Full-automatic tool changing control method and device, electronic equipment and storage medium

Abstract

The invention discloses a full-automatic tool changing control method applied to a cutting machine. The method is executed by coordinating a plurality of functional modules through a control unit, and comprises the following steps: S1, tool taking operation: grabbing a new tool from a tool magazine through a power sequence of'moving pressing-reverse rotation locating-forward rotation lifting ', and starting secondary positioning to cooperate with micro-action to carry out fault-tolerant correction when adsorption fails; s2, tool disengaging operation is conducted, adsorption is relieved after the old tool is fixed by the clamping mechanism, and the old tool is reliably disengaged through an inertia disengaging strategy; s3, tool release verification: controlling a tool rest to pass through a self-adaptive detection window, and judging a tool release result according to a sensor signal closed loop; and S4, independently running empty tool detection, and performing cross validation by monitoring the state of a pressure sensor at the tail end of the tool magazine and combining an operation log to realize tool magazine vacancy early warning. Through the integrated and closed-loop control process, the tool changing success rate and the equipment automation level are remarkably improved, and manual intervention and fault risks are reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of cutting equipment, in particular to a full-automatic tool changing control method and device for a cutting machine, electronic equipment and a storage medium. BACKGROUND

[0002] In modern precision machining, cutting machines are widely used for processing of sheet materials such as flexible printed circuit boards (FPCB), optical films, cloth, paper, etc. To improve production flexibility and efficiency, automatic tool changing function has become a key module of high-end cutting equipment. An ideal automatic tool changing system should be able to complete the entire process of taking a new cutting tool from the tool magazine, safely unloading the old cutting tool from the actuator and confirming the result without human intervention.

[0003] Currently, the technical development in this field focuses on the automation of partial functions. For example, existing technical solutions aim to achieve the function of automatically grabbing the tool (“tool taking”) from the tool magazine, moving the cutting tool from the storage position to the main tool holder through a mechanical linkage mechanism or an independent drive mechanism. In addition, there are also some independent solutions that focus on how to unload the used cutting tool from the tool holder (“tool unloading”). However, these technologies often only optimize a single isolated link in the tool changing process.

[0004] The deficiency of the prior art is that there is a lack of a complete method that seamlessly connects and intelligently controls the two key actions of “tool taking” and “tool unloading” as well as the crucial “result verification” link. That is, the tool taking and unloading actions are usually disjointed in control logic and physical execution, and do not constitute a coherent automation sequence. The operator may need to switch modes or manually intervene between taking a new tool and unloading an old tool, affecting efficiency. More critically, after the unloading action is performed, there is a lack of a reliable and automatic means to instantly verify whether the cutting tool has been successfully unloaded from the tool holder. Existing solutions often assume that the unloading action is successful or rely on visual inspection by the operator. If the unloading fails and is not detected, the old cutting tool remains on the tool holder, which can easily cause collisions, damage to the cutting tool or equipment, and non-planned downtime and safety risks during subsequent tool taking or processing.

[0005] Therefore, there is an urgent need in the art for a full-automatic tool changing control scheme that can comprehensively control the entire tool changing process, especially one that integrates the three core steps of tool taking, tool unloading, and automatic verification of the tool unloading result into a reliable, closed-loop control process. SUMMARY

[0006] Therefore, the present application aims to provide a full-automatic tool changing control method, device, equipment and storage medium to solve the problem of fragmented tool changing process and lack of closed-loop verification in the prior art, resulting in low efficiency and poor reliability.

[0007] To achieve the above object, the present application adopts the following technical solutions: In a first aspect, the present application provides a full-automatic tool changing control method, applied to a cutting machine, executed by a control unit, comprising the following steps: S1, a tool taking step: controlling a tool holder of a tool taking mechanism to move to a tool taking position of a tool magazine and performing a pressing-down action; in response to the pressing-down action, triggering a lifting tool mechanism and a driving mechanism to enter a power transmission state; then controlling the driving mechanism to drive the lifting tool mechanism to lift a target cutting tool in the tool magazine until the target cutting tool is adsorbed and fixed by the tool holder; S2, a tool unloading step: controlling the tool holder carrying a cutting tool to be unloaded to move to a tool unloading station, so that the cutting tool to be unloaded is clamped and fixed by a clamping mechanism; in the clamped state, the adsorption and fixation of the tool holder to the cutting tool to be unloaded is released; then controlling the tool holder to move, so that the cutting tool to be unloaded is moved out of the clamping mechanism and falls off from the tool holder; S3, a tool unloading verification step: after the tool unloading step, controlling the tool holder to move through a detection position; acquiring a sensor signal of the detection position, and judging whether the cutting tool to be unloaded has been successfully unloaded based on the sensor signal.

[0008] Preferably, before the S1 tool taking step and / or the S2 tool unloading step are executed, a visual reference association calibration step is further included: acquiring an image of a visual reference mark provided on the clamping mechanism and / or the detection position; determining an actual position of the visual reference mark based on the image, and determining a relative position of the clamping mechanism and / or the detection position according to the position of the tool taking position and the visual reference mark, so that the tool holder can be aligned with the clamping mechanism and / or the detection position.

[0009] Preferably, in the S1 tool taking step, the step of "triggering a lifting tool mechanism and a driving mechanism to enter a power transmission state" specifically includes: the pressing-down action of the tool holder is converted into an axial displacement of a power input part of the lifting tool mechanism through a mechanical trigger assembly, so that the power input part and an output part of the driving mechanism enter a meshing preparation state capable of transmitting rotary power.

[0010] Preferably, after the power input part and the output part enter the meshing preparation state, the S1 tool taking step further includes: controlling the output part of the driving mechanism to first reverse by a preset angle, so that the output part and the power input part complete meshing; then controlling the output part to rotate forward to drive the lifting tool mechanism to perform a lifting action.

[0011] Preferably, the step S2, "removing the cutter to be unloaded from the clamping mechanism and detaching it from the tool holder," specifically includes: controlling the tool holder to horizontally move the cutter to be unloaded out of the clamping mechanism and to a clearance area; then controlling the tool holder to perform reciprocating motion in the clearance area so that the cutter to be unloaded is detached from the tool holder by inertial force.

[0012] Preferably, in the S3 blade removal verification step, the detection position is provided with a swingable detection component with a detection window; if there is an unremoved cutting blade remaining on the blade holder, the cutting blade will contact and push the detection component to swing as it enters the detection window, thereby entering the detection window and triggering the sensor.

[0013] Preferably, the method further includes an empty blade detection step: monitoring the signal of a pressure sensor located at the end of the guide rail of the tool magazine assembly; when all the cutting blades in the guide rail are removed and the tool magazine assembly is in an empty state, the elastic actuating element of the tool magazine assembly acts on the pressure sensor; and generating and outputting an empty blade status prompt based on the trigger signal of the pressure sensor.

[0014] Preferably, the method further includes a cutting blade length adjustment step: in response to a length adjustment command, an electric push rod or a lead screw mechanism is controlled to drive the adsorption fixing structure and the adsorbed cutting blade to move along the axial direction of the blade holder, thereby adjusting the length of the cutting blade extending out of the blade holder.

[0015] Preferably, the S1 blade retrieval step further includes a secondary positioning step: after the drive mechanism drives the blade lifting mechanism to perform the first lifting action, if the target cutting blade is not effectively attracted and fixed by the blade holder, the following coordinated action is performed: controlling an electric push rod or a lead screw mechanism in the blade holder to drive the suction and fixing structure in the blade holder to perform at least one reciprocating motion along the axial direction of the target cutting blade; simultaneously, controlling the drive mechanism to continue driving the blade lifting mechanism to perform at least one additional lifting action; through the coordination of the reciprocating motion of the suction and fixing structure and the additional lifting action of the blade lifting mechanism, the top of the target cutting blade enters the predetermined position in the blade holder and is attracted and fixed.

[0016] Preferably, the determination condition for "if the target cutting blade is not effectively attracted and fixed by the blade holder" is as follows: after the first lifting action is completed, when the blade holder begins to rise, a sensor detects whether the target cutting blade is still on the lifting mechanism, or detects whether the load current of the blade holder is lower than the threshold when the attraction is successful.

[0017] Secondly, the present invention also provides a fully automatic tool changing control device for use in a cutting machine, comprising: a tool taking control module for executing the S1 tool taking step; a tool removing control module for executing the S2 tool removing step; and a verification module for executing the S3 tool removing verification step.

[0018] Preferably, it further includes a visual positioning module for performing the visual reference association calibration step as described in claim 2; and / or an empty blade detection module for performing the empty blade detection step; and / or an adjustment control module for performing the cutting blade length adjustment step; and / or a secondary positioning module for performing the secondary positioning step as described.

[0019] Thirdly, the present invention also provides a cutting device, comprising: a control unit; a tool magazine; a tool retrieval mechanism, including a motion slide that can be driven by the control unit and a tool holder disposed at its movable end, the tool holder being provided with an adsorption and fixing structure; a tool lifting mechanism and a first driving mechanism; a clamping mechanism and a tool removal detection device disposed at a tool removal station; the control unit is configured to execute the fully automatic tool changing control method as described in the first aspect.

[0020] Preferably, it also includes a visual reference mark disposed on the rack and an image acquisition module disposed on the tool holder.

[0021] Preferably, the knife removal detection device includes a detection body that can be oscillated, the detection body having a detection window and a guide portion, and a sensor being provided at the detection window.

[0022] Preferably, the tool holder is further provided with an electric push rod or lead screw mechanism for driving the adsorption fixing structure to reciprocate along the axial direction.

[0023] Fourthly, the present invention also includes an electronic device comprising: one or more processors; a memory; and one or more programs, wherein the one or more programs are stored in the memory and configured to be executed by the one or more processors, the one or more programs including instructions for performing the fully automatic tool change control method of the first aspect.

[0024] Fifthly, the present invention also provides a storage medium storing a computer program, which, when executed by a processor, implements the fully automatic tool changing control method as described in the first aspect.

[0025] This invention integrates the three core steps of "blade removal," "blade unloading," and "blade unloading verification" into a coherent and intelligent control sequence, uniformly scheduled by a single control unit. This eliminates the fragmentation between processes, achieves fully automated blade changing, significantly improves blade changing efficiency, and reduces manual intervention. By introducing an independent "blade unloading verification step," the system can automatically and instantly confirm whether the old cutting blade has been successfully unloaded. This avoids serious safety accidents such as cutting blade collisions and equipment damage caused by undetected blade unloading failures, greatly improving the reliability of equipment operation. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below.

[0027] Figure 1 This is a flowchart of the fully automatic tool changing control method in the embodiment.

[0028] Figure 2 This is a block diagram of the control module of the automatic tool changing system in the embodiment.

[0029] Figure 3 This is the overall flowchart of the fully automatic tool changing control method in the embodiment.

[0030] Figure 4 This is a flowchart of step S1, the tool removal operation, in the embodiment.

[0031] Figure 5 This is a flowchart of step S2, the blade removal operation, in the embodiment.

[0032] Figure 6 This is a flowchart of the S3 blade removal verification process in the embodiment.

[0033] Explanation of reference numerals in the attached figures: 100-Control unit, 200-Tool removal control module, 300-Tool removal control module, 400-Verification module, 500-Vision positioning module, 700-Adjustment control module, 800-Secondary positioning module. Detailed Implementation

[0034] To make the objectives, technical solutions, and advantages of this invention clearer, the specific implementation methods of this invention will be comprehensively and deeply described below in conjunction with the control logic of this invention and the hardware system on which this logic is implemented. This section will describe in detail how the control unit 100, through software programs and algorithms, coordinates and schedules various sensors, actuators, and mechanical mechanisms to complete the complex operation sequence of fully automatic tool changing. The description will cover the complete control chain from initial calibration and core processes to status monitoring, aiming to enable those skilled in the art to fully understand and reproduce this invention.

[0035] Example Reference Figures 1 to 3 As shown, this invention is implemented on a cutting machine equipped with an automatic tool changer system. The control center of this system is a control unit 100, which can be a programmable logic controller (PLC), an industrial computer (IPC), or an embedded system designed specifically for motion control. This control unit 100 can establish bidirectional communication with the following functional modules via industrial Ethernet, fieldbus, or pulse / direction interface: The tool retrieval control module 200 is responsible for planning and executing the complete sequence (S1 step) of retrieving a new cutting tool from the tool magazine. Its internal logic includes: calling the tool magazine coordinates, generating the motion path, controlling the downward trigger, managing the "reverse-forward" power sequence of the drive mechanism, monitoring the adsorption status, and calling the secondary positioning fault-tolerant subroutine under specific conditions.

[0036] The tool removal control module 300 is responsible for planning and executing the complete sequence (S2 step) for safely unloading the old cutting tool from the tool holder. Its internal logic includes: calling the coordinates of the clamping mechanism, controlling the tool advance and clamping confirmation, issuing a safe release command, controlling the removal action, and executing an active inertial detachment strategy.

[0037] Verification module 400: Responsible for automatically verifying the unloading result (step S3) after the tool removal operation. Its logic is as follows: control the tool holder to pass through the detection window, collect and analyze sensor signals from the tool removal detection device, determine whether the tool removal was successful or not according to preset logic, and trigger corresponding result processing (such as process completion or alarm).

[0038] Visual positioning module 500: Operates during system initialization or periodic maintenance to perform visual reference association calibration. In daily operation, it can also be used as an optional pre-processing step to determine the relative coordinates of the clamping mechanism and the detection position relative to the origin. Its logic is: control image acquisition, run the recognition algorithm, calculate the coordinates of the target position, and generate corresponding positioning commands.

[0039] Empty tool detection module 600: Independent of the main tool change process, it operates periodically at a low frequency. Its logic is as follows: It reads the digital or analog signal from the pressure sensor at the end of the tool magazine, determines whether the tool magazine is empty based on the signal status (such as high or low level), and manages the generation and elimination of empty tool status prompts.

[0040] The adjustment and control module 700 is activated in response to external commands (such as HMI input or host computer commands). Its logic is as follows: it receives the target length value, calculates the difference between the current position and the target length value, sends the corresponding pulse or analog control signal to the cutting blade length adjustment mechanism, and can achieve closed-loop control through encoder feedback.

[0041] Secondary positioning module 800: Called by tool retrieval control module 200 under specific conditions (adsorption determination failure). Its logic is: to coordinate the electric push rod mechanism inside the tool holder and the external tool lifting drive mechanism to execute a set of preset, synchronous short-stroke reciprocating and additional lifting actions.

[0042] Before the equipment is put into operation, a one-time system initialization and calibration process must be performed. This process is guided by a dedicated calibration program within the control unit 100. The steps include: Establishment of Mechanical Reference: The operator uses a detachable positioning fixture. This fixture is positioned and fixed on the machine frame by engaging with a standard hole on the frame via its own positioning pin. A alignment slot of the same diameter and coaxial with the tool magazine's tool-taking port is machined on the fixture; its axis is ensured to be coaxial with the theoretical tool-taking port axis of the tool magazine during manufacturing. The control unit 100 first controls the motion slide, driving the tool holder to move to the origin of its mechanical coordinate system (determined by zero-point sensors for each axis). Then, the tool holder is lowered, attempting to insert its cylindrical bottom end into the slot of the positioning fixture. This process can be monitored via the motion slide's load current, grating ruler feedback, or visual observation. If it smoothly inserts to the bottom, it proves that the origin of the tool holder's movement trajectory is consistent with the physical reference defined by the positioning fixture, completing the "zeroing" and verification of the mechanical coordinate system. If insertion is obstructed, the tool magazine's installation position needs to be fine-tuned or the motion slide calibrated.

[0043] In some implementations, visual coordinate system mapping is also included: after the mechanical reference is established, a visual reference marker is installed at a defined position on the frame, and its relative position to the tool magazine's tool-taking edge is determined during manufacturing using positioning fixtures or other tooling. The control unit 100 then controls the tool holder to move, causing a vision camera (such as an industrial camera) fixed to the tool holder to focus on the visual reference marker (e.g., a marker with a "T"-shaped calibrated groove, with its intersection point as a reference; the visual reference marker is entirely white for easier identification). After the vision camera captures an image, the image coordinates of the marker's feature points are identified at the sub-pixel level using an image processing algorithm running within the control unit 100.

[0044] Based on the current position of the tool holder in the calibrated mechanical coordinate system, the control unit 100 executes a hand-eye calibration algorithm (e.g., the Tsai-Lenz method) to calculate the transformation matrix between the vision camera coordinate system and the mechanical coordinate system. Thus, the position identified by the vision system can be accurately transformed into the mechanical coordinate system. For example, if a visual reference marker is installed on the clamping mechanism or inspection position, the relative position can be determined. Simultaneously, since the tool magazine, clamping mechanism, and tool release detection device are all fixed to the frame through mechanical mounting, their theoretical positions in the mechanical coordinate system are also stored in the database of the control unit 100.

[0045] The goal of the tool retrieval phase is to reliably retrieve a target cutting tool from the designated tool magazine and attach it to the tool holder for the cutting task. When the control unit 100 receives a tool change command from the host computer or internal job queue, it triggers the tool retrieval thread. The tool holder movement can be implemented by a motion slide or a robotic arm. This embodiment uses a motion slide to move the tool holder; the motion slide can be an XYZ three-axis servo system, and its fully automatic tool change control method includes the following steps: Reference Figure 4 As shown, S1.1 Movement and Pressing Down: The control unit 100 first calls the stored origin coordinates of the tool magazine's tool-picking position. Based on these coordinates, it generates a movement path instruction for the tool holder from its current position (such as the previous machining position or safety position) to directly above the origin coordinates. This instruction drives the motion slide of the tool-picking mechanism, causing the tool holder, fixed at its movable end, to move in the horizontal plane (XY axis) to the vertical projection position of the origin coordinates, and to stop at a preset "safe height" in the Z-axis direction.

[0046] Subsequently, the control unit 100 sends a "press down" command to the Z-axis servo drive of the motion slide. This command drives the tool holder to move vertically downward along the Z-axis, with the target position being the preset "trigger depth". The control unit 100 reads the encoder feedback from the Z-axis servo motor in real time and performs a closed-loop comparison with the set "trigger depth" value to ensure that the pressing action is in place. This pressing process is not only for spatial proximity, but one of its core purposes is mechanical triggering.

[0047] S1.2 Response to the pressing action, triggering power transmission state preparation: When the control unit 100 confirms through encoder feedback that the tool holder has reached the "trigger depth," it logically determines that "the pressing action is completed and the mechanical triggering condition is met." Mechanically, at this moment, the trigger block fixedly mounted on the side of the tool holder has contacted and applied pressure to a force-bearing arm (such as the force-bearing part of the swing arm assembly) on the tool lifting mechanism. This pressure is converted into a linear displacement along the axial direction of a power input component inside the tool lifting mechanism through a purely mechanical lever mechanism.

[0048] This displacement moves the power input component from an "initial position" separated from the output end of the drive mechanism to a "meshing position". In the "meshing position", the snap-fit ​​structure (e.g., circumferentially distributed grooves) on the power input component and the output end of an independently set drive mechanism (e.g., a servo motor driven by a damper) enter a space range where they can interlock axially. The control logic of the control unit 100 is to treat the detectable electronic signal of "pressing down in place" as a permission signal for subsequent power engagement and lifting operations. The system state formally transitions from the "positioning and pressing down stage" to the "preparatory power transmission stage".

[0049] S1.3 Drive Mechanism Start-up and Power Engagement Control: After the state transition, the control unit 100 immediately sends the first control command to the independent drive mechanism (preferably a servo motor with an encoder, which can be connected in series with a rotary damper): controls its output shaft to reverse by a preset angle θ1 (e.g., 180°) at a set speed and torque.

[0050] The purpose of this "reverse positioning" command is to actively find the engagement point. During the reversal process, the outer surface of the output end of the drive mechanism (such as the locking pin) slides relative to the power input end face, which is already in the "engageable position". When the sliding reaches a certain angle and the phase of the locking pin aligns with the phase of a groove on the power input component, the two quickly complete radial engagement under the action of the continuous thrust triggered by the downward pressure of the tool holder, achieving a reliable power connection.

[0051] Understandably, reverse positioning retains fault tolerance and has a buffering effect. The preset reverse angle θ1 ensures that even if there is a random deviation in the initial phase, there is sufficient rotation range to find the engagement point. The series damper allows the output to undergo limited relative rotation when encountering slight alignment resistance, thereby absorbing shock and protecting mechanical components. The control unit 100 can indirectly determine the occurrence of the engagement event by monitoring the real-time current or torque feedback of the servo motor during the reverse process (for example, the engagement moment may be accompanied by a brief torque peak or change).

[0052] S1.4 Drive the lifting mechanism to perform the lifting: After the preset reversal angle θ1 is completed, the control unit 100 immediately (or according to the engagement judgment signal) issues the second continuous control command: controlling the output shaft of the drive mechanism to rotate forward. At this time, since the power connection has been established in the previous step, the forward rotation power is reliably transmitted to the lifting mechanism. The internal mechanism of the lifting mechanism (e.g., a lever or boss) converts the input rotational motion into a vertically upward linear thrust, which acts on the lifting component (e.g., a slider) supporting the target cutting blade.

[0053] The control unit 100 controls the lifting stroke H by controlling the forward rotation angle θ2 or the time T. During this lifting process, the target cutting blade supported by the lifting component rises smoothly and vertically, and its top gradually approaches and finally enters the fixing groove (with an adsorption fixing structure set in the fixing groove) or adsorption area at the bottom of the blade holder.

[0054] S1.5 As the lifting action ends, the target cutting blade should reach the preset "adsorption position," with its top fully in contact with the adsorption and fixing structure (such as a permanent magnet or electromagnet) inside the blade holder. To confirm successful blade retrieval, the control unit 100 uses one or more of the following methods to determine the status: Load current monitoring method: After the lifting action is completed, the control unit 100 attempts to control the motion slide to drive the tool holder to perform a short "trial rise" (e.g., 0.5mm) along the Z-axis. Simultaneously, the real-time load current of the Z-axis servo motor is sampled. If the cutting blade is firmly attracted, the tool holder needs to overcome the weight and attraction force of the cutting blade to rise, and the load current will remain at a threshold level significantly higher than the "no-load rise" reference value. If attraction fails, the load current will be approximately equal to the no-load reference value. The control unit 100 can determine the attraction status by comparing the real-time current with the preset "attraction success current threshold".

[0055] Direct detection method: A photoelectric sensor is installed at the initial support position of the blade lifting mechanism. After the control unit 100 issues a lifting command, the sensor signal is read again after a set time delay. If the signal status changes from "blade present" to "blade absent", it can be indirectly inferred that the blade has been removed.

[0056] Once the control unit 100 confirms, based on any of the aforementioned judgment logics, that "the target cutting blade has been attracted and fixed by the tool holder," it determines that the core objective of the S1 tool retrieval step has been achieved. Subsequently, the control unit 100 controls the motion slide to drive the tool holder (along with the attracted cutting blade) to a safe height, disengaging it from the tool magazine area. The rise of the tool holder causes the trigger block to disengage from the lifting mechanism's force arm, and the entire lifting mechanism automatically returns to its initial state under the action of its internal return spring, ready for the next cycle. The control unit 100 records the successful tool retrieval operation and can update the system status log.

[0057] In this embodiment, the secondary positioning step in the S1 tool retrieval process is a fault-tolerant and enhancement sub-process within the main S1 tool retrieval flow. It aims to overcome the problem of initial lifting and adsorption failure caused by mechanical manufacturing tolerances, cutting tool size deviations, or small foreign objects through proactive, coordinated micro-motion control. It is understood that the above-mentioned confirmation of whether tool retrieval was successful, if determined to have failed, will trigger a secondary positioning step. The specific steps include: Once adsorption is determined to have failed (S1.6), the control unit 100 immediately interrupts the normal subsequent process (such as the tool holder rising directly) and switches to the secondary positioning control mode. The core of this mode is to synchronously drive two actuators to generate a coordinated micro-adjustment.

[0058] S1.61: Axial reciprocating motion of the adsorption and fixing structure. The control unit 100 sends a pre-programmed sequence of motion commands to the axial driver (i.e., the electric push rod or lead screw mechanism) integrated inside the tool holder to realize the reciprocating axial motion of the adsorption and fixing structure. For example, rapid advance ΔL1 (e.g., 1.5mm) - pause T1 (e.g., 100ms) - rapid return to the original position - pause T2 (e.g., 50ms) - rapid advance ΔL2 again (e.g., 1mm).

[0059] This command causes the adsorption and fixing structure (such as a permanent magnet) to generate one or more "push-release-push" pulse-like actions on the top of the cutting blade along the axial direction of the cutting blade. Parameters such as ΔL1, ΔL2, T1, and T2 can be optimized according to the type of cutting blade.

[0060] S1.62: Additional Lifting Action of the Tool Lifting Mechanism: The aforementioned axial reciprocating motion command and the command issued to the drive mechanism (controlling the tool lifting mechanism) are triggered simultaneously and operate in coordination. At the same moment as controlling the axial micro-motion actuator, the control unit 100 issues a new motion command to the servo motor of the drive mechanism: driving the tool lifting mechanism to perform an additional lifting action. This additional lifting can be coordinated with the rhythm of the axial push, for example, during the "forward" phase of the axial actuator.

[0061] The physical principle and control objective of the synergistic effect. The design intent of this synergistic control is as follows: When the cutting blade, although it has entered the fixing groove of the blade holder due to the top chamfer, is stuck because a slight misalignment at the edge prevents it from entering the adsorption groove that matches the chamfer, the axial reciprocating motion provides a small horizontal vibration force and position adjustment, which helps to "loosen" the stuck point and allows the top of the cutting blade to be more deeply aligned with the adsorption groove. The additional short-distance lifting provides a continuous, gentle lifting force in the vertical direction, which, in conjunction with the axial motion, creates a dynamic effect of "shaking and lifting".

[0062] This coordinated micro-motion of two degrees of freedom greatly increases the probability that the cutting blade will disengage from an incorrect jamming position and slide into the correct adsorption position. After executing a set of preset coordinated actions (e.g., a complete reciprocating and lifting cycle), the control unit 100 will return to execute the adsorption state determination logic in S1.5.

[0063] S1.63 Process Closure and Exit Conditions: The secondary positioning process is a configurable loop: Successful Exit: If the judgment logic confirms "successful adsorption" after executing N (N is usually 1-3) collaborative action loops, the control unit 100 exits the secondary positioning mode and continues to execute subsequent actions such as tool holder lifting in step S1.

[0064] Failure Exit: If the maximum number of retries (e.g., 3 times) is reached and the result is still "Adsorption Failure", the control unit 100 determines that the current tool retrieval process has ultimately failed. It will perform a safety operation: control the drive mechanism to reverse so that the tool lifting mechanism descends and resets, control the tool holder to rise to a safe position, and send a clear "Tool Retrieval Failure - Secondary Positioning Uncorrected" alarm message to the host computer or human-machine interface, prompting manual inspection (such as checking the cutting blade size, tool holder groove cleanliness, etc.).

[0065] Reference Figure 5As shown, this embodiment further assumes that the cutting blade to be unloaded has been attracted and fixed by the blade holder, and that the control unit 100 has stored the key position coordinates of the blade release station. The blade release step includes: S2.1 Transferring the cutting tool to the unloading station and performing clamping: The control unit 100 first calls the calibrated position coordinates of the clamping mechanism. Based on these coordinates and the current position of the tool holder, a safe motion path instruction is planned and generated. This instruction drives the motion slide, moving the tool holder carrying the cutting tool to be unloaded from its current position (such as the machining position or temporary storage position in the previous step) to a "tool entry preparation position" near the origin coordinates. This position ensures that the cutting tool axis is initially aligned with the guide entrance of the clamping mechanism on the horizontal plane.

[0066] Subsequently, the control unit 100 sends a "feed" command to the motion slide, driving the tool holder to extend the cutting blade along the Z-axis to a height compatible with the clamping mechanism, and then slowly feeds the cutting blade into the guide port of the clamping mechanism at a low speed along the horizontal direction (which can be the X or Y axis). To ensure reliable clamping, the control unit 100 can use the following strategies for monitoring and judgment during this process: Load monitoring method: Continuously monitor the load current of the servo motor performing the "feed" action. When the cutting blade tip contacts and enters the V-shaped guide port of the clamping mechanism (such as a spring-return gripper), the load current will rise gradually; when the cutting blade is fully pushed in, and the gripper remains closed and clamps the cutting blade shank under the action of the spring force, the load current will reach a stable "clamping and holding" threshold. The control unit 100 determines that the "clamping and fixing" action has been completed by recognizing this current characteristic.

[0067] Position-force hybrid control method: A small contact force threshold is set in the feed command. When the tool holder moves according to the position command, and the system detects that the actual contact force has reached the threshold, it switches to force holding mode to maintain the contact force for a certain period of time to ensure that the grippers are fully closed and clamped.

[0068] Once the control unit 100 confirms that "clamping and fixing have been completed" through any of the above methods, it records the current state and prepares to perform the next operation.

[0069] S2.2 Release the suction fixation while in the clamping state. After confirming that the cutting blade has been reliably fixed by the external clamping mechanism, the control unit 100 executes the "release suction" command. The specific content of this command depends on the design of the blade holder suction fixation structure: If an electromagnet is used: the control unit 100 sends a "power off" command to the electromagnet driver. The electromagnet's magnetism quickly disappears, and its attraction to the cutting blade is released.

[0070] If it is a movable permanent magnet assembly: the control unit 100 sends a command to the miniature actuator (such as a voice coil motor or a small electric push rod) that drives the permanent magnet to move axially, so that it drives the permanent magnet to move backward (away from the cutting blade) by a preset stroke, thereby significantly weakening or eliminating the magnetic force acting on the cutting blade.

[0071] To ensure that the adsorption force has been effectively released, the control unit 100 may briefly delay for a few milliseconds after issuing the release command, and then attempt to drive the tool holder to perform a small "pullback test" (e.g., move 0.1mm in the opposite direction of the feed). Simultaneously, the motor load current during the pullback test is monitored. If the current is extremely low (close to no load), it indicates that the adsorption has been released and the clamping mechanism is firmly holding the tool; if the current suddenly increases, it may indicate that the adsorption has not been completely released or the clamping has failed, in which case an alarm or retry procedure may be triggered.

[0072] S2.3 After confirming the removal and detachment of the cutting blade from the adsorption system, the control unit 100 then performs an operation to finally detach the cutting blade. This operation includes the following two consecutive sub-steps: Step S2.31: Horizontal removal from the clamping mechanism: The control unit 100 sends a command to the motion slide, driving the tool holder to move horizontally in the opposite direction of the feed path. The movement distance must ensure that the cutting part of the cutting blade is completely removed from the gripper range of the clamping mechanism, and the entire cutting blade is moved to a preset "avoidance zone" above the equipment worktable. There are no components below this area that could obstruct the cutting blade from falling. During this movement, since the suction force has been released, the cutting blade is only connected to the tool holder fixing groove by the slight friction or mechanical jamming that may exist. It is very easy for it to fall directly under its own gravity. A recovery device or a slide rail can be set below the avoidance zone to guide the cutting blade out of the cutting equipment.

[0073] Step S2.32: Perform inertial detachment action: To ensure the cutting blade reliably separates from the tool holder, the control unit 100 executes an active "jitter" or "vibration" control strategy. Specifically, the control unit controls the motion slide to drive the tool holder, within the "avoidance zone," to perform several rapid, short-stroke reciprocating movements in one or more directions (preferably horizontal, or combined with a slight vertical direction). For example, the tool holder is instructed to perform a reciprocating motion of "forward 2mm - backward 2mm - forward 2mm" with high acceleration.

[0074] Its control principle is as follows: by suddenly accelerating and decelerating the blade holder, sufficient inertial force is generated. This inertial force acts on the cutting blade, which can easily overcome the residual small static friction or mechanical interference between the cutting blade and the blade holder, causing the cutting blade to undergo relative displacement with the blade holder under the action of inertia. Finally, under the action of gravity, it completely falls off the blade holder and falls into the preset recovery device or slide below.

[0075] After the inertial release action is completed, the control unit 100 can drive the tool holder to move a short distance and read the load current of the motion slide again. If the current returns to the typical no-load state, it can indirectly verify that the cutting tool has been released. After the cutting tool is removed, the spring reset mechanism of the clamping mechanism will automatically reset the jaws and return to the ready state.

[0076] Reference Figure 6 As shown, further, in this embodiment, the tool removal verification step is executed immediately after the tool removal step S2 is completed. Its core purpose is to form a control closed loop and perform a final verification of the tool removal result. The control unit 100 has stored the position coordinates of the tool removal detection window. The specific steps include: S3.1 Controlling the tool holder to move past the detection position: The control unit 100 calls the calibrated detection window position coordinates. A path command is generated, driving the motion slide to control the tool holder (theoretically in an unloaded state) to move from its post-tool removal position away from the clamping mechanism, i.e., from the clearance zone to the tool removal detection window. This ensures that the tool holder body or any remaining cutting blade can enter the detection window or pass through its detection area. This path can be designed to pass through in a straight line or stop directly within the detection window. If it passes directly through the detection window, the control unit 100 will precisely control the speed and attitude of the tool holder as it passes through the detection area to ensure the effectiveness of the detection.

[0077] S3.2 Acquiring Sensor Signals and Adaptive Detection Process: As the tool holder moves through the detection area, the control unit 100 samples the sensor signal located at the detection position in real time at a high frequency or reads the sensor signal within a specific time window. This sensor can be a photoelectric sensor (such as a through-beam or reflective sensor), whose beam forms an invisible "detection surface" at the detection window.

[0078] One point to add is the adaptive scheme of the detection component: the component supporting the detection window is mounted on a support structure that can swing slightly freely around an axis, and is equipped with a reset mechanism. Its signal logic includes: Scenario A (successful tool removal, tool holder unloaded): the bottom of the tool holder body is above the detection window. If a cutting tool is present, the shank of the cutting tool extending from the bottom of the tool holder body will be within the detection window. Since there is no protrusion (the cutting tool's extended shank), the sensor beam is not blocked, and its output signal remains "open" throughout the passage of the tool holder (e.g., the through-beam sensor receiver continuously receives a light signal and outputs a high level).

[0079] Scenario B (Cut blade removal failure, cutting blade remaining on the tool holder): The cutting blade remains attached to the tool holder. When the tool holder moves under the command of the control unit 100, if the remaining cutting blade is in the correct position, it will directly enter the detection window; if there is a slight positional error, it will contact the guide ramp at the entrance of the detection window. At this time, the mechanical adaptive characteristic comes into play: the contact force will push the entire detection component to produce a compliant, slight sway. This sway is not an obstacle, but is guided by the control unit 100 along a preset linear motion path to become a mechanical action that "guides" the skewed cutting blade into the detection window. Once the cutting blade is guided into the window, it will inevitably block the sensor beam.

[0080] Therefore, the sensor signals acquired by the control unit 100 directly reflect the results of the above physical process: If a continuous "smooth" signal is received, it corresponds to scenario A.

[0081] If a "blocking" pulse appears in the sensor signal within the time window of the tool holder passing through (the signal changes from unobstructed to blocked, and then returns to unobstructed), then it corresponds to scenario B.

[0082] S3.3 Logical judgment based on sensor signals: The control unit 100 has a preset judgment algorithm to analyze the acquired sensor signal sequence: Signal feature extraction: Within a preset time window when the tool holder passes through the detection area, check whether the sensor signal undergoes a complete transition from "unobstructed" to "obstructed" and back to "unobstructed". Simultaneously, analyze whether the width of the obstruction pulse matches the expected physical time of the cutting tool obstruction.

[0083] Logical judgment: "Successful removal of blade": If the sensor signal remains "unobstructed" throughout the entire monitoring time window (or no signal fluctuation exceeds the set "obstruction" threshold), the control unit 100 determines that "blade removal verification passed", meaning that the cutting blade to be unloaded has been successfully removed.

[0084] If a “blade removal failure” is detected within the monitoring time window, the control unit 100 determines that the blade removal verification has failed, meaning that there are still residual cutting blades on the blade holder that have not been successfully removed.

[0085] S3.4 Post-processing of verification results and system response: Based on the judgment result, control unit 100 executes different post-processing instructions to achieve closed-loop control: If the verification is successful: Control unit 100 records the tool change process as successful. The internal "Tool Change in Progress" flag can be cleared, the cutting tool status updated, and the cutting machine allowed to continue subsequent processing tasks or enter standby mode. The tool holder can be moved back to a safe position.

[0086] If verification fails: Control unit 100 immediately triggers an exception handling procedure, which includes, but is not limited to: The inertial detachment action of S2.32 can be re-executed, and the tool removal verification can be performed again.

[0087] Emergency Alarm: Triggers an audible and visual alarm and displays a clear warning message on the human-machine interface, such as "Tool removal verification failed! The cutting tool may still be attached to the tool holder!" Process interruption and safety protection: Forcefully pause the current automatic process. Control the motion slide to move the tool holder to a specific "problem-handling position" (such as a safe corner away from the machining area and tool magazine) to prevent accidental collisions with residual cutting tools.

[0088] In some implementations, an S4 empty tool detection step is also included, which serves as a separate, accompanying status monitoring function to provide automated early warning for the management of the cutting tool inventory in the tool magazine.

[0089] In the design of the tool magazine assembly, a pressure sensor (such as a microswitch or a thin-film pressure sensor) is integrated at the end of its circular guide rail (i.e., the end furthest from the tool exit end). The installation position of the sensor's triggering component (such as a button or sensing surface) is calculated to match the endpoint of the movement trajectory of the elastic actuating component (such as a spring pawl) inside the tool magazine in a specific state.

[0090] The function of the elastic actuator in the tool magazine is to continuously apply a pushing force to the arranged cutting blades. When there is at least one cutting blade in the guide rail, the side of the last cutting blade will block the free end of the actuator, limiting its swing angle towards the center. At this time, the other end of the actuator (or a protruding structure) cannot contact or reach the position to trigger the pressure sensor.

[0091] When the last cutting blade in the guide rail is removed and the entire guide rail becomes empty, the unobstructed elastic actuating element will swing towards the center of the cutter head to its maximum angle under the drive of its built-in torsion or tension spring. At this maximum angle position, a specific part of the actuating element (such as the tail protrusion) will precisely contact and press the trigger component of the pressure sensor.

[0092] The control unit 100 continuously or periodically (e.g., every 100 milliseconds) reads the electrical signal status of the pressure sensor via a general-purpose digital input port or a dedicated sensor signal acquisition module. This signal is typically a switching signal. Normal (not triggered): When the sensor is not pressed, the output level is high (or low).

[0093] Triggered state: When the sensor is pressed, the output level flips.

[0094] The control unit 100 has an internal de-jitter processing program for the signal to filter out transient false signals that may be caused by mechanical vibration and ensure the stability of the status judgment.

[0095] The control unit 100 executes the following judgment logic sequence: S4.1 Signal validity check: When the signal of the pressure sensor changes from "not triggered" to "triggered" and remains stable for more than the de-jittering time (e.g., 50 milliseconds), the control unit 100 initially determines that "the sensor has been effectively triggered".

[0096] S4.2: System Status Analysis: Control unit 100 will not immediately report an empty tool based solely on sensor signals. It will analyze the current system's operation log. A key cross-validation is that the sensor trigger event must occur after a successful execution of the "S1 tool retrieval step" from the tool magazine. This is because the actuating element will only lose its obstruction and swing to the trigger position when the last tool has been retrieved.

[0097] S4.3: Empty tool state determination: If both "sensor continuously triggers" and "the most recent operation on the tool magazine was a successful tool retrieval" are met simultaneously, the control unit 100 will ultimately determine that the tool magazine is in an "empty state".

[0098] S4.4: Generation and Output Prompt: Upon determining an empty tool state, the control unit 100 immediately executes a prompt output operation. This typically includes: Internal status flag update: Updating the tool magazine's flag status to "empty" in the control unit 100's memory and non-volatile storage area. Human-Machine Interface Prompt: A prominent warning window or icon pops up through the device's host computer software or touchscreen human-machine interface, clearly indicating which tool magazine (e.g., "Tool Magazine A") is empty, possibly accompanied by text prompts such as "Please add a cutting tool." Audible and visual alarm: Driving the three-color indicator light installed on the device to switch to a flashing yellow state, and possibly activating a buzzer to emit an intermittent alert sound to attract the attention of on-site operators. Data reporting: In networked devices, the control unit 100 can send this empty tool event and tool magazine number to the upper-level production management system via industrial Ethernet or fieldbus to achieve a higher level of material early warning.

[0099] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A fully automatic tool changing control method, applied to a cutting machine, characterized in that, Performed by the control unit, the steps include: S1. Tool Retrieval Step: Control the tool holder of the tool retrieval mechanism to move to the tool retrieval position in the tool magazine and perform a pressing action; in response to the pressing action, trigger a tool lifting mechanism and a drive mechanism to enter the power transmission state; then control the drive mechanism to drive the tool lifting mechanism to lift the target cutting tool in the tool magazine until the target cutting tool is attracted and fixed by the tool holder; S2, Unloading Step: Control the tool holder carrying the unloaded cutting blade to move to an unloading station, so that the unloaded cutting blade is clamped and fixed by a clamping mechanism; in the clamping state, release the suction and fixation of the tool holder on the unloaded cutting blade; then control the tool holder to move, remove the unloaded cutting blade from the clamping mechanism, so that it falls off the tool holder; S3. Blade removal verification step: After the blade removal step, control the blade holder to move past a detection position; acquire the sensor signal at the detection position, and determine whether the cutting blade to be unloaded has been successfully removed based on the sensor signal.

2. The fully automatic tool changing control method according to claim 1, characterized in that, Before performing the S1 tool removal step and / or the S2 tool removal step, a visual reference association calibration step is also included: Acquire images of visual reference markers located on the clamping mechanism and / or detection position; Based on the image, the actual position of the visual reference mark is determined, and according to the position of the tool picking position and the position of the visual reference mark, the relative position of the clamping mechanism and / or the detection position is determined, so that the tool holder can be aligned with the clamping mechanism and / or the detection position.

3. The fully automatic tool changing control method according to claim 1, characterized in that, The step S1, "triggering a tool lifting mechanism and a driving mechanism to enter the power transmission state," specifically includes: The downward pressing action of the tool holder is converted into the axial displacement of a power input component of the tool lifting mechanism through a mechanical triggering component, so that the power input component and an output component of the drive mechanism enter a meshing preparation state capable of transmitting rotational power.

4. The fully automatic tool changing control method according to claim 3, characterized in that, After the power input component and the output component enter the engagement preparation state, the S1 tool removal step further includes: The output component of the drive mechanism is first reversed by a preset angle so that the output component engages with the power input component; then the output component is controlled to rotate forward to drive the lifting mechanism to perform a lifting action.

5. The fully automatic tool changing control method according to claim 1, characterized in that, The step S2, "removing the cutter to be unloaded from the clamping mechanism and detaching it from the tool holder," specifically includes: controlling the tool holder to horizontally move the cutter to be unloaded out of the clamping mechanism and to a clearance area; then controlling the tool holder to perform reciprocating motion in the clearance area so that the cutter to be unloaded is detached from the tool holder by inertial force.

6. The fully automatic tool changing control method according to claim 1, characterized in that, In the S3 blade removal verification step, the detection position is provided with a swingable detection component with a detection window; if there is an unremoved cutting blade remaining on the blade holder, the cutting blade will contact and push the detection component to swing as it enters the detection window, thereby entering the detection window and triggering the sensor.

7. The fully automatic tool changing control method according to claim 1 or 2, characterized in that, It also includes a dry-blade inspection step: Monitor the signal from the pressure sensor located at the end of the guide rail of the tool magazine assembly; When all the cutting blades in the guide rail are removed and the machine is in an empty state, the elastic actuating element of the blade magazine assembly acts on the pressure sensor. Based on the trigger signal from the pressure sensor, an empty tool status prompt is generated and output.

8. The fully automatic tool changing control method according to claim 1, characterized in that, It also includes a cutting blade length adjustment step: in response to a length adjustment command, an electric push rod or a lead screw mechanism is controlled to drive the adsorption fixing structure and the adsorbed cutting blade to move along the axial direction of the blade holder, thereby adjusting the length of the cutting blade extending out of the blade holder.

9. The fully automatic tool changing control method according to claim 8, characterized in that, The S1 tool retrieval step also includes a secondary positioning step: after the drive mechanism drives the tool lifting mechanism to perform the first lifting action, if the target cutting tool is not effectively attracted and fixed by the tool holder, the following coordinated action is performed: Control the movement of an electric push rod or a lead screw mechanism inside the tool holder to drive the adsorption and fixing structure inside the tool holder to reciprocate at least once along the axial direction of the target cutting tool; Simultaneously, the drive mechanism is controlled to continue driving the blade lifting mechanism to perform at least one additional lifting action; through the reciprocating motion of the adsorption and fixing structure and the additional lifting action of the blade lifting mechanism, the top of the target cutting blade enters the predetermined position within the blade holder and is adsorbed and fixed.

10. The fully automatic tool changing control method according to claim 9, characterized in that, The determination condition for "if the target cutting blade is not effectively attracted and fixed by the blade holder" is as follows: after the first lifting action is completed, when the blade holder begins to rise, a sensor detects whether the target cutting blade is still on the lifting mechanism, or detects whether the load current of the blade holder is lower than the threshold when the attraction is successful.

11. A fully automatic tool changing control device, applied to a cutting machine, characterized in that, include: A tool retrieval control module is used to execute the tool retrieval step S1 as described in claim 1; A tool removal control module is used to execute the S2 tool removal step as described in claim 1 or 5; The verification module is used to perform the S3 knife removal verification step as described in claim 1 or 6.

12. The fully automatic tool changing control device according to claim 11, characterized in that, It also includes a visual positioning module for performing the visual reference association calibration step as described in claim 2; and / or an empty blade detection module for performing the empty blade detection step as described in claim 7; and / or an adjustment control module for performing the cutting blade length adjustment step as described in claim 8; and / or a secondary positioning module for performing the secondary positioning step as described in claim 9 or 10.

13. An electronic device, characterized in that, include: One or more processors; Memory; One or more programs, wherein the one or more programs are stored in the memory and configured to be executed by the one or more processors, the one or more programs including instructions for performing the fully automatic tool change control method as described in any one of claims 1 to 10.

14. A storage medium, characterized in that, The storage medium stores a computer program, which, when executed by a processor, implements the fully automatic tool changing control method as described in any one of claims 1 to 10.

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