adjustment of the alignment position of the lathe spindle grinding head and the tailstock power head. Alignment accuracy can only be judged based on experience, making it prone to coaxiality deviations due to operational errors, which in turn lead to problems such as excessive runout in subsequent grinding. Second, grinding parameter control is coarse, with the rotation speed often using a fixed value without dynamic adjustment based on the workpiece material hardness and center hole diameter. This results in over-grinding of hard workpieces and under-grinding of soft workpieces. Grinding time is also subjectively determined manually, leading to poor quality consistency in batch processing. Third, tooling adaptability is limited. The first drawback is the lack of a dedicated clamping fixture for gear shafts with different pitch circle sizes, which takes a long time to change the fixture and the clamping force cannot be adaptively adjusted according to the workpiece specifications, posing a risk of unstable clamping or damage to the workpiece. The second drawback is the lack of an effective overload protection mechanism. When the grinding resistance increases, the load status of the servo motor cannot be monitored in real time, which can easily lead to motor burnout due to overload. Furthermore, the processing flow lacks standardized linkage logic, which can easily cause the tailstock and fixture to move erratically. The third drawback is the lack of traceability for batch processing quality. It is impossible to record and correlate the grinding parameters of each workpiece, making it difficult to locate the cause when quality problems occur, which is not conducive to process optimization and quality control. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a highly efficient and intelligent control system for center hole grinding positioning. This invention uses a dynamic positioning deviation compensation algorithm, combined with a position detection unit to collect deviations in real time and calculate compensation amounts, to drive the tailstock fine-tuning mechanism to achieve precise alignment, ensuring that the coaxiality of the spindle grinding head and the tailstock power head always meets the preset requirements. Through a grinding speed adaptive algorithm, the target speed is dynamically calculated, and the deviation is corrected in real time with the help of the detection unit, avoiding the problems of over-grinding of hard workpieces and under-grinding of soft workpieces caused by a fixed speed. The grinding time is set according to the center hole specifications to ensure processing consistency. Then, through a tooling clamping force adaptive algorithm, the appropriate clamping force is calculated, and the linkage spring adjustment component and the ball adjustment bolt realize universal clamping of multi-specification workpieces, taking into account clamping stability and adaptability flexibility, to meet the processing needs of gear shafts of different specifications.

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a high-efficiency intelligent control system for center hole grinding and positioning, the system comprising: Positioning module, parameter control module, tooling clamping module, overload protection module, quality control module and PLC controller; Positioning module: It presets the coaxial reference parameters of the lathe spindle grinding head and the tailstock power head, collects the alignment deviation through the position detection unit, calculates the displacement compensation of the tailstock fine-tuning mechanism, drives the tailstock fine-tuning mechanism to make adjustments, and feeds back the positioning ready signal to the PLC controller. Parameter control module: includes a speed control submodule and a time control submodule. The speed control submodule has a built-in parameter library and calculates the target speed to control the operation of the grinding head. The time control submodule sets the grinding time according to the center hole specification. After the timer reaches the target, it sends a power shut-off command to the PLC controller. Tooling clamping module: It receives the workpiece pitch circle size information through the PLC controller, calculates the actual clamping force, controls the connecting rod clamping assembly to perform the clamping action, and then uses the detection assembly to determine whether the actual clamping force meets the standard to lock the clamping state. At the same time, it adjusts the clamping range through the spring adjustment assembly and the ball adjustment bolt, and retains the horizontal radial degree of freedom of the tooling after clamping and locking. Overload protection module: Collects servo motor load status data through load detection unit and calculates the actual load rate of motor. When the load exceeds the safety threshold, adjusts the servo motor speed and triggers an alarm. Then, it links each execution unit sequentially through PLC controller according to the processing flow. Quality control module: Before processing, it receives batch information of workpieces, calls the appropriate parameters through the built-in parameter library, analyzes the quality deviation rate of processing parameters, collects processing parameters in real time, and stores them with the unique identifier of the corresponding workpiece. When the quality deviation rate exceeds the normal range, it marks the corresponding workpiece and sends a pause processing command to the PLC controller.

[0006] Furthermore, in the positioning module, the position detection unit collects the alignment deviation between the center hole of the gear shaft workpiece and the double grinding head, and calculates the displacement compensation amount of the tailstock fine-tuning mechanism through a positioning deviation dynamic compensation algorithm. Based on the displacement compensation amount, the tailstock fine-tuning mechanism is driven to make adjustments. At the same time, the position detection unit detects the compensation deviation data in real time until the deviation meets the preset requirements.

[0007] Furthermore, in the positioning module, the calculation formula for the positioning deviation dynamic compensation algorithm is as follows: ,in, For the first The actual displacement compensation amount of the secondary tailstock fine-tuning mechanism. The positioning deviation dynamic correction coefficient was determined after calibration with 10 sets of standard parts. For the first The alignment deviation value collected by the secondary position detection unit. The historical compensation amount attenuation coefficient, For the first The compensation amount is obtained through historical data. This is the penalty coefficient for exceeding the threshold deviation. These are the preset coaxial reference parameters; when At that time, the deviation preset requirement was met.

[0008] Furthermore, the parameter control module includes a speed control submodule with a built-in parameter library corresponding to the workpiece material and the diameter of the center hole. It calculates the target speed of the grinding head through a grinding speed adaptive algorithm. Based on the target speed of the grinding head, it sends a drive signal through the servo motor drive component to drive the servo motor to control the operation of the grinding head. It also has a speed detection unit to collect the actual speed of the grinding head and correct the drive signal. The time control submodule sets the grinding time according to the center hole specifications. It starts timing when grinding is triggered and sends a power shutdown command to the PLC controller after the set grinding time is reached.

[0009] Furthermore, the calculation formula for the grinding speed adaptive algorithm in the parameter control module is as follows: ,in, The target rotational speed of the grinding head. As the reference speed, The Rockwell hardness of the workpiece. As the reference hardness, For maximum hardness, This is the hardness influence coefficient. The actual diameter of the center hole. As the reference aperture, For the maximum aperture, This is the aperture influence coefficient; The servo motor drive assembly operates according to the target rotation speed of the grinding head. Output drive signal, and the speed detection unit collects the actual speed in real time. ,when At that time, the drive signal is corrected to adjust the speed.

[0010] Furthermore, in the tooling clamping module, the workpiece pitch circle dimension information is received by the PLC controller, and the actual clamping force is calculated by the tooling clamping force adaptive algorithm to generate a clamping command. After receiving the clamping command, the linkage clamping assembly executes the clamping action. The tooling clamping force adaptive algorithm is as follows: ,in, This is the actual clamping force. This is the force amplification factor for the connecting rod clamping assembly. The preload of the spring adjusting assembly. To adjust the force transmission coefficient of the ball-mounted adjustment bolt, To measure the actual adjustment displacement of the ball-mounted adjusting bolt. The pitch circle diameter of the reference workpiece. This is the actual pitch circle diameter of the workpiece currently being machined.

[0011] Furthermore, in the overload protection module, the load status data of the servo motor is collected by the load detection unit, and the actual load rate of the motor is calculated by the motor overload early warning algorithm. The calculation formula of the motor overload early warning algorithm is as follows: ,in, This represents the actual load rate of the motor. This is the real-time operating current of the motor. This is the rated current of the motor. This is the coefficient representing the influence of rotational speed on load. This refers to the actual grinding speed. This refers to the rated speed of the motor. when At that time, a speed adjustment command is sent to the servo motor, and an alarm is triggered simultaneously.

[0012] Furthermore, in the overload protection module, each execution unit includes an execution unit for tailstock drive, tool clamping, grinding start, power shutdown, tailstock retraction, tool release, and completion prompt.

[0013] Furthermore, in the quality control module, before processing, batch information of the workpiece is received through the interactive interface of the PLC controller, and suitable processing parameters are called from the built-in parameter library corresponding to the workpiece material, rotation speed, time, and clamping parameters. The quality deviation rate of the processing parameters is analyzed by the batch processing comprehensive deviation rate algorithm. The calculation formula of the batch processing comprehensive deviation rate algorithm is as follows: ,in, This refers to the quality deviation rate. This is the weighting coefficient for the speed deviation. This refers to the actual rotational speed of the grinding head. Preset the rotation speed for the grinding head. This is the weighting coefficient for grinding time deviation. This refers to the actual grinding time. To preset the grinding time, This is the clamping force deviation weighting coefficient. This is the actual clamping force. Preset clamping force; when At that time, the corresponding workpiece is marked and a pause processing command is sent to the PLC controller.

[0014] Compared with existing technologies, this efficient and intelligent control system for center hole grinding and positioning has the following advantages: I. This invention utilizes a dynamic positioning deviation compensation algorithm, combined with a position detection unit to collect deviations in real time and calculate compensation amounts, driving the tailstock fine-tuning mechanism to achieve precise alignment. This ensures that the coaxiality of the spindle grinding head and the tailstock power head always meets preset requirements. Through an adaptive grinding speed algorithm, the target speed is dynamically calculated, and the detection unit corrects deviations in real time, avoiding over-grinding of hard workpieces and under-grinding of soft workpieces caused by fixed speeds. Grinding time is set according to the center hole specifications to ensure processing consistency. Furthermore, an adaptive clamping force algorithm calculates the appropriate clamping force, linking the spring adjustment component and the ball-mounted adjustment bolt to achieve universal clamping of multiple workpiece specifications, balancing clamping stability and adaptability to meet the processing needs of gear shafts of different specifications.

[0015] Second, this invention uses a motor overload early warning algorithm to collect servo motor load status data in real time and calculate the load rate. When the load exceeds the safety threshold, the speed is immediately adjusted and an alarm is triggered to prevent the motor from burning out due to excessive grinding resistance. At the same time, the execution unit is linked according to the preset process to ensure the orderly connection of the processing flow, reduce production interruptions caused by equipment failure and process disorder. Before batch processing, the corresponding parameters in the built-in parameter library are called, and the parameter deviation is analyzed by the batch processing comprehensive deviation rate algorithm. Processing data is collected in real time and associated with the unique identifier of the workpiece. When the deviation exceeds the normal range, the workpiece is marked and processing is paused. This facilitates subsequent quality analysis and problem localization, ensuring the stability of batch processing quality and providing data support for production process optimization, thereby improving production efficiency and product qualification rate.

[0016] Other advantages, objectives and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination or study, or may be learned from the practice of the invention. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0018] Figure 1 Flowchart of a high-efficiency intelligent control system for center hole grinding and positioning; Figure 2 A framework diagram of a high-efficiency intelligent control system for center hole grinding and positioning. Detailed Implementation

[0019] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0020] Example 1: Positioning Module: In a batch grinding scenario for 45 steel standard gear shafts in automotive transmissions, a manufacturer of automotive transmission components receives a batch order for 45 steel standard gear shafts. These gear shafts are used as input shafts in manual transmissions and require IT5-level grinding of the outer diameter. The order volume is large, and the grinding accuracy of the center hole must meet preset requirements, with no burrs on the surface, to adapt to the rhythm of a continuous production line. Using preset coaxial reference parameters of the lathe spindle grinding head and the tailstock power head, a laser displacement sensor is used to collect the alignment deviation between the center hole of the 45 steel gear shaft workpiece and the dual grinding heads. The sampling frequency of this laser displacement sensor is 90-100Hz. After the workpiece is placed on the lathe fixture, the PLC controller activates the laser displacement sensor. The initial detection shows that the alignment deviation exceeds the preset coaxial reference parameters. The displacement compensation amount of the tailstock fine-tuning mechanism is calculated using a dynamic compensation algorithm for positioning deviation. The calculation formula for the dynamic compensation algorithm for positioning deviation is as follows: ,in, For the first The actual displacement compensation amount of the secondary tailstock fine-tuning mechanism. The positioning deviation dynamic correction coefficient was determined after calibration with 10 sets of standard parts. For the first The alignment deviation value collected by the secondary position detection unit. The historical compensation amount attenuation coefficient, For the first The compensation amount is obtained through historical data. This is the penalty coefficient for exceeding the threshold deviation. The pre-set coaxial reference parameters are used; and the tailstock fine-tuning mechanism is adjusted based on the displacement compensation amount. Simultaneously, a laser displacement sensor detects the compensated deviation data. When the alignment deviation is less than the coaxial reference parameters, a positioning ready signal is fed back to the PLC controller, triggering the next process, such as... Figure 1 As shown.

[0021] Parameter control module: Includes a speed control submodule and a time control submodule. After receiving the positioning ready signal from the PLC controller, the speed control submodule calls the parameters corresponding to 45 steel and the workpiece center hole specifications from the built-in parameter library, and calculates the target speed of the grinding head through a grinding speed adaptive algorithm. The calculation formula of the grinding speed adaptive algorithm is as follows: ,in, The target rotational speed of the grinding head. As the reference speed, The Rockwell hardness of the workpiece. As the reference hardness, For maximum hardness, This is the hardness influence coefficient. The actual diameter of the center hole. As the reference aperture, For the maximum aperture, The aperture influence coefficient is used; the servo motor drive component outputs a drive signal according to the target speed of the grinding head, controlling the servo motor to drive the grinding head, while the speed detection unit collects the actual speed in real time. ,when At the same time, the drive signal is corrected to adjust the speed, and the time control submodule sets the grinding time according to the workpiece center hole specifications and 45 steel material. The timing is synchronized when the grinding starts. After the timer reaches the set grinding time, a power shut-off command is sent to the PLC controller, and the tailstock power head is simultaneously triggered to prepare to retreat.

[0022] Tooling clamping module: Receives the pitch circle dimension information of the 45 steel gear shaft via the PLC controller, and calculates the actual clamping force using an adaptive tooling clamping force algorithm. The adaptive tooling clamping force algorithm is as follows: ,in, This is the actual clamping force. This is the force amplification factor for the connecting rod clamping assembly. The preload of the spring adjusting assembly. To adjust the force transmission coefficient of the ball-mounted adjustment bolt, To measure the actual adjustment displacement of the ball-mounted adjusting bolt. The pitch circle diameter of the reference workpiece. The actual pitch circle diameter of the workpiece is used for machining. Based on the actual clamping force, a clamping command is sent to the connecting rod clamping assembly to execute the clamping action. At the same time, the detection assembly collects the clamping force in real time. When the clamping force reaches the calculated actual clamping force, the clamping state is locked. Since the workpiece pitch circle size is consistent with the reference workpiece pitch circle diameter, the ball adjusting bolt does not need to be adjusted. The spring adjusting assembly and the ball adjusting bolt maintain their current state to adapt to the workpiece pitch circle size. After clamping and locking, a certain degree of freedom in the horizontal radial direction of the tooling is retained to avoid grinding defects caused by slight misalignment of the double grinding heads.

[0023] Overload protection module: This module acquires real-time operating current data of the servo motor using a current sensor to obtain load status data. It then calculates the actual motor load rate using a motor overload warning algorithm. The calculation formula for this algorithm is as follows: ,in, This represents the actual load rate of the motor. This is the real-time operating current of the motor. This is the rated current of the motor. This is the coefficient representing the influence of rotational speed on load. This refers to the actual grinding speed. The rated speed of the motor; the actual load rate of the motor calculated during normal grinding. If the grinding resistance increases due to wear of the grinding head, the calculated actual motor load rate will not be triggered. At the same time, a speed adjustment command is sent to the servo motor to reduce the speed. Simultaneously, an audible and visual alarm is triggered to issue a continuous warning signal. Based on the preset processing flow, the PLC controller sequentially links the tailstock drive unit, tooling clamping unit, grinding start unit, and other execution units. The preset processing flow includes the following steps in sequence: tailstock forward lifting, double-top positioning, tooling clamping, grinding start, timing end and power shutdown, tailstock retraction, tooling release, and completion prompt, to avoid process confusion.

[0024] Quality Control Module: Before batch processing, the module receives workpiece batch information through the PLC controller's interface. This batch information includes the material corresponding to the workpiece model, the center hole specification, and the batch quantity. It then retrieves suitable parameters from a built-in parameter library showing the correspondence between workpiece material, rotation speed, time, and clamping parameters, and distributes these parameters to the positioning module, parameter control module, tooling clamping module, and overload protection module. During processing, the module analyzes the quality deviation rate of processing parameters using a batch processing comprehensive deviation rate algorithm. The calculation formula for this algorithm is as follows: ,in, This refers to the quality deviation rate. This is the weighting coefficient for the speed deviation. This refers to the actual rotational speed of the grinding head. Preset the rotation speed for the grinding head. is the weight coefficient of the grinding time deviation, is the actual grinding time, is the preset grinding time, is the weight coefficient of the clamping force deviation, is the actual clamping force, is the preset clamping force; and the actual rotation speed, actual grinding time, and actual clamping force data of each workpiece are collected in real time. The actual rotation speed comes from the rotation speed detection unit, the actual grinding time comes from the time control sub-module, and the actual clamping force comes from the detection component, and a unique workpiece identifier is generated and stored in the local database in association; when the quality deviation rate , it is determined that the workpiece is qualified and processing continues; if the actual clamping force of a workpiece is abnormal due to spring fatigue, when , immediately mark the workpiece as to be inspected and send a pause processing instruction to the PLC controller, and resume processing after replacing the spring.

[0025] In summary, for the batch grinding scenario of the 45 steel standard gear shaft of the automotive transmission, the positioning module presets the coaxial reference parameters of the grinding head on the lathe spindle and the power head of the tailstock, collects the alignment deviation through the laser displacement sensor, calculates the compensation amount through the positioning deviation dynamic compensation algorithm, drives the tailstock fine adjustment mechanism to adjust to the deviation standard and feedback the ready signal; the parameter regulation module calls the adapted parameters, calculates the target rotation speed through the grinding rotation speed adaptive algorithm, controls the operation of the servo motor and sends a power-off instruction according to the set grinding time; the tooling clamping module receives the pitch circle size information to calculate the clamping force, drives the connecting rod clamping component to the locked state and adapts to the size; the overload protection module monitors the motor load, adjusts the rotation speed, alarms and联动执行单元 when the threshold is exceeded; the quality control module calls the parameters and analyzes the quality deviation rate, and each module is联动 through the PLC controller to meet the requirements of batch production for accuracy and efficiency.

[0026] Embodiment 2: Positioning module: In the customized grinding scenario of the large-aperture carbide gear shaft of mining machinery, a certain heavy machinery enterprise customizes a large-aperture carbide gear shaft. This gear shaft is used for the output shaft of the mining machinery reducer, needs to withstand high-load impacts, is made of carbide, has a large center hole diameter, and a small number of single batches. It is required that the surface roughness and coaxiality after center hole grinding meet the requirements of high-precision machining. By presetting the coaxial reference parameters of the grinding head on the lathe spindle and the power head of the tailstock, a laser displacement sensor is used to collect the alignment deviation between the center hole of the carbide gear shaft and the double grinding heads. The sampling frequency of this laser displacement sensor is 100 - 110Hz. After the workpiece is placed, due to the large weight of the carbide workpiece, the initial alignment deviation is slightly large. The PLC controller controls the laser displacement sensor to start. The first detected alignment deviation exceeds the preset coaxial reference parameters. The displacement compensation amount is calculated through the positioning deviation dynamic compensation algorithm, and the tailstock fine adjustment mechanism is driven to execute this compensation amount. The calculation formula of its positioning deviation dynamic compensation algorithm is: The tailstock fine-tuning mechanism is adjusted based on the displacement compensation amount, and the deviation data after compensation is detected by the laser displacement sensor. When the alignment deviation is less than the coaxial reference parameter, a positioning ready signal is fed back to the PLC controller.

[0027] The parameter control module includes a speed control submodule and a time control submodule. After receiving the positioning ready signal from the PLC controller, the speed control submodule calls the parameters corresponding to the cemented carbide and large-diameter center holes from the parameter library, and calculates the target speed of the grinding head through a grinding speed adaptive algorithm. The calculation formula of the grinding speed adaptive algorithm is as follows: The servo motor drive component outputs a drive signal according to the target rotation speed of the grinding head, controlling the servo motor to drive the grinding head to rotate, and the rotation speed detection unit calibrates the rotation speed in real time. ,when At the same time, the drive signal is corrected to adjust the speed; the time control submodule sets a longer grinding time according to the large diameter center hole and the hard alloy material to ensure the grinding quality. After the set grinding time is reached, a power shutdown command is sent to the PLC controller.

[0028] Tooling clamping module: Receives the gear shaft pitch circle dimension information from the customized drawing parameters via the PLC controller. Calculates the actual clamping force using an adaptive tooling clamping force algorithm. The adaptive tooling clamping force algorithm is as follows: The clamping mechanism sends a clamping command to the connecting rod clamping assembly based on the actual clamping force, and performs the clamping action. The connecting rod clamping assembly is a heavy-duty gripper that can meet the large clamping force requirements. The detection component collects the clamping force in real time. When the detected clamping force reaches the calculated actual clamping force, the clamping state is locked. Because the carbide workpiece is heavy and the pitch circle size is larger than that of the reference workpiece, the ball gauge adjustment bolt needs to be adjusted outward by a certain displacement to adapt to the pitch circle size. The spring adjustment assembly uses a high-strength spring to adapt to the large preload requirement. It works in conjunction with the ball gauge adjustment bolt to expand the clamping range to adapt to the current pitch circle size. After clamping and locking, a certain degree of freedom in the horizontal radial direction of the tooling is retained.

[0029] Overload protection module: It acquires load status data by collecting servo motor current through a current sensor, and calculates the actual load rate of the motor through a motor overload early warning algorithm. The calculation formula of the motor overload early warning algorithm is as follows: The actual load rate of the motor calculated during normal grinding. Normal operation; however, if the resistance increases due to clogged grinding head abrasive particles, the calculated actual motor load rate will be affected. At that time, a speed adjustment command is sent to the servo motor to reduce the speed, and an audible and visual alarm is triggered simultaneously. Figure 2 As shown, the PLC controller links the tailstock drive, tooling clamping and other execution units according to the preset processing flow to avoid motor damage due to overload.

[0030] Quality control module: Before processing, it receives workpiece batch information through the interactive interface of the PLC controller. This batch information includes the material, center hole specifications, and batch quantity of the customized gear shaft, and calls the adapted parameters from the parameter library with the corresponding relationship of workpiece material - rotational speed - time - clamping parameters built-in, and then sends them to the positioning module, parameter regulation module, tooling clamping module, and overload protection module; During processing, it analyzes the quality deviation rate of processing parameters through the batch processing comprehensive deviation rate algorithm. The calculation formula of the batch processing comprehensive deviation rate algorithm is: ; and it collects the actual rotational speed, actual grinding time, and actual clamping force of each piece in real time and stores them in association with the unique identifier of the workpiece; When the quality deviation rate is met, the workpiece is judged to be qualified and processing continues; When is the case, then mark this workpiece and send a pause processing instruction to the PLC controller.

[0031] In summary, for the customized grinding scenario of large - aperture carbide gear shafts in mining machinery, the positioning module uses a spindle grinding head adapted to the large aperture, and after collecting the alignment deviation and compensating, the alignment meets the standard; The parameter regulation module calculates the adapted target rotational speed and sets a longer grinding time according to the characteristics of carbide and large aperture; The tooling clamping module receives the large pitch diameter size information, calculates the clamping force, and uses the jaws and high - strength springs to achieve clamping and adapt to the size; The overload protection module monitors the motor load, and when the threshold is exceeded, it protects the equipment and联动流程 (it seems there is an error here, it might be "interlocks the process"); The quality control module calls parameters and analyzes the deviation rate. Each module works together to ensure that the surface roughness and coaxiality of the customized parts meet the standards, meeting the high - reliability requirements of mining machinery and the subsequent processing requirements of super - hard abrasives.

[0032] The above is only a preferred embodiment of the present invention, and it is not a limitation to the present invention in any form. Although the present invention has been disclosed above with the preferred embodiment, it is not intended to limit the present invention. Any person skilled in the art can make some changes or modifications to be equivalent embodiments with equivalent changes within the scope of the technical solution of the present invention. However, as long as it does not depart from the content of the technical solution of the present invention, any brief modification, equivalent change, and modification made to the above embodiment based on the technical essence of the present invention still fall within the scope of the technical solution of the present invention.

Claims

1. A high-efficiency intelligent control system for center hole grinding positioning, characterized in that, The system comprises: A positioning module, a parameter control module, a tool clamping module, an overload protection module, a quality control module and a PLC controller; The positioning module: preset the coaxial reference parameters of the lathe spindle grinding head and the tailstock power head, collect the alignment deviation through the position detection unit, calculate the displacement compensation of the tailstock fine adjustment mechanism, drive the tailstock fine adjustment mechanism for adjustment, and feed back the positioning ready signal to the PLC controller; The parameter control module: including a speed control sub-module and a time control sub-module, the speed control sub-module has a parameter library, and calculates the target speed to control the grinding head operation, the time control sub-module sets the grinding time according to the center hole specification, and sends the power off instruction to the PLC controller after the timing reaches the standard; The tool clamping module: receives the workpiece pitch circle size information through the PLC controller, calculates the actual clamping force, controls the connecting rod clamping assembly to execute the clamping action, and determines whether the actual clamping force meets the standard through the detection assembly to lock the clamping state, and adjusts the clamping range through the spring adjustment assembly and the ball adjustment bolt, and retains the tool horizontal radial freedom degree after clamping and locking; The overload protection module: collects the load state data of the servo motor through the load detection unit, calculates the actual load rate of the motor, adjusts the speed of the servo motor when the safety threshold is exceeded, triggers an alarm, and sequentially links each execution unit through the PLC controller according to the processing flow; The quality control module: receives the workpiece batch information before processing, calls the adaptive parameters through the built-in parameter library, analyzes the quality deviation rate of the processing parameters, collects the processing parameters in real time, associates the corresponding workpiece unique identifier storage, and when the quality deviation rate exceeds the normal range, marks the corresponding workpiece and sends the pause processing instruction to the PLC controller.

2. The center hole lapping positioning high-efficiency intelligent control system according to claim 1, characterized in that, In the positioning module, the position detection unit collects the alignment deviation of the gear shaft workpiece center hole and the double grinding head, and calculates the displacement compensation of the tailstock fine adjustment mechanism through the positioning deviation dynamic compensation algorithm, drives the tailstock fine adjustment mechanism for adjustment based on the displacement compensation, and detects the deviation data after compensation in real time through the position detection unit until the deviation meets the preset requirements.

3. The center hole lapping positioning high-efficiency intelligent control system according to claim 2, characterized in that, In the positioning module, the calculation formula for the positioning deviation dynamic compensation algorithm is as follows: ,in, For the first The actual displacement compensation amount of the secondary tailstock fine-tuning mechanism. The positioning deviation dynamic correction coefficient was determined after calibration with 10 sets of standard parts. For the first The alignment deviation value collected by the secondary position detection unit. The historical compensation amount attenuation coefficient, For the first The compensation amount is obtained through historical data. This is the penalty coefficient for exceeding the threshold deviation. These are the preset coaxial reference parameters; When the deviation preset requirement is reached.

4. The center hole lapping positioning high-efficiency intelligent control system according to claim 1, wherein, In the parameter control module, the speed control sub-module has a parameter library corresponding to the workpiece material and the center hole diameter, calculates the target speed of the grinding head through the grinding speed adaptive algorithm, sends the driving signal through the servo motor driving assembly based on the target speed of the grinding head, drives the servo motor to control the grinding head operation, and configures the speed detection unit to collect the actual speed of the grinding head and correct the driving signal; the time control sub-module sets the grinding time according to the center hole specification, starts timing when the grinding starts, and sends the power off instruction to the PLC controller after the timing reaches the set grinding time.

5. The center hole lapping positioning high-efficiency intelligent control system according to claim 4, characterized in that, The parameter regulation module, a calculation formula of the grinding rotation speed self-adaptive algorithm is: Wherein, is a target rotation speed of the grinding head, is a reference rotation speed, is a workpiece Rockwell hardness, is a reference hardness, is a maximum hardness, is a hardness influence coefficient, is an actual aperture of a center hole, is a reference aperture, is a maximum aperture, is an aperture influence coefficient. The servo motor driving assembly adjusts the target rotating speed of the grinding head The output driving signal is adjusted according to the actual rotating speed collected by the rotating speed detection unit When the driving signal is corrected to adjust the rotating speed.

6. The center hole lapping positioning high-efficiency intelligent control system according to claim 1, wherein, In the tool clamping module, the workpiece pitch circle size information is received by the PLC controller, the actual clamping force is calculated by the tool clamping force self-adaptive algorithm, the clamping instruction is generated, and the connecting rod clamping assembly executes the clamping action after receiving the clamping instruction, and the tool clamping force self-adaptive algorithm is: Wherein, is the actual clamping force, is the force amplification coefficient of the connecting rod clamping assembly, is the pre-tightening force of the spring adjusting assembly, is the force transmission coefficient of the ball adjusting bolt, is the actual adjustment displacement of the ball adjusting bolt, is the pitch circle diameter of the reference workpiece, is the actual pitch circle diameter of the current machining workpiece.

7. The center hole lapping positioning high-efficiency intelligent control system according to claim 1, wherein, The overload protection module, through the load detection unit acquires the load state data of the servo motor, and calculates the actual load rate of the motor through the motor overload early warning algorithm, and the calculation formula of the motor overload early warning algorithm is: Wherein, The actual load rate of the motor, The real-time working current of the motor, The rated current of the motor, The speed-to-load influence coefficient, The actual grinding speed, The rated speed of the motor; When a speed adjustment command is sent to the servo motor, and an alarm is triggered at the same time.

8. The center hole lapping positioning high-efficiency intelligent control system according to claim 1, wherein, In the overload protection module, each execution unit includes tailstock drive, tool clamping, grinding start, power off, tailstock retreat, tool release and completion prompt execution units.

9. The center hole lapping positioning high-efficiency intelligent control system according to claim 1, wherein, In the quality control module, the workpiece batch information is received through the interactive interface of the PLC controller before processing, and the adaptive processing parameters are called from the parameter library of the built-in workpiece material-speed-time-clamping parameter correspondence, and the quality deviation rate of the processing parameters is analyzed through the batch processing comprehensive deviation rate algorithm. The calculation formula of the batch processing comprehensive deviation rate algorithm is: Wherein, is the quality deviation rate, is the speed deviation weight coefficient, is the actual speed of the grinding head, is the preset speed of the grinding head, is the grinding time deviation weight coefficient, is the actual grinding time, is the preset grinding time, is the clamping force deviation weight coefficient, is the actual clamping force, is the preset clamping force; When the marking corresponds to the workpiece and sends a pause machining instruction to the PLC controller.

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