A soft magnetic core polishing compensation method and device

Abstract

The application is suitable for the technical field of soft magnetic core manufacturing, and particularly relates to a soft magnetic core polishing compensation method and device, which comprises the following steps: controlling a detection module to detect the soft magnetic core arranged in a pre-feeding detection area before polishing, and screening the soft magnetic core to be processed which meets the preset condition; controlling a transfer module to transfer the soft magnetic core to be processed to a processing station, and after detecting that the soft magnetic core to be processed enters the processing station and is fixed through a position sensing module, obtaining the initial inductance parameter, initial surface state parameter and polishing area environment parameter of the soft magnetic core to be processed; determining the processing adaptation state of the soft magnetic core to be processed according to the initial inductance parameter, initial surface state parameter and polishing area environment parameter; and adjusting the grinding wheel feeding parameter, cooling parameter and fine grinding time parameter of the soft magnetic core polishing compensation device according to the processing adaptation state. The embodiment of the application can solve the problems of insufficient performance consistency of the soft magnetic core after polishing and easy processing damage.

Description

Technical Field

[0001] This application belongs to the field of soft magnetic core manufacturing technology, and in particular relates to a soft magnetic core grinding compensation method and equipment. Background Technology

[0002] Soft magnetic cores are core components of electronic devices such as power supplies, sensors, and communication equipment. Their surface finish and dimensional accuracy directly affect the electromagnetic conduction efficiency and lifespan of these devices. During the pressing and molding process of soft magnetic cores, factors such as material flowability and mold wear can easily cause microburrs, local protrusions, or dimensional deviations on the surface. These defects can lead to problems such as excessive assembly gaps and unstable electromagnetic performance. Therefore, a grinding process is needed to compensate for these surface defects. Grinding removes these defects and compensates for dimensional or surface deviations during molding, ultimately bringing the soft magnetic core to the preset processing standards. Currently, the mainstream grinding compensation method for soft magnetic cores in the industry mainly involves batch grinding with uniform parameters. This involves first screening out soft magnetic cores with obvious visual damage, and then batch processing the remaining cores using pre-set fixed grinding parameters.

[0003] However, the existing soft magnetic core grinding compensation methods still have limitations in practical applications. For example, most existing soft magnetic core grinding compensation methods only screen out severely defective soft magnetic cores by appearance. When grinding with uniform grinding parameters, they do not systematically consider the differences in electromagnetic performance and subtle differences in surface defects of different soft magnetic cores, nor do they take into account changes in environmental conditions in the grinding area (such as the impact of ambient temperature and humidity on heat dissipation during grinding). This leads to inconsistent electromagnetic performance of some soft magnetic cores after grinding, and some soft magnetic cores suffer from cracking and surface damage due to mismatched grinding parameters. This not only affects the production yield of soft magnetic cores but also increases the rework costs and processing time for enterprises. Summary of the Invention

[0004] This application provides a method and equipment for compensating for grinding soft magnetic cores, which can solve the problems of insufficient performance consistency and easy processing damage of soft magnetic cores after grinding due to initial electromagnetic performance deviation, uneven surface state and fluctuation of processing environment.

[0005] In a first aspect, embodiments of this application provide a soft magnetic core grinding compensation method, applied to a soft magnetic core grinding compensation device. The soft magnetic core grinding compensation device includes a detection module, a pre-feeding detection area, a transfer module, a position sensing module, and a processing station. The method includes:

[0006] The detection module is controlled to perform pre-grinding detection on the soft magnetic cores located in the pre-feeding detection area, and to screen out the soft magnetic cores to be processed that meet the preset conditions.

[0007] The control module transfers the soft magnetic core to be processed from the pre-loading detection area to the processing station. After the position sensing module detects that the soft magnetic core to be processed has entered the processing station and is fixed, it acquires at least one set of monitoring parameters associated with the soft magnetic core to be processed. The at least one set of monitoring parameters includes the initial inductance parameter, initial surface state parameter, and grinding area environmental parameter of the soft magnetic core to be processed.

[0008] Based on the initial inductance parameters, the initial surface state parameters, and the environmental parameters of the polishing area, the processing adaptation state of the soft magnetic core to be processed is determined;

[0009] The grinding parameters of the soft magnetic core grinding compensation device are adjusted according to the processing adaptation state. The grinding parameters include grinding wheel feed parameters, cooling parameters, and fine grinding time parameters.

[0010] The technical solutions described in this application embodiment have at least the following technical effects:

[0011] The soft magnetic core grinding compensation method provided in this application first uses a control detection module to perform pre-grinding detection on the soft magnetic cores located in the pre-loading detection area, screening out the soft magnetic cores to be processed that meet preset conditions. This effectively eliminates initially unqualified soft magnetic cores, reducing the problem of ineffective grinding of unqualified soft magnetic cores and reducing processing resource waste and cost losses. Then, a control transfer module transfers the soft magnetic cores to be processed from the pre-loading detection area to the processing station. After the position sensing module detects that the soft magnetic cores to be processed have entered the processing station and are stably fixed, at least one set of monitoring parameters associated with the soft magnetic cores to be processed is acquired. The at least one set of monitoring parameters includes the initial inductance parameters, initial surface state parameters, and grinding area environmental parameters of the soft magnetic cores to be processed. This not only reduces grinding deviations caused by displacement of the soft magnetic cores during the grinding process, but also provides... Subsequent assessments provide comprehensive, multi-dimensional data support, reducing the problem of biased judgments caused by relying on a single parameter. Then, based on the initial inductance parameters, initial surface state parameters, and grinding area environmental parameters, the processing adaptation state of the soft magnetic core to be processed is determined. This can accurately identify the actual processing adaptation degree of different soft magnetic cores to be processed, providing a precise basis for subsequent grinding parameter adjustments. Finally, the grinding parameters of the soft magnetic core grinding compensation equipment are adjusted according to the processing adaptation state. The grinding parameters include grinding wheel feed parameters, cooling parameters, and fine grinding time parameters. Differentiated grinding parameter adaptation can be achieved for soft magnetic cores to be processed in different processing adaptation states, replacing the traditional uniform parameter grinding mode. This effectively improves the performance consistency of the soft magnetic core after grinding, while reducing processing damage to the soft magnetic core caused by grinding parameter mismatch, ensuring product yield and processing reliability.

[0012] Secondly, embodiments of this application provide a soft magnetic core grinding compensation device, applied to a soft magnetic core grinding compensation equipment. The soft magnetic core grinding compensation equipment includes a detection module, a pre-feeding detection area, a transfer module, a position sensing module, and a processing station. The device includes:

[0013] The detection unit is used to control the detection module to perform pre-grinding detection on the soft magnetic cores located in the pre-feeding detection area, and to screen out the soft magnetic cores to be processed that meet the preset conditions.

[0014] The acquisition unit is used to control the transfer module to transfer the soft magnetic core to be processed from the pre-loading detection area to the processing station, and after the position sensing module detects that the soft magnetic core to be processed has entered the processing station and is fixed, it acquires at least one set of monitoring parameters associated with the soft magnetic core to be processed. The at least one set of monitoring parameters includes the initial inductance parameter, initial surface state parameter and grinding area environmental parameter of the soft magnetic core to be processed.

[0015] The determining unit is used to determine the processing adaptation state of the soft magnetic core to be processed based on the initial inductance parameters, the initial surface state parameters, and the environmental parameters of the polishing area.

[0016] The adjustment unit is used to adjust the grinding parameters of the soft magnetic core grinding compensation device according to the processing adaptation state. The grinding parameters include grinding wheel feed parameters, cooling parameters, and fine grinding time parameters.

[0017] Thirdly, embodiments of this application provide a soft magnetic core grinding compensation device, including a detection module, a pre-loading detection area, a transfer module, a position sensing module, a processing station, and a controller. The controller is electrically connected to the detection module, the transfer module, and the position sensing module, respectively. The controller includes a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it implements the method described in any of the first aspects above.

[0018] It is understood that the beneficial effects of the second and third aspects mentioned above can be found in the relevant descriptions in the first aspect mentioned above, and will not be repeated here. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1This is a schematic flowchart of a soft magnetic core polishing compensation method provided in an embodiment of this application;

[0021] Figure 2 This is a schematic diagram of the working process of a soft magnetic core grinding and compensation device provided in an embodiment of this application;

[0022] Figure 3 This is a schematic diagram of the low-fit pre-verification process in the soft magnetic core polishing compensation method provided in an embodiment of this application;

[0023] Figure 4 This is a schematic diagram of the soft magnetic core grinding and compensation device provided in the embodiments of this application;

[0024] Figure 5 This is a schematic diagram of the soft magnetic core grinding compensation device provided in the embodiments of this application. Detailed Implementation

[0025] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods have been omitted so as not to obscure the description of this application with unnecessary detail.

[0026] It should be understood that, when used in this application specification and the appended claims, the term "comprising" indicates the presence of the described features, integrals, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or a collection thereof.

[0027] In related technologies, most soft magnetic core grinding compensation methods only rely on visual screening to exclude severely unqualified soft magnetic cores. When grinding with uniform grinding parameters, they do not systematically consider the differences in electromagnetic performance and subtle differences in surface defects of different soft magnetic cores, nor do they take into account the changes in environmental conditions of the grinding area (such as the impact of ambient temperature and humidity on heat dissipation during grinding). This leads to inconsistent electromagnetic performance of some soft magnetic cores after grinding, and some soft magnetic cores suffer from cracking and surface damage due to mismatched grinding parameters. This not only affects the production yield of soft magnetic cores, but also increases the rework costs and processing time for enterprises.

[0028] To address the aforementioned issues, this application provides a method and apparatus for compensating for grinding soft magnetic cores. In this method, a control detection module first performs pre-grinding inspection on the soft magnetic cores located in the pre-loading inspection area, screening out those meeting preset conditions. This effectively eliminates initially unqualified soft magnetic cores, reducing the need for subsequent ineffective grinding of unqualified cores and minimizing waste of processing resources and costs. Next, a control transfer module transfers the soft magnetic cores from the pre-loading inspection area to the processing station. After the position sensing module detects the core entering and stabilizing at the processing station, at least one set of monitoring parameters associated with the core is acquired. These parameters include the core's initial inductance parameters, initial surface state parameters, and grinding area environmental parameters. This not only reduces grinding waste but also minimizes the need for further grinding. During the grinding process, the soft magnetic core experiences grinding deviation due to displacement. This provides comprehensive, multi-dimensional data support for subsequent judgments, reducing the problem of biased judgments caused by relying on a single parameter. Then, based on the initial inductance parameters, initial surface state parameters, and grinding area environmental parameters, the processing adaptation state of the soft magnetic core to be processed is determined. This accurately identifies the actual processing adaptation degree of different soft magnetic cores to be processed, providing a precise basis for subsequent grinding parameter adjustments. Finally, the grinding parameters of the soft magnetic core grinding compensation device are adjusted according to the processing adaptation state. The grinding parameters include grinding wheel feed parameters, cooling parameters, and fine grinding time parameters. Differentiated grinding parameter adaptation can be achieved for soft magnetic cores to be processed in different processing adaptation states, replacing the traditional uniform parameter grinding mode. Therefore, the soft magnetic core grinding compensation method provided in this application effectively improves the performance consistency of the soft magnetic core after grinding, while reducing processing damage to the soft magnetic core caused by grinding parameter mismatch, ensuring product yield and processing reliability.

[0029] The soft magnetic core grinding compensation method provided in this application embodiment can be applied to a soft magnetic core grinding compensation device. In this case, the soft magnetic core grinding compensation device is the execution subject of the soft magnetic core grinding compensation method provided in this application embodiment. This application embodiment does not impose any restrictions on the specific type of soft magnetic core grinding compensation device.

[0030] It is understandable that soft magnetic core grinding and compensation equipment is used to grind and process soft magnetic cores used in electronic devices such as power supplies, sensors, and communication equipment. This process removes burrs and unevenness from the surface of the soft magnetic core after it has been formed, corrects dimensional deviations, and ensures that the surface finish and dimensional accuracy of the soft magnetic core meet the requirements for subsequent assembly and electromagnetic performance.

[0031] Please see Figure 4In some embodiments, the soft magnetic core grinding compensation device 1 may include a detection module 11, a pre-feeding detection area 12, a transfer module 13, a position sensing module 14, a processing station 15, a parameter analysis module 16, a grinding parameter adjustment module 17, a grinding execution mechanism 18, and a controller 19. The processing station 15 includes a fixture assembly 151. The controller 19 is electrically connected to the detection module 11, the transfer module 13, the position sensing module 14, the processing station 15, the parameter analysis module 16, the grinding parameter adjustment module 17, and the grinding execution mechanism 18, respectively.

[0032] It is understood that the detection module 11 is located directly above or to the side of the pre-loading detection area 12. It is a detection device in the soft magnetic core grinding compensation equipment 1 that collects initial parameters of the soft magnetic core. It is used to identify appearance defects, measure key dimensions, and detect initial inductance values ​​of the soft magnetic cores temporarily stored in the pre-loading detection area 12. This provides raw data for subsequent screening of qualified soft magnetic cores and determining processing suitability, reducing the likelihood of soft magnetic cores with appearance damage, dimensional errors, or abnormal inductance entering the grinding process. The detection module 11 may include, for example, a vision inspection component, an inductance testing component, and a size sensing component. The vision inspection component is the core component for appearance inspection, including an industrial CCD camera, a ring light source, and an image analysis unit. The industrial CCD camera captures images of the soft magnetic core surface, the ring light source provides uniform illumination to reduce shadow interference, and the image analysis unit compares the images with preset appearance standards (such as no scratches, no missing corners) to identify appearance defects. The inductance testing component is used to detect the initial inductance parameters. It includes an inductance probe, a signal generator, and a data acquisition unit. The inductance probe is attached to the pins or core of the soft magnetic core. The signal generator outputs a standard test signal, and the data acquisition unit records the actual inductance value of the soft magnetic core. The size sensing component is used to detect critical dimensions. It includes a laser displacement sensor and a linear guide. The laser displacement sensor moves along the guide to scan the length, width, thickness, and other dimensions of the soft magnetic core and compares them with a preset size range. The detection module 11 completely covers the loading area of ​​the pre-loading detection zone 12, ensuring that every soft magnetic core entering the pre-loading detection zone 12 can be detected. The detection module 11 is electrically connected to the controller 19 and transmits the collected appearance data, size data, and initial inductance data to the controller 19 in real time.

[0033] The pre-loading inspection area 12 is located at the feeding end (the initial position of the equipment) of the soft magnetic core grinding compensation device 1. It is a transitional area for the temporary storage and positioning of soft magnetic cores. It is used to temporarily place the soft magnetic cores to be processed and to keep them within the detection range of the inspection module 11 through a fixed positioning structure. At the same time, it provides a stable picking position for the transfer module 13, reducing the possibility of detection errors or transfer failures caused by the positional deviation of the soft magnetic cores. The pre-loading inspection area 12 may include, for example, a loading platform, positioning pins, and a waste guide channel. The loading platform is the supporting component for temporarily storing the soft magnetic cores. It is made of wear-resistant aluminum alloy and has grooves (such as rectangular grooves or circular grooves) on its surface that match the shape of the soft magnetic cores to reduce the slippage of the soft magnetic cores. The positioning pins are components used for precise positioning of the soft magnetic cores. They are symmetrically arranged on both sides of the grooves on the loading platform and are inserted into the positioning holes of the soft magnetic cores or fit against the edges of the soft magnetic cores to control the positional error of the soft magnetic cores within a preset range. The waste guide trough is located on one side of the loading platform and is used to receive the soft magnetic cores that are determined to be unqualified by the detection module 11. The waste is guided into the waste box outside the soft magnetic core grinding compensation device 1 by the inclined slope. The loading platform of the pre-loading detection area 12 is directly above the detection components (such as CCD camera and laser sensor) of the detection module 11. The discharge end of the loading platform is connected to the material picking position of the transfer module 13. Qualified soft magnetic cores are taken away from the loading platform by the transfer module 13, and unqualified soft magnetic cores are pushed to the waste guide trough by the transfer module 13.

[0034] The transfer module 13 is located between the pre-loading inspection area 12 and the processing station 15. It is a conveying device in the soft magnetic core grinding compensation equipment 1 that enables the cross-regional transport of soft magnetic cores. It smoothly and accurately transports qualified soft magnetic cores from the pre-loading inspection area 12 to the fixture assembly 151. Simultaneously, it can transport processed soft magnetic cores from the processing station 15 to the finished product area, or transport unqualified soft magnetic cores from the pre-loading inspection area 12 to the scrap area, thus achieving an orderly flow of soft magnetic cores within the soft magnetic core grinding compensation equipment 1. The transfer module 13 may include, for example, a linear robotic arm, a pneumatic gripper, and a guide rail drive unit. The linear robotic arm, which implements the transport trajectory, includes an aluminum alloy guide rail, a slider, and a servo motor. The slider reciprocates along the guide rail between the pre-loading inspection area 12 and the processing station 15. The pneumatic gripper is the actuator for grasping the soft magnetic core. Installed below the slider of the robotic arm, it is driven by a cylinder to open and close two elastic grippers. Silicone pads are attached to the inside of the grippers to ensure clamping force without damaging the surface of the soft magnetic core. The guide rail drive unit is connected to the servo motor of the robotic arm. Upon receiving control signals, it drives the motor to operate, controlling the robotic arm's movement speed and start / stop timing. The transfer module 13 is electrically connected to the controller 19, receiving material picking, handling, and unloading commands from the controller 19. The material picking position of the transfer module 13 corresponds to the loading platform groove in the pre-loading detection area 12, and the material unloading position corresponds to the positioning seat of the clamp assembly 151.

[0035] The position sensing module 14 is located around the clamp assembly 151 (such as on both sides and above the clamp positioning seat). It is a feedback device in the soft magnetic core grinding compensation device 1 for detecting the positioning of the soft magnetic core. It is used to detect in real time whether the soft magnetic core placed by the transfer module 13 has accurately fallen into the positioning position of the clamp assembly 151 and whether it is completely in contact with the clamp surface. This reduces the problem of grinding position deviation (such as uneven grinding amount, grinding of non-target areas) caused by the misalignment of the soft magnetic core. At the same time, it feeds back the positioning signal to the controller 19 to trigger the subsequent clamping and grinding start actions. The position sensing module 14 may include, for example, a diffuse reflection photoelectric sensor, a metal proximity switch, and a signal amplification unit. The diffuse reflection photoelectric sensor is installed on the side of the clamp assembly 151. The transmitting end outputs infrared light. If the soft magnetic core is in position, the light is reflected back to the receiving end by the soft magnetic core, and a material presence signal is output. A metal proximity switch is installed below the fixture positioning base, corresponding to the metal area at the bottom of the soft magnetic core. When the soft magnetic core is fully in contact with the positioning base, the proximity switch detects a distance ≤ a preset distance and outputs a contact signal. The signal amplification unit amplifies the weak signals from the photoelectric sensor and the proximity switch into a standard signal recognizable by the controller 19. The position sensing module 14 is electrically connected to the controller 19, transmitting the material presence signal and the contact signal to the controller 19. The detection range of the position sensing module 14 completely covers the positioning area of ​​the fixture assembly 151. The controller 19 will only control the fixture assembly 151 to clamp the soft magnetic core when both sensors output a position signal.

[0036] The processing station 15 is located at the discharge end of the transfer module 13, directly below the grinding actuator 18. It is the area in the soft magnetic core grinding compensation device 1 where the soft magnetic core is fixed and ground. It is used to firmly fix the soft magnetic core to be processed by the clamping assembly 151, providing a stable grinding reference for the grinding actuator 18, preventing displacement of the soft magnetic core during grinding, and simultaneously bearing the grinding debris and coolant, ensuring grinding accuracy and the cleanliness of the soft magnetic core grinding compensation device 1. The clamping assembly 151 of the processing station 15 may include, for example, a pneumatic clamping cylinder, a positioning base, a debris guide hole, and a coolant recovery tank. The pneumatic clamping cylinder is the actuator for fixing the soft magnetic core, symmetrically arranged on both sides of the positioning base. When the cylinder piston rod extends, it pushes the pressure block to press against the top of the soft magnetic core. The clamping force can be adjusted by a pressure regulating valve. The positioning base is the reference component for positioning the soft magnetic core. A positioning groove matching the bottom surface of the soft magnetic core is formed on its surface, and wear-resistant ceramic sheets are adhered inside the groove to reduce frictional damage between the soft magnetic core and the base. Debris guide holes are evenly distributed within the positioning groove of the positioning base to guide metal / ceramic debris generated during grinding into the collection box below. A coolant recovery tank surrounds the outside of the positioning base in a ring structure to collect the coolant sprayed from the grinding actuator 18 and return it to the cooling system for recycling. The clamp assembly 151 is electrically connected to the controller 19 and receives clamping / releasing commands. The clamp assembly 151 is positioned directly above the grinding wheel assembly of the grinding actuator 18. The feed end of the positioning base connects to the discharge position of the transfer module 13. The debris collection box is connected below the debris guide holes, and the coolant recovery tank is connected to the cooling system piping.

[0037] The parameter analysis module 16 is integrated into the soft magnetic core grinding compensation device 1. It is a specialized data processing device for processing detection parameters and calculating the adaptation status. It receives the raw detection parameters transmitted by the controller 19, preprocesses the parameters (such as error elimination and unit standardization), calculates the processing adaptation comprehensive value according to preset weights, and finally feeds back the standardized parameters and comprehensive value to the controller 19, providing data support for the controller 19 to determine the processing adaptation status. The parameter analysis module 16 is electrically connected to the controller 19, receives the raw parameters sent by the controller 19, and outputs standardized parameters and processing adaptation comprehensive value.

[0038] The grinding parameter adjustment module 17 is located between the processing station 15 and the electrical control cabinet (near the grinding actuator 18). It serves as an intermediate adapter in the soft magnetic core grinding compensation device 1, converting control commands into actuator drive signals. It receives grinding parameter adjustment commands (such as grinding wheel speed, coolant flow rate, and grinding duration) from the controller 19, converts these commands into drive signals that the grinding actuator 18 can directly recognize, and simultaneously collects the actuator's operating status in real time, feeding it back to the controller 19 to ensure precise execution of the grinding parameters. The grinding parameter adjustment module 17 may include, for example, a servo driver, an electromagnetic flow control valve, a time relay, and a signal acquisition unit. The servo driver is connected to the drive motor of the grinding actuator 18, receives speed commands from the controller 19, outputs PWM pulse signals to control the motor speed, and simultaneously collects the actual motor speed through an encoder, feeding it back to the controller 19. The electromagnetic flow control valve is connected to the cooling system's piping, receives flow commands from the controller 19, and outputs analog voltage signals to control the valve opening, achieving precise control of the coolant flow rate. The time relay receives the grinding duration command from the controller 19, sets the delay time, and outputs a stop signal after the duration is reached, triggering the grinding actuator 18 to stop. The signal acquisition unit collects the status signals (such as fault signals and running signals) of the driver, valve, and relay and transmits them to the controller 19 to facilitate fault diagnosis of the soft magnetic core grinding compensation device 1.

[0039] The grinding actuator 18 is located directly above the processing station 15. It is the actuator in the soft magnetic core grinding compensation device 1 that performs grinding compensation on the soft magnetic core. Driven by the grinding parameter adjustment module 17, it uses a grinding wheel assembly to perform targeted grinding (such as removing surface burrs, correcting air gap dimensions, and adjusting inductance) on the soft magnetic core fixed on the processing station 15. Simultaneously, coolant is sprayed through a cooling nozzle to reduce the grinding temperature, ultimately processing the soft magnetic core to the preset surface accuracy and dimensional requirements. The grinding actuator 18 may include, for example, a grinding wheel assembly, a Z-axis lifting unit, a cooling nozzle, and a debris shield. The grinding wheel assembly is the core component of the grinding process, including a diamond grinding wheel (suitable for the soft magnetic core material) and a high-speed drive motor. The motor drives the grinding wheel to rotate at high speed, achieving grinding through contact between the grinding wheel edge or end face and the soft magnetic core. The Z-axis lifting unit includes a ball screw and a servo motor, driving the grinding wheel assembly to move vertically and adjusting the contact depth (i.e., grinding amount) between the grinding wheel and the soft magnetic core. A cooling nozzle is installed on the side of the grinding wheel assembly and connected to the cooling system via a pipe. The nozzle outlet is aimed at the grinding contact point, spraying atomized coolant for both cooling and lubrication. The chip shield has a semi-enclosed structure, wrapping around the outside of the grinding wheel assembly, with only a grinding opening at the bottom, reducing the contamination of the soft magnetic core grinding compensation device 1 by grinding chip splashing. The drive end of the grinding actuator 18 is electrically connected to the output end of the grinding parameter adjustment module 17, receiving commands for speed, lifting, and cooling. The grinding position of the grinding actuator 18 corresponds to the positioning seat of the fixture assembly 151. The cooling nozzle is connected to the cooling system pipe, and the bottom of the chip shield is connected to the coolant recovery tank of the processing station 15.

[0040] The controller 19 is the central device in the soft magnetic core grinding compensation equipment 1, which realizes overall control and logical decision-making for the entire process. It receives various signals transmitted from the detection module 11, position sensing module 14, parameter analysis module 6, and grinding parameter adjustment module 17, performs calculations and decisions according to preset program logic, and then sends control commands to the transfer module 13, fixture assembly 151, parameter analysis module 16, and grinding parameter adjustment module 17, connecting all modules of the soft magnetic core grinding compensation equipment 1 in series to ensure the orderly and automatic operation of the grinding compensation process. The controller 19 can be, for example, a PLC, a microprocessor, or an embedded controller.

[0041] To better understand the soft magnetic core grinding compensation method provided in the embodiments of this application, the specific implementation process of the soft magnetic core grinding compensation method provided in the embodiments of this application will be described by way of example below.

[0042] Figure 1 A schematic flowchart of a soft magnetic core grinding compensation method provided in an embodiment of this application is shown. The soft magnetic core grinding compensation method includes:

[0043] S100, the control and detection module 11 performs pre-grinding detection on the soft magnetic cores located in the pre-feeding detection area 12 and selects the soft magnetic cores to be processed that meet the preset conditions.

[0044] Understandably, the preset conditions are the criteria for judging whether a soft magnetic core is worth polishing. These include thresholds for appearance defects (such as the allowable range of quantitative indicators like scratch depth, missing corner area, and number of cracks) and thresholds for dimensional deviations (such as the allowable difference range between key dimensions like length, width, and thickness and the preset processing dimensions). The soft magnetic cores to be processed are those that, after being screened by the detection module 11, have appearance defects that do not exceed the preset defect thresholds and dimensional deviations that do not exceed the preset dimensional deviation thresholds. These are the soft magnetic cores that will be processed in the subsequent polishing process.

[0045] As an optional embodiment of this application, in S100, the control detection module 11 performs pre-grinding detection on the soft magnetic cores located in the pre-feeding detection area 12, and selects the soft magnetic cores to be processed that meet the preset conditions, including:

[0046] S110, the control and detection module 11 acquires the appearance image of the soft magnetic core, and performs defect identification on the appearance image to obtain the degree of appearance defect of the soft magnetic core.

[0047] It can be understood that the appearance image is a full-surface image of the soft magnetic core in the pre-loading inspection area 12 taken by the vision inspection component in the inspection module 11, which needs to cover the top surface, bottom surface, and four sides of the soft magnetic core. Defects are abnormal states on the surface or in local areas of the soft magnetic core that do not meet preset quality standards. These can include linear scratches distributed along the surface of the soft magnetic core, irregular corner chips caused by impacts, through-cut or non-through cracks, and edge burrs remaining from the production process. The degree of appearance defects is a comprehensive result after quantifying all identified defects. It can be calculated using a weighted summation method of defect type weight × defect quantification value. The weights of different defect types are set according to their impact on the performance of the soft magnetic core. The final specific value is used to intuitively characterize the severity of the appearance defects of the soft magnetic core.

[0048] For example, the vision inspection component of the control inspection module 11 activates the industrial CCD camera, simultaneously turns on the ring light source, and adjusts the light intensity to a preset shadowless range to reduce the problem of reflection caused by strong light or blurring of details caused by weak light. It then captures images of the soft magnetic core in the pre-loading inspection area 12 from multiple preset shooting angles to obtain an appearance image covering the entire surface of the soft magnetic core. Subsequently, the image analysis unit of the vision inspection component performs preprocessing on each image, including denoising (using conventional image denoising algorithms such as Gaussian filtering), grayscale conversion (converting the color image into a standard grayscale image), and edge enhancement (using edge enhancement algorithms such as the Laplacian operator). The preprocessed image is then matched with a stored image of a defect-free standard soft magnetic core to mark all deviation areas. The defect type in the deviation area is determined by contour analysis (e.g., linear continuous deviation is a scratch, irregular polygonal deviation is a missing corner, and discontinuous linear deviation is a crack). The score for a single scratch is calculated according to preset rules: Scratch = Length × Preset Length Weight + Depth × Preset Depth Weight; Missing Corner = Area × Preset Area Weight; Crack = Length × Preset Crack Length Weight + Quantity × Preset Crack Quantity Weight. Finally, the scores of all defects are summed to obtain the degree of appearance defect.

[0049] S120, the control detection module 11 measures the key dimensions of the soft magnetic core and obtains the dimensional deviation value between the key dimensions and the preset processing dimension range.

[0050] It is understandable that critical dimensions are the core dimensions that directly affect the subsequent assembly accuracy and electromagnetic performance of the soft magnetic core. These dimensions need to be determined based on the application scenario of the soft magnetic core, including the effective length along the magnetic circuit direction, the width and thickness perpendicular to the magnetic circuit direction, the diameter of the positioning holes used for assembly, and the center distance between the positioning holes. The dimensional deviation value is the difference between the actual value of the critical dimension measured by the dimensional sensing component of the detection module 11 and the preset machining dimension.

[0051] For example, the dimension sensing component of the control detection module 11 activates the laser displacement sensor, driving the laser displacement sensor to measure the soft magnetic core along a preset scanning path: when measuring length, the laser displacement sensor moves from one end to the other along the length direction of the soft magnetic core, records the position coordinates of the starting point and the ending point, and calculates the difference between the two to obtain the actual length value; the same applies when measuring width and thickness, scanning along the width and thickness directions respectively; when measuring the diameter of the positioning hole, the laser displacement sensor takes points at preset intervals around the circumference of the positioning hole, and takes the average of multiple measurements as the actual diameter value; when measuring the center distance of the positioning holes, the center coordinates of the two positioning holes are first measured, and the absolute value of the coordinate difference is calculated as the actual center distance value. Then, the actual value of each critical dimension is subtracted from the preset processing dimension to obtain the dimension deviation value.

[0052] S130, select soft magnetic cores to be processed that have appearance defects less than a preset defect threshold and size deviation less than a preset size deviation threshold.

[0053] It is understandable that the preset defect threshold is the maximum permissible value for appearance defects in the soft magnetic core, which needs to be determined based on the application scenario and polishing capability of the soft magnetic core. The preset dimensional deviation threshold is the maximum permissible dimensional deviation value for the soft magnetic core, which must be less than the maximum compensation amount in subsequent polishing processes.

[0054] For example, the preset defect threshold and preset size deviation threshold stored in the controller 19 are called. First, the degree of appearance defect is compared with the preset defect threshold, and then the absolute value of each size deviation value is compared with the preset size deviation threshold. If the degree of appearance defect is less than the preset defect threshold, and the absolute value of all size deviation values ​​is less than the preset size deviation threshold, then it is determined to be a soft magnetic core to be processed. If any one of them is not satisfied, it is determined to be a non-conforming soft magnetic core, which is then transferred to the waste area by the transfer module 13.

[0055] By adopting steps S110 to S130 above, a dual-dimensional detection method combining visual inspection and dimensional sensing is used to replace traditional manual visual screening. This reduces screening errors caused by subjective human judgment, improves screening accuracy, and eliminates soft magnetic cores with excessive appearance defects and excessive dimensional deviations that are not worth polishing through quantitative threshold screening. This reduces the unnecessary costs of soft magnetic core polishing compensation equipment 1 running idle, grinding wheel wear, and coolant waste caused by such soft magnetic cores entering the subsequent polishing process. It lays the foundation for subsequent adjustment of polishing parameters based on the differences in the initial state, effectively alleviating the problem of inconsistent performance after polishing due to large differences in the initial state of soft magnetic cores, and the problem that some soft magnetic cores are still unqualified after polishing due to excessive defects. In this way, the yield and performance consistency of the polished soft magnetic cores are improved.

[0056] S200, the control transfer module 13 transfers the soft magnetic core to be processed from the pre-loading detection area 12 to the processing station 15, and after the position sensing module 14 detects that the soft magnetic core to be processed has entered the processing station 15 and is fixed, it acquires at least one set of monitoring parameters associated with the soft magnetic core to be processed. The at least one set of monitoring parameters includes the initial inductance parameter, initial surface state parameter and grinding area environmental parameter of the soft magnetic core to be processed.

[0057] It is understandable that monitoring parameters are a multi-dimensional data set used to determine the suitability of soft magnetic cores for grinding, and must reflect the initial characteristics of the soft magnetic core and the influence of the processing environment. Initial inductance parameters are the inductance characteristics of the soft magnetic core before grinding, reflecting its initial electromagnetic performance and serving as a key basis for adjusting grinding parameters to ensure final electromagnetic performance. Initial surface condition parameters are detailed characteristic data of the surface of the soft magnetic core, such as surface roughness and the distribution and depth of micro-scratches / dents, used to guide the fineness of surface treatment during grinding. Grinding area environmental parameters are environmental data around processing station 15 that affect the grinding effect and core performance, such as ambient temperature and relative humidity. Fluctuations in temperature and humidity affect the grinding heat dissipation efficiency and the stability of the soft magnetic core material.

[0058] As an optional embodiment of this application, in S200, the control transfer module 13 transfers the soft magnetic core to be processed from the pre-loading detection area 12 to the processing station 15, including:

[0059] S201, the real-time position information of the soft magnetic core to be processed in the pre-loading detection area 12 is obtained through the transfer module 13.

[0060] It can be understood that the real-time position information is the coordinate data of the soft magnetic core to be processed in the loading table groove of the pre-loading detection area 12, which is collected by the transfer module 13 through its integrated position sensing components (such as encoders and laser positioners). It includes the specific coordinate values ​​of the X-axis (along the length direction of the loading table) and the Y-axis (along the width direction of the loading table), which is used to determine the picking center point of the soft magnetic core so that the gripping claw of the transfer module 13 can be aligned with the magnetic core.

[0061] For example, the control transfer module 13 activates its own position sensing component to collect coordinate data of the soft magnetic core to be processed in the groove of the loading platform in the pre-loading detection area 12 at a preset frequency. For example, the encoder determines the X-axis coordinate by recording the movement distance of the linear robotic arm slider, and the laser positioner determines the Y-axis coordinate by emitting a laser beam to detect the distance between the edge of the soft magnetic core and the reference line of the loading platform. The collected coordinate data is transmitted to the controller 19, which filters the coordinate data (removing interference signals) to obtain the real-time position information of the soft magnetic core to be processed.

[0062] S202, based on the real-time position information, control the transfer module 13 to move to the soft magnetic core to be processed, and adapt and clamp the soft magnetic core to be processed according to its size.

[0063] It is understandable that the adaptation clamping is the clamping action in which the pneumatic clamping claw of the transfer module 13 adjusts the opening degree of the clamping claw according to the key dimensions (such as length and width) of the soft magnetic core being processed, so that the inner side of the clamping claw fits the surface of the soft magnetic core in accordance with the preset requirements (maintaining clamping force without damaging the soft magnetic core).

[0064] For example, the controller 19 sends a movement command to the guide rail drive unit of the transfer module 13 based on the real-time position information, controls the linear robotic arm to move along the guide rail to directly above the soft magnetic core to be processed, and at the same time calls the length and width data of the soft magnetic core to send an opening and closing degree adjustment command to the pneumatic gripper, so that the opening and closing degree of the gripper is adapted to the width of the magnetic core (the contact area between the gripper and the surface of the soft magnetic core after the gripper is closed is not less than a preset ratio). Then, the controller controls the linear robotic arm to descend, so that the gripper contacts the surface of the soft magnetic core, and then controls the gripper to close to the preset clamping force (set according to the material of the soft magnetic core), thus completing the adaptation and clamping.

[0065] S203, the control transfer module 13 detects in real time whether there are obstacles within the path range during the transfer process of the transfer module 13 in the preset path.

[0066] It is understood that obstacles refer to objects other than the soft magnetic core to be transferred that may collide with the transfer module 13 within the space of the preset transfer path (the fixed path from the pre-loading detection area 12 to the processing station 15) of the transfer module 13. These include unqualified soft magnetic cores that have not been cleaned in time, loose or fallen parts of the soft magnetic core grinding compensation equipment 1, and foreign objects that have entered from the outside. These objects need to be detected in real time to ensure the safety of the transfer.

[0067] For example, the control transfer module 13 activates its integrated obstacle detection sensor (such as an infrared ranging sensor). During the transfer along the preset path, it transmits detection signals (such as infrared signals) to the path range at preset detection intervals (covering the entire path and without detection blind spots). The sensor receives the reflected signal. If the distance value of the reflected signal is less than the preset safety distance, it is determined that there is an obstacle in the path range. If the distance value of the reflected signal is greater than or equal to the preset safety distance, it is determined that there is no obstacle.

[0068] S204, if an obstacle is detected, the control transfer module 13 stops the transfer and records the position of the obstacle, and then adjusts the transfer path according to the preset obstacle avoidance rules.

[0069] It is understandable that recording the location of an obstacle involves the transfer module 13 transmitting its real-time location (obtained via an encoder) and the obstacle's direction relative to itself (detected via a sensor) to the controller 19 when it detects an obstacle. The controller 19 then stores this information for subsequent investigation of the obstacle's source. The preset obstacle avoidance rules are path adjustment strategies preset in the controller 19 for different obstacle types. These include two types: bypass (when the obstacle is a fixed object, a safe detour path is calculated within the path range) and waiting (when the obstacle is a temporarily moving object, transfer is paused and a preset time is waited; if the obstacle is still not removed, the bypass strategy is activated).

[0070] For example, if the transfer module 13 detects an obstacle, the controller 19 immediately sends a pause command to the guide rail drive unit to stop the transfer module 13 from moving. Simultaneously, it records the current position coordinates of the transfer module 13 and the relative direction of the obstacle, and displays a warning message indicating that an obstacle has been detected on the touchscreen operation unit. Then, the controller 19 invokes a preset obstacle avoidance rule, first determining the obstacle type. For example, through multiple sensor detections, if the obstacle's position remains unchanged, it is a fixed obstacle; if its position changes, it is a temporary obstacle. If it is a fixed obstacle, a detour path is calculated, for example, offsetting a preset distance away from the obstacle from the preset path. If it is a temporary obstacle, a preset time is waited. If the obstacle still exists after the preset time, the detour path adjustment is initiated.

[0071] S205, the transfer module 13, after adjusting the transfer path, continues to transfer the clamped soft magnetic core to be processed to the designated placement position of the processing station 15.

[0072] It can be understood that the designated placement position is a pre-set positioning area on the fixture assembly of processing station 15 that matches the shape of the soft magnetic core to be processed.

[0073] For example, the controller 19 sends an adjusted transfer path instruction to the transfer module 13, controls the linear robotic arm to continue moving along the new path, and controls the robotic arm to reduce its moving speed when it approaches the designated placement position of the processing station 15. After reaching directly above the designated placement position, the controller controls the robotic arm to descend to a preset height (so that the soft magnetic core can be placed smoothly on the fixture assembly), and then controls the pneumatic gripper to release, placing the soft magnetic core to be processed in the designated placement position, thus completing the transfer.

[0074] By adopting the above steps S201 to S205, real-time positioning and adaptive clamping are used to reduce clamping offset and magnetic core damage caused by position deviation in traditional transportation, ensuring that the position of the soft magnetic core to be processed is stable and the surface is intact during transportation. Then, real-time obstacle detection and dynamic obstacle avoidance solve the problem of collision and soft magnetic core falling caused by sudden obstacles in the transportation path, improving the safety and stability of the transportation process. This lays the foundation for subsequent fixation and positioning of the soft magnetic core, reduces the position offset of grinding caused by transportation deviation, and indirectly improves the dimensional accuracy and performance consistency of the soft magnetic core after grinding.

[0075] As an optional embodiment of this application, S200, the position sensing module 14 detects that the soft magnetic core to be processed has entered the processing station 15 and is fixed, including:

[0076] S211, the control position sensing module 14 detects the pressure signal at the designated placement position of the processing station 15. When the pressure signal reaches the preset pressure threshold, it is determined that the soft magnetic core to be processed has entered the processing station 15.

[0077] It can be understood that the pressure signal is the pressure value generated by the pressure sensor of the position sensing module 14 (installed at the bottom of the designated placement position of the processing station 15) after the soft magnetic core to be processed is placed in the designated position. The preset pressure threshold is a preset pressure critical value used to determine whether the soft magnetic core has entered the processing station 15.

[0078] For example, the controller 19 controls the pressure sensor of the position sensing module 14 to start, collect the pressure value at the designated placement position of the processing station 15 in real time, and compare the collected pressure value with the preset pressure threshold in real time: if the pressure value is continuously lower than the preset pressure threshold, it is determined that the soft magnetic core to be processed has not entered the processing station 15; if the pressure value is continuously reached or higher than the preset pressure threshold, it is determined that the soft magnetic core to be processed has entered the processing station 15, and sends a soft magnetic core arrival signal to the controller 19.

[0079] S212, the position sensing module 14 is controlled to detect the position deviation of the soft magnetic core to be processed entering the processing station 15 and obtain the position deviation data of the soft magnetic core to be processed.

[0080] It is understood that the position deviation data is the specific difference between the actual position of the soft magnetic core and the specified position in the X-axis, Y-axis and Z-axis directions, which is detected by the position sensing module 14. It is used to quantify the degree of position offset of the soft magnetic core and provide a basis for subsequent position correction.

[0081] For example, the controller 19 controls the metal proximity switch of the position sensing module 14 (installed on both sides of the X-axis and Y-axis at the designated placement position) to start, detect the distance between the edge of the soft magnetic core and the switch, and calculate the difference between the actual position and the designated position in the X-axis and Y-axis directions. At the same time, it controls the laser displacement sensor (installed directly above the designated placement position) to start, detect the distance between the top surface of the soft magnetic core and the laser displacement sensor, and calculate the difference between the actual position and the designated position in the Z-axis direction. Then, the differences in the three directions of X-axis, Y-axis and Z-axis are summarized to obtain the position deviation data of the soft magnetic core to be processed.

[0082] S213, based on the position deviation data, control the fixture assembly to perform position correction on the soft magnetic core to be processed until the position deviation data is less than the preset position deviation threshold, and then clamp and fix the soft magnetic core to be processed.

[0083] It is understandable that the preset position deviation threshold is a preset maximum allowable deviation value for determining whether the position of the soft magnetic core is qualified. According to the grinding accuracy setting of the grinding actuator 18, there are corresponding position deviation thresholds in the X-axis, Y-axis and Z-axis directions.

[0084] For example, the controller 19 sends a correction command to the fine-tuning mechanism of the clamping assembly based on the position deviation data: for negative / positive deviations in the X-axis, it controls the pneumatic pusher of the fine-tuning mechanism in the X-axis direction to push the soft magnetic core in the positive / negative direction; for negative / positive deviations in the Y-axis, it controls the pneumatic pusher of the fine-tuning mechanism in the Y-axis direction to push the magnetic core in the positive / negative direction; for negative / positive deviations in the Z-axis, it controls the electric support platform of the fine-tuning mechanism in the Z-axis direction to make up / down fine adjustments. During the correction process, the position sensing module 14 provides real-time feedback of position deviation data until the deviation data in all directions are less than the preset position deviation threshold. Subsequently, the controller 19 sends a clamping command to the pneumatic clamping cylinder, controlling the pressure block to descend and press against the top surface of the soft magnetic core, maintaining the preset clamping force (set according to the material of the soft magnetic core), and completing the clamping and fixing.

[0085] By adopting the above steps S211 to S213, the problem of the soft magnetic core not fully entering the processing station 15 or misjudgment of position offset caused by the traditional visual positioning method is reduced by first confirming the pressure signal judgment and position deviation detection. This improves the accuracy of the soft magnetic core entering the processing station 15. Then, through precise position correction and stable clamping and fixing, the position deviation of the soft magnetic core is controlled within the preset range, which solves the problem of misalignment of the grinding area caused by the position offset of the soft magnetic core. This provides a stable positioning basis for the soft magnetic core for subsequent adjustment of grinding parameters based on monitoring parameters.

[0086] As an optional embodiment of this application, in step S200, at least one set of monitoring parameters associated with the soft magnetic core to be processed is acquired. The at least one set of monitoring parameters includes the initial inductance parameter, initial surface state parameter, and environmental parameters of the polishing area of ​​the soft magnetic core to be processed, including:

[0087] S221. Based on the model of the soft magnetic core to be processed, determine the acquisition priority of at least one set of monitoring parameters; among them, the initial inductance parameter is the first priority, the initial surface state parameter is the second priority, and the environmental parameter of the grinding area is the third priority.

[0088] It is understandable that the acquisition priority is the order in which the controller 19 sets the acquisition sequence for the initial inductance parameters, initial surface state parameters, and environmental parameters of the grinding area based on the model of the soft magnetic core to be processed (different models of soft magnetic cores have different application scenarios and performance requirements) and the degree of influence of the monitoring parameters on the grinding effect. If the parameters with higher priority do not meet the standards, there is no need to acquire the subsequent lower priority parameters, so as to save acquisition time and resources.

[0089] For example, the controller 19 calls a preset table of model and acquisition priority based on the model of the soft magnetic core to be processed. The table sets the priority based on the degree of influence of parameters on grinding: the initial inductance parameter directly determines the electromagnetic performance of the soft magnetic core (it must meet the standard after grinding, otherwise the soft magnetic core is scrapped), and is set as the first priority; the initial surface condition parameter affects the surface treatment accuracy of grinding (if it exceeds the standard, grinding is difficult and defects are easy to remain), and is set as the second priority; the environmental parameters of the grinding area only indirectly affect the heat dissipation of grinding (which can be compensated by adjusting the cooling parameters), and is set as the third priority; finally, the acquisition priority of the monitoring parameters of the current soft magnetic core is determined to be initial inductance parameter > initial surface condition parameter > environmental parameters of the grinding area.

[0090] S222, control the soft magnetic core grinding compensation device 1 to first collect the initial inductance parameters of the first priority. If the initial inductance parameters are within the preset valid range, then continue to collect the initial surface state parameters of the second priority.

[0091] It is understandable that the preset effective range is a pre-defined numerical range for determining whether the initial inductance parameters are worth polishing. This range is set based on the standard inductance value corresponding to the model of the soft magnetic core to be processed. The upper limit is the standard value + preset positive deviation, and the lower limit is the standard value - preset negative deviation. If the initial inductance parameters exceed the preset effective range, even if the subsequent parameters meet the standard, it will be difficult to make the electromagnetic performance of the soft magnetic core qualified after polishing, so subsequent data acquisition is stopped.

[0092] For example, the controller 19 sends a data acquisition command to the inductance testing component of the detection module 11, controls the inductance probe to contact the pins or core of the soft magnetic core to be processed, the signal generator outputs a preset test signal, and the data acquisition unit records the initial inductance parameters of the soft magnetic core. The controller 19 compares the acquired initial inductance parameters with a preset valid range. If the initial inductance parameters are within the preset valid range, it sends a data acquisition command to the vision inspection component of the detection module 11 to continue acquiring the initial surface state parameters. If the initial inductance parameters exceed the preset valid range, it determines that the soft magnetic core has no polishing value, controls the transfer module 13 to transfer the soft magnetic core to the non-conforming product temporary storage area, and stops subsequent data acquisition.

[0093] S223, if the initial surface state parameters meet the preset quality requirements, then continue to collect the environmental parameters of the third priority grinding area.

[0094] It is understandable that the preset quality requirements are pre-defined standards for determining whether the initial surface condition parameters meet the grinding conditions. These include the maximum allowable value of surface roughness and the maximum depth and number of micro-scratches / dents. If the initial surface condition parameters exceed the preset quality requirements, the surface quality of the soft magnetic core after grinding will be difficult to meet the standards, so subsequent data collection will be stopped.

[0095] For example, the controller 19 receives initial surface state parameters collected by the vision inspection component of the detection module 11, including surface roughness, scratch depth / number, and indentation depth / number. It compares the initial surface state parameters with preset quality requirements. If all parameters in the initial surface state parameters meet the preset quality requirements, such as surface roughness ≤ preset value, scratch / indentation depth ≤ preset value, and number ≤ preset value, it sends a collection command to the environmental sensor to continue collecting environmental parameters of the polishing area. If any parameter in the initial surface state parameters does not meet the preset quality requirements, it is determined that the soft magnetic core has no polishing value, and the control transfer module 13 transfers the soft magnetic core to the non-conforming product temporary storage area and stops subsequent collection.

[0096] S224, the collected initial inductance parameters, initial surface state parameters and polishing area environmental parameters are correlated and matched to form at least one complete set of monitoring parameters.

[0097] It can be understood that the association matching means that the controller 19 binds the initial inductance parameters, initial surface state parameters, and grinding area environmental parameters of the same soft magnetic core to be processed through a unique identifier (such as the ID number generated by the detection module 11 for each soft magnetic core), so that each group of monitoring parameters corresponds to only one soft magnetic core to be processed.

[0098] For example, the controller 19 assigns a unique ID number to each soft magnetic core to be processed, and binds the initial inductance parameters, initial surface state parameters, and environmental parameters of the grinding area (such as temperature and humidity) to the ID number. After binding, the initial inductance parameters, initial surface state parameters, and environmental parameters of the grinding area are formatted uniformly (such as unit standardization and data precision uniformity) to form a complete set of monitoring parameters corresponding to the unique soft magnetic core, and stored in the storage unit of the controller 19.

[0099] By employing steps S221 to S224 above, and collecting data according to priority, magnetic cores with substandard initial inductance parameters and initial surface state parameters are first screened out, thus reducing the use of such soft magnetic cores for subsequent data collection and polishing resources and ineffective processing costs. Then, through parameter association and matching, each set of monitoring parameters is matched one-to-one with the soft magnetic core to be processed, solving the problem of incorrect polishing parameter adjustment caused by parameter confusion during the parallel processing of multiple soft magnetic cores in traditional methods. This further alleviates the problems of improper polishing parameter adjustment and poor core performance consistency caused by inaccurate adaptation.

[0100] S300 determines the processing adaptation state of the soft magnetic core to be processed based on the initial inductance parameters, initial surface state parameters, and environmental parameters of the grinding area.

[0101] It can be understood that the processing adaptation state is the degree of adaptation of the soft magnetic core to the grinding parameters determined by the controller 19 based on the initial characteristics (initial inductance, initial surface condition) and processing environment (grinding area environment) of the soft magnetic core to be processed. It is divided into three categories: high adaptation state (excellent initial characteristics, stable environment, easy adjustment of grinding parameters and easy achievement of performance standards after grinding), medium adaptation state (general initial characteristics, basically stable environment, grinding parameters need to be adjusted specifically), and low adaptation state (poor initial characteristics, large environmental fluctuations, grinding parameters need to be adjusted carefully to avoid damage). It is used to guide the differentiated adjustment of subsequent grinding parameters.

[0102] As an optional embodiment of this application, S300, based on the initial inductance parameters, initial surface state parameters, and grinding area environmental parameters, determines the processing adaptation state of the soft magnetic core to be processed, including:

[0103] S310, the control parameter analysis module 16 receives the initial inductance parameters, initial surface state parameters, and grinding area environmental parameters, and preprocesses the initial inductance parameters, initial surface state parameters, and grinding area environmental parameters to obtain standardized inductance parameters, standardized surface state parameters, and standardized environmental parameters.

[0104] It can be understood that preprocessing is a series of data processing actions performed by the ARM data processing chip of the parameter analysis module 16 on the received initial inductance parameters, initial surface state parameters, and grinding area environmental parameters. This includes data cleaning (removing outliers, such as inductance parameter jumps caused by transient interference), unit unification (converting the parameter units of different acquisition components to preset standard units), and numerical normalization (converting parameter values ​​to standardized values ​​within a preset range for easier subsequent weighted calculations). Preprocessed parameters are more suitable for comparison of compatibility and calculation of comprehensive values. Standardized parameters are those obtained after preprocessing, with unified units and values ​​within a preset range. These include standardized inductance parameters (normalized values ​​of the initial inductance parameters), standardized surface state parameters (normalized values ​​of the initial surface state parameters), and standardized environmental parameters (normalized values ​​of the grinding area environmental parameters).

[0105] For example, the controller 19 and the control parameter analysis module 16 receive initial inductance parameters, initial surface state parameters, and grinding area environmental parameters through a data interface circuit. The ARM data processing chip first cleans the initial inductance parameters, initial surface state parameters, and grinding area environmental parameters: it uses a preset algorithm (such as a Kalman filter algorithm) to remove abnormal jump values ​​in the initial inductance parameters, eliminates scratch depth values ​​exceeding reasonable ranges in the initial surface state parameters, and filters instantaneous fluctuation values ​​in the environmental parameters. Then, it unifies the units: it unifies the unit of the initial inductance parameters to μH, the unit of surface roughness in the initial surface state parameters to μm, and the unit of temperature in the environmental parameters to ℃ and the unit of humidity to %RH. Finally, it performs numerical normalization: it converts the cleaned and normalized initial inductance parameters, initial surface state parameters, and grinding area environmental parameters into standardized values ​​in the 0-1 range according to a preset formula, for example, standardized value = (actual value - minimum value) / (maximum value - minimum value), to obtain standardized inductance parameters, standardized surface state parameters, and standardized environmental parameters.

[0106] S320 determines the degree of inductance compatibility by comparing standardized inductance parameters with preset inductance reference range, determines the degree of surface compatibility by comparing standardized surface state parameters with preset surface quality standards, and determines the degree of environmental compatibility by comparing standardized environmental parameters with preset environmental compatibility range.

[0107] It is understandable that the preset inductance reference range is a numerical range set after normalization based on the standard inductance value corresponding to the soft magnetic core model. It is divided into three sub-ranges: excellent, good, and poor. Different sub-ranges correspond to the inductance compatibility levels of high (easy to meet the standard after polishing), medium (requires targeted adjustment), and low (requires careful polishing), respectively. The preset surface quality standard is a numerical range set after normalization based on the preset quality requirements before polishing. It is also divided into three sub-ranges: excellent, good, and poor. It corresponds to the surface condition of easy to polish to a qualified finish, requiring fine polishing, and difficult to polish. The preset environmental compatibility range is a numerical range set after normalization based on the environmental parameter range that stabilizes the polishing effect. It is also divided into three sub-ranges: excellent, good, and poor. It corresponds to the environmental compatibility levels of no negative impact on polishing, minor impact that can be compensated for, and significant impact that requires key adjustments.

[0108] For example, the controller 19 first calls the preset inductance reference range, preset surface quality standard, and preset environmental adaptation range, and then performs the comparison one by one according to the parameter type: the standardized inductance parameters are compared with the preset inductance reference range to determine the sub-interval to which the standardized inductance parameters belong to determine the degree of inductance adaptation and the corresponding score; the standardized surface state parameters are compared with the preset surface quality standard to determine the degree of surface adaptation and the corresponding score; if the standardized environmental parameters contain multi-dimensional data (such as temperature and humidity), they are first integrated into a single standardized comprehensive value according to preset rules (such as arithmetic mean and weighted summation), and then the comprehensive value is compared with the preset environmental adaptation range to determine the degree of environmental adaptation and the corresponding score.

[0109] S330, the control parameter analysis module 16 performs a comprehensive analysis of the inductance adaptation degree, surface adaptation degree and environmental adaptation degree to obtain the comprehensive processing adaptation value.

[0110] It is understandable that the processing adaptation comprehensive value is a numerical value obtained after comprehensive analysis, which quantitatively characterizes the overall adaptation degree of the soft magnetic core to be processed. The numerical range is set according to the weight and score (such as 0-100 points) and is used to determine the processing adaptation status in the future.

[0111] For example, the controller 19 sends a comprehensive analysis command to the parameter analysis module 16, calling preset weights for each degree of adaptation, such as inductance adaptation weight A%, surface adaptation weight B%, and environmental adaptation weight C%, where A+B+C=100. The ARM data processing chip obtains the comprehensive processing adaptation value according to the preset formula: Comprehensive Processing Adaptation Value = Inductance Adaptation Score × Inductance Adaptation Weight + Surface Adaptation Score × Surface Adaptation Weight + Environmental Adaptation Score × Environmental Adaptation Weight.

[0112] S340, based on the preset range of the processing adaptation comprehensive value, determine the processing adaptation state of the soft magnetic core to be processed: if the processing adaptation comprehensive value is in the first preset range, determine the processing adaptation state as high adaptation state; if the processing adaptation comprehensive value is in the second preset range, determine the processing adaptation state as medium adaptation state; if the processing adaptation comprehensive value is in the third preset range, determine the processing adaptation state as low adaptation state; wherein, the lower limit of the first preset range is greater than the upper limit of the second preset range, and the lower limit of the second preset range is greater than the upper limit of the third preset range.

[0113] It is understandable that the preset intervals are pre-defined ranges of comprehensive processing adaptation values ​​used to determine the processing adaptation status. These intervals are set based on extensive grinding experiment data, ensuring that different intervals correspond to different grinding difficulties and parameter adjustment requirements. The first preset interval is a high-scoring interval corresponding to high-adaptation states; only cores in high-adaptation states will have their comprehensive values ​​fall within this interval. The second preset interval is a medium-scoring interval corresponding to medium-adaptation states; only cores in medium-adaptation states will have their comprehensive values ​​fall within this interval. The third preset interval is a low-scoring interval corresponding to low-adaptation states; only cores in low-adaptation states will have their comprehensive values ​​fall within this interval.

[0114] For example, the controller 19 calls a preset range and compares the processing adaptation comprehensive value with the preset range: if the processing adaptation comprehensive value is in the first preset range, the processing adaptation state is determined to be a high adaptation state; if the processing adaptation comprehensive value is in the second preset range, the processing adaptation state is determined to be a medium adaptation state; if the processing adaptation comprehensive value is in the third preset range, the processing adaptation state is determined to be a low adaptation state.

[0115] By adopting the above steps S310 to S340, through parameter preprocessing and standardized comparison, the original parameters of different dimensions and units are converted into a unified standard of adaptability, which solves the problems of inconsistent dimensions and inaccurate comparison caused by the traditional direct judgment of original parameters. Then, through weighted comprehensive analysis and interval judgment, the overall adaptability of the initial characteristics of the soft magnetic core to the environment is quantified, which effectively solves the problems of one-size-fits-all grinding parameters and poor core performance consistency (some cores are over-ground and some are under-ground) caused by inaccurate adaptation state judgment.

[0116] S400, adjusts the grinding parameters of the soft magnetic core grinding compensation device 1 according to the processing adaptation status. The grinding parameters include grinding wheel feed parameters, cooling parameters, and fine grinding time parameters.

[0117] It is understandable that the grinding parameters are a set of parameters controlling the grinding actuator 18 to achieve precise grinding. These parameters need to be dynamically adjusted according to the processing adaptation status to improve the performance consistency and processing quality of the soft magnetic core after grinding. The grinding wheel feed parameters are parameters controlling the movement of the grinding wheel assembly of the grinding actuator 18, including the grinding wheel feed speed and feed depth. The cooling parameters are parameters controlling the cooling nozzle of the grinding actuator 18, including the coolant flow rate and coolant temperature. The fine grinding duration parameter is the duration for the grinding actuator 18 to perform the fine grinding process, used to correct minor dimensional deviations from the initial grinding and optimize surface finish.

[0118] As an optional embodiment of this application, in S400, the grinding parameters of the soft magnetic core grinding compensation device 1 are adjusted according to the processing adaptation state. The grinding parameters include grinding wheel feed parameters, cooling parameters, and fine grinding time parameters, including:

[0119] S410: Obtain the processing adaptation status and call the processing adaptation status and parameter adjustment strategy library. The strategy library is divided into the first parameter tuning rule corresponding to the high adaptation status, the second parameter tuning rule corresponding to the medium adaptation status, and the third parameter tuning rule corresponding to the low adaptation status.

[0120] It can be understood that the strategy library is a set of data preset in the controller 19 storage unit, containing the correspondence between processing adaptation states and grinding parameter adjustment rules. The adjustment rules are formulated based on a large amount of grinding experimental data (the optimal parameter combination under different adaptation states), so that each adaptation state has a corresponding parameter adjustment logic that can achieve the highest efficiency and best quality. The parameter adjustment rules are the specific logic for adjusting grinding parameters set in the strategy library for a certain processing adaptation state, including the parameter adjustment order, parameter adjustment range, and parameter linkage relationship (how other parameters are adjusted synchronously after one parameter is adjusted).

[0121] For example, the controller 19 acquires the machining adaptation status and calls the strategy library from the storage unit. In the strategy library: the first parameter tuning rule (high adaptation status) prioritizes efficiency, setting the high-efficiency range for the grinding wheel feed parameters, the auxiliary range for the cooling parameters, and the baseline range for the fine grinding time; the second parameter tuning rule (medium adaptation status) prioritizes accuracy, setting the fine range for the fine grinding time and the linkage rules for the grinding wheel and cooling parameters; the third parameter tuning rule (low adaptation status) prioritizes safety, setting the stable range for the cooling parameters, the low-loss range for the grinding wheel feed parameters, and the matching range for the fine grinding time. Based on the current machining adaptation status, the corresponding parameter tuning rule is determined and called.

[0122] S420, if the processing adaptation state is high adaptation state, the control grinding parameter adjustment module 17 adjusts the grinding wheel feed parameter to the high efficiency range preset by the first parameter adjustment rule according to the first parameter adjustment rule, and then adjusts the cooling parameter to the auxiliary range preset by the first parameter adjustment rule that matches the grinding wheel feed parameter, so as to keep the fine grinding time parameter within the reference range preset by the first parameter adjustment rule.

[0123] It can be understood that the high-efficiency range is a preset range of grinding wheel feed parameters in the first parameter tuning rule, suitable for a highly adaptable state (good initial characteristics and stable environment). Within this range, the grinding wheel feed speed and depth are set to higher values ​​(to improve grinding efficiency), while ensuring that the dimensional accuracy and surface finish of the soft magnetic core meet the standards after grinding. The auxiliary range is a preset range of cooling parameters in the first parameter tuning rule, matching the grinding wheel feed parameters in the high-efficiency range. The higher the feed parameters (the more grinding heat), the better the coolant flow rate and coolant temperature are set in the auxiliary range (the stronger the heat dissipation effect), reducing the problem of heat accumulation. The reference range is a preset range of fine grinding time in the first parameter tuning rule, suitable for a highly adaptable state. The time in this range is set to a reference value (it does not need to be too long to meet the standard), balancing accuracy and efficiency.

[0124] For example, if the processing adaptation state is a high adaptation state, the controller 19 sends a first parameter adjustment rule instruction to the grinding parameter adjustment module 17: first, it controls the servo driver to adjust the grinding wheel feed speed to the high efficiency range preset by the first parameter adjustment rule and adjusts the feed depth to the high efficiency range; then, according to the adjusted grinding wheel feed parameters, it controls the electromagnetic flow control valve to adjust the coolant flow rate to the auxiliary range and controls the cooling system to adjust the coolant temperature to the auxiliary range; finally, it controls the time relay to keep the fine grinding time parameter in the reference range.

[0125] S430, if the processing adaptation state is medium adaptation state, the control grinding parameter adjustment module 17 first adjusts the fine grinding time parameter to the fine range preset by the second parameter adjustment rule according to the second parameter adjustment rule, and then adjusts the grinding wheel feed parameter and cooling parameter synchronously according to the linkage rule preset by the second parameter adjustment rule.

[0126] It is understandable that the fine grinding range is a preset fine grinding time range in the second parameter adjustment rule, suitable for moderately adapted conditions (general initial characteristics, basically stable environment). The time of this range is set higher than the benchmark range (to correct rough grinding deviations and improve surface finish), reducing the occurrence of substandard surface quality due to general initial characteristics. The linkage rule is a preset logic in the second parameter adjustment rule used to synchronously adjust the grinding wheel feed parameters and cooling parameters. That is, after the grinding wheel feed parameters are adjusted, the cooling parameters are adjusted synchronously according to a preset ratio (such as increasing the feed speed by 10% and the coolant flow rate by 8%), so that the heat dissipation effect matches the grinding heat, reducing heat accumulation or overcooling.

[0127] For example, if the processing adaptation state is medium adaptation state, the controller 19 sends a second parameter adjustment rule instruction to the grinding parameter adjustment module 17: first, it controls the time relay to adjust the fine grinding time parameter to the fine range; then, according to the linkage rule of the second parameter adjustment rule, it controls the servo driver to adjust the grinding wheel feed speed to the medium speed range and the feed depth to the medium depth range, and at the same time controls the electromagnetic flow control valve to adjust the coolant flow rate to the medium flow range and the coolant temperature to the medium temperature range according to the linkage ratio (e.g., for every 10% increase in feed speed, the flow rate increases by 8%).

[0128] S440, if the processing adaptation state is low adaptation state, the control grinding parameter adjustment module 17 first adjusts the cooling parameter to the stable range preset by the third parameter adjustment rule according to the third parameter adjustment rule, then adjusts the grinding wheel feed parameter to the low wear range preset by the third parameter adjustment rule, and finally adjusts the fine grinding time parameter to the adaptation range according to the matching relationship preset by the third parameter adjustment rule and the final value of the grinding wheel feed parameter.

[0129] It can be understood that the stable range is a preset cooling parameter range in the third parameter tuning rule, suitable for low-fitness conditions (poor initial characteristics, large environmental fluctuations). In this range, the coolant flow rate and temperature are set to stable values ​​(small fluctuation range) to ensure stable heat dissipation and reduce high-temperature damage to the magnetic core caused by environmental fluctuations or poor initial characteristics. The low-loss range is a preset grinding wheel feed parameter range in the third parameter tuning rule, suitable for low-fitness conditions. In this range, the feed speed and feed depth are set to lower values ​​(to reduce grinding losses and reduce over-grinding of soft magnetic cores), protecting soft magnetic cores with poor initial characteristics. The matching relationship is a preset correspondence between the fine grinding time parameter and the grinding wheel feed parameter in the third parameter tuning rule (e.g., the lower the feed speed and the shallower the feed depth, the longer the fine grinding time needs to be to ensure surface quality), used to determine the final fine grinding time.

[0130] For example, if the processing adaptation state is low adaptation state, the controller 19 sends a third parameter adjustment rule instruction to the grinding parameter adjustment module 17: first, it controls the electromagnetic flow control valve to adjust the coolant flow rate to a stable range and the cooling system to adjust the coolant temperature to a stable range; then, it controls the servo driver to adjust the grinding wheel feed speed to a low-loss range and the feed depth to a low-loss range; finally, according to the preset matching relationship (such as a feed speed of 20mm / min and a feed depth of 0.005mm corresponding to a fine grinding time of 15-20s), it controls the time relay to adjust the fine grinding time parameter to the adaptation range.

[0131] S450 performs cross-validation on the adjusted grinding wheel feed parameters, cooling parameters, and fine grinding time parameters to obtain parameter conflict results. If the parameter conflict result is no parameter conflict, the adjusted grinding wheel feed parameters, cooling parameters, and fine grinding time parameters are output to the grinding actuator 18.

[0132] Cross-validation is understood to be a compatibility check performed by controller 19 on the three adjusted grinding parameters. This includes: the matching of grinding wheel feed parameters and cooling parameters (i.e., whether the grinding heat corresponding to the grinding wheel feed parameters is within the heat dissipation capacity of the cooling parameters); the matching of grinding wheel feed parameters and fine grinding time parameters (i.e., whether the grinding amount corresponding to the grinding wheel feed parameters matches the correction capability of the fine grinding time); and the matching of cooling parameters and fine grinding time parameters (i.e., whether the heat dissipation effect of the cooling parameters can support continuous heat dissipation within the fine grinding time, reducing grinding abnormalities caused by parameter inconsistencies). The parameter conflict result is the result of cross-validation determining parameter compatibility, categorized as no parameter conflict (all parameters are compatible) and parameter conflict (two or three sets of parameters are incompatible, such as excessively high feed parameters but excessively low cooling parameters). If a conflict exists, the parameters need to be readjusted.

[0133] For example, the controller 19 calls the preset cross-validation rules to verify the adjusted grinding parameters: verify the grinding wheel feed parameters and cooling parameters, verify the feed parameters and fine grinding time, and verify the cooling parameters and fine grinding time. If all verification items pass, the parameter conflict result is determined to be no parameter conflict, and the adjusted parameters are sent to the grinding actuator 18. If a certain verification item fails, it is determined that there is a parameter conflict, and the system returns to S420, S430, and S440 to readjust the parameters.

[0134] By adopting the above steps S410 to S450, and through state-based parameter adjustment rules, differentiated parameter strategies are formulated for soft magnetic cores in different adaptation states. This solves the problems of low efficiency of high-adaptability magnetic cores and easy damage of low-adaptability magnetic cores caused by traditional single-parameter strategies. Furthermore, through parameter linkage adjustment and cross-verification, the adjusted parameters are made compatible and matched with each other, reducing grinding abnormalities caused by parameter conflicts (such as magnetic core burnout due to insufficient heat dissipation, and dimensional deviations due to excessive feed). The final output of precise grinding parameters can be specifically adapted to soft magnetic cores in different states, significantly improving the dimensional accuracy, surface quality, and electromagnetic performance consistency of the ground soft magnetic cores.

[0135] Please see Figure 3 As an optional embodiment of this application, in S500, when the processing adaptation state is determined to be a low adaptation state, before adjusting the grinding parameters of the soft magnetic core grinding compensation device 1 according to the low adaptation state, a low adaptation pre-verification is further included. The low adaptation pre-verification includes:

[0136] S510, the control parameter analysis module 16 generates pre-grinding parameters adapted to the low-fitting state based on the initial inductance parameters and initial surface state parameters; the grinding wheel feed speed of the pre-grinding parameters is less than the conventional grinding wheel feed speed of the soft magnetic core grinding compensation device 1, the fine grinding time of the pre-grinding parameters is less than the conventional fine grinding time of the soft magnetic core grinding compensation device 1, and the cooling parameters of the pre-grinding parameters are consistent with the conventional grinding cooling parameters of the soft magnetic core grinding compensation device 1.

[0137] It is understandable that the pre-grinding parameters are temporary grinding parameters generated by the parameter analysis module 16 for soft magnetic cores in low-fitting states, used for pre-verification. The regular grinding parameters (regular grinding wheel feed speed, regular grinding fine grinding time, and regular grinding cooling parameters) are standard grinding parameters preset in the controller 19 for soft magnetic cores in normal states (non-low-fitting states), serving as a reference benchmark for the pre-grinding parameters.

[0138] For example, the controller 19 sends a pre-grinding parameter generation instruction to the parameter analysis module 16. The parameter analysis module 16 calls the initial inductance parameters and initial surface state parameters, and combines them with the risk level of the low-adaptation state to generate pre-grinding parameters according to the low-risk pre-grinding principle: the grinding wheel feed speed is set to a first preset percentage of the normal grinding speed, the fine grinding time is set to a second preset percentage of the normal grinding time, and the cooling parameters (flow rate, temperature) are kept consistent with the normal grinding parameters. The first preset percentage and the second preset percentage are both less than 100%, so that the grinding wheel feed speed of the pre-grinding is less than the normal grinding wheel feed speed and the fine grinding time is less than the normal grinding fine grinding time.

[0139] S520, the control and detection module 11 collects the surface state parameters of the non-critical grinding area of ​​the soft magnetic core to be processed, and obtains the surface state parameters of the non-critical grinding area; the non-critical grinding area is the edge redundant area on the soft magnetic core to be processed that does not affect the electrical performance and assembly accuracy.

[0140] It is understandable that the non-critical grinding area is the redundant edge part on the soft magnetic core to be processed. This non-critical grinding area does not involve the magnetic circuit of the soft magnetic core (does not affect electrical performance) or the assembly interface (does not affect assembly accuracy). Even if the pre-grinding effect is not good, it will not lead to the overall scrapping of the soft magnetic core, making it an ideal area for pre-verification. The surface state parameters of the non-critical grinding area are the surface state data (such as surface roughness, scratch depth / number) collected by the detection module 11 for this non-critical grinding area, which are used as a comparison benchmark before and after pre-grinding.

[0141] For example, the controller 19 sends a non-critical area detection command to the detection module 11. First, the visual inspection component identifies the edge redundant areas of the soft magnetic core to be processed (such as the non-magnetic circuit areas at both ends of the length direction of the soft magnetic core and the non-assembly areas on both sides of the width direction). Then, the controller controls the visual inspection component and the size sensing component to collect surface state parameters of the edge redundant areas, including surface roughness, depth and number of micro scratches, depth and number of depressions, to obtain the surface state parameters of the non-critical grinding area.

[0142] S530, the control grinding actuator 18 performs pre-grinding operation on the non-critical grinding area of ​​the soft magnetic core to be processed according to the pre-grinding parameters.

[0143] It is understandable that the pre-grinding operation is a localized, low-risk grinding action performed by the grinding actuator 18 on non-critical grinding areas based on the pre-grinding parameters. The purpose of pre-grinding is to verify whether the pre-grinding parameters can improve the surface condition of the soft magnetic core.

[0144] For example, the controller 19 sends a pre-grinding command to the grinding actuator 18. First, the position sensing module 14 locates the coordinates of the non-critical grinding area of ​​the soft magnetic core to be processed. Then, the controller controls the grinding wheel assembly of the grinding actuator 18 to move directly above the non-critical grinding area. According to the pre-grinding parameters, the grinding wheel is started to rotate and the cooling nozzle sprays coolant to perform pre-grinding on the non-critical area. During the pre-grinding process, the position sensing module 14 monitors the position of the grinding wheel in real time to ensure that the soft magnetic core does not exceed the range of the non-critical grinding area.

[0145] S540, the control and detection module 11 re-acquires the surface state parameters of the non-critical grinding area to obtain the surface state parameters after pre-grinding. At the same time, the control parameter analysis module 16 calculates the improvement rate between the surface state parameters of the non-critical grinding area and the surface state parameters after pre-grinding.

[0146] It is understandable that the surface state parameters after pre-grinding are the surface state data (consistent with the parameter types collected by S520) re-collected by the detection module 11 for non-critical grinding areas after the pre-grinding operation is completed, used for comparison with the state before pre-grinding. The improvement rate is the degree of improvement of the surface state after pre-grinding relative to the state before pre-grinding, calculated by the parameter analysis module 16. It can be obtained by the formula: Improvement rate = (Parameter value before pre-grinding - Parameter value after pre-grinding) / Parameter value before pre-grinding × 100%, such as roughness improvement rate, scratch depth improvement rate. The average of the improvement rates of each parameter is taken as the final improvement rate, used to determine the effect of pre-grinding.

[0147] For example, after pre-grinding is completed, the controller 19 controls the detection module 11 to re-collect the surface state parameters of the non-critical grinding area to obtain the surface state parameters after pre-grinding. At the same time, it sends an improvement rate calculation instruction to the parameter analysis module 16. The parameter analysis module 16 calculates the improvement rate of each parameter according to the preset formula. For example, the roughness improvement rate = (roughness before pre-grinding - roughness after pre-grinding) / roughness before pre-grinding × 100%, and the scratch depth improvement rate = (scratch depth before pre-grinding - scratch depth after pre-grinding) / scratch depth before pre-grinding × 100%. The average value is taken as (roughness improvement rate + scratch depth improvement rate) / 2 to obtain the final improvement rate.

[0148] S550, if the improvement rate is greater than or equal to the preset improvement threshold, it is determined that the soft magnetic core to be processed can be qualified by adjusting the grinding parameters, and the grinding parameters of the soft magnetic core grinding compensation device 1 according to the low adaptation state are adjusted.

[0149] It is understandable that the preset improvement threshold is a preset critical value for judging whether the pre-polishing effect is qualified. It is set based on the principle that the pre-polishing effect can represent the formal polishing effect (e.g., if the improvement rate is ≥50%, then the key area is considered to meet the standard after formal polishing). If the improvement rate meets the standard, it means that the pre-polishing parameters are in the right direction, and the soft magnetic core has a high probability of being qualified after formally adjusting the polishing parameters.

[0150] For example, controller 19 calls a preset improvement threshold, compares the improvement rate with the preset improvement threshold, and if the improvement rate is greater than or equal to the preset improvement threshold, it determines that the soft magnetic core to be processed can be qualified by adjusting the grinding parameters; then it returns to S440 and continues to execute the step of adjusting the formal grinding parameters according to the low adaptation state.

[0151] S560, if the improvement rate is less than the preset improvement threshold, the control transfer module 13 will transfer the soft magnetic core to be processed to the non-conforming product temporary storage area and terminate the subsequent grinding process of the soft magnetic core to be processed.

[0152] It is understandable that the non-conforming product temporary storage area is a pre-set area in the soft magnetic core grinding compensation equipment 1, used to store low-fit soft magnetic cores that have been judged by the low-fit pre-verification as unable to pass the grinding process, so as to reduce the situation where such soft magnetic cores enter the formal grinding process, occupy resources or cause the soft magnetic core grinding compensation equipment 1 to malfunction.

[0153] For example, if the improvement rate is less than the preset improvement threshold, the controller 19 determines that even if the grinding parameters are adjusted, the soft magnetic core to be processed is difficult to achieve qualified grinding, and sends a transfer instruction to the transfer module 13 to control the transfer module 13 to transfer the soft magnetic core from the processing station 15 to the non-conforming product temporary storage area. At the same time, it sends a termination instruction to each module of the soft magnetic core grinding compensation device 1 to stop all subsequent grinding-related actions (such as parameter adjustment and grinding execution).

[0154] By adopting the above steps S510 to S560, the feasibility of grinding low-fit magnetic cores is verified before formal grinding by pre-grinding non-critical areas and judging the improvement rate. This reduces the problem of a large number of scrapped low-fit soft magnetic cores caused by traditional direct grinding of critical areas, reduces processing risks and costs, and protects the critical areas of low-fit soft magnetic cores by using low-risk pre-grinding parameters. It also improves the flexibility of subsequent processing of unqualified soft magnetic cores (such as partial recycling). Finally, only low-fit soft magnetic cores that can pass grinding are allowed to enter the formal grinding, which further improves the overall soft magnetic core grinding yield.

[0155] It should be understood that the sequence number of each step in the above embodiments does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application.

[0156] Corresponding to the soft magnetic core grinding compensation method described in the above embodiments, this application also provides a soft magnetic core grinding compensation device, the various modules of which can realize the various steps of the soft magnetic core grinding compensation method. Figure 5 A structural block diagram of the soft magnetic core grinding compensation device provided in the embodiments of this application is shown. For ease of explanation, only the parts related to the embodiments of this application are shown.

[0157] Reference Figure 5 The device includes:

[0158] The detection unit is used to control the detection module 11 to perform pre-grinding detection on the soft magnetic cores set in the pre-feeding detection area 12, and to screen out the soft magnetic cores to be processed that meet the preset conditions.

[0159] The acquisition unit is used to control the transfer module 13 to transfer the soft magnetic core to be processed from the pre-loading detection area 12 to the processing station 15, and after the position sensing module 14 detects that the soft magnetic core to be processed has entered the processing station 15 and is fixed, it acquires at least one set of monitoring parameters associated with the soft magnetic core to be processed. The at least one set of monitoring parameters includes the initial inductance parameter, initial surface state parameter and grinding area environmental parameter of the soft magnetic core to be processed.

[0160] The determination unit is used to determine the processing adaptation state of the soft magnetic core to be processed based on the initial inductance parameters, initial surface state parameters, and grinding area environmental parameters.

[0161] The adjustment unit is used to adjust the grinding parameters of the soft magnetic core grinding compensation device 1 according to the processing adaptation status. The grinding parameters include grinding wheel feed parameters, cooling parameters, and fine grinding time parameters.

[0162] It should be noted that the information interaction and execution process between the above-mentioned devices / units are based on the same concept as the method embodiments of this application. For details on their specific functions and technical effects, please refer to the method embodiments section, and they will not be repeated here.

[0163] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional units and modules is merely an example. In practical applications, the above functions can be assigned to different functional units and modules as needed, that is, the internal structure of the device can be divided into different functional units or modules to complete all or part of the functions described above. The functional units and modules in the embodiments can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit. Furthermore, the specific names of the functional units and modules are only for easy differentiation and are not intended to limit the scope of protection of this application. The specific working process of the units and modules in the above system can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0164] This application also provides a soft magnetic core grinding compensation device. Figure 4 This is a schematic diagram of the structure of a soft magnetic core grinding and compensation device 1 provided in an embodiment of this application. Figure 4 As shown, the soft magnetic core grinding compensation device 1 of this embodiment includes: at least one processor 191 ( Figure 4 Only one is shown in the image), at least one memory 192 ( Figure 4 (Only one is shown in the image) and a computer program 193 stored in the at least one memory 192 and executable on the at least one processor 191. When the processor 191 executes the computer program 193, it causes the soft magnetic core grinding compensation device 1 to perform the steps in any of the above-described soft magnetic core grinding compensation method embodiments, or causes the soft magnetic core grinding compensation device 1 to perform the functions of each module / unit in the above-described device embodiments.

[0165] Exemplarily, the computer program 193 may be divided into one or more modules / units, which are stored in the memory 192 and executed by the processor 191 to complete this application. The one or more modules / units may be a series of computer program instruction segments capable of performing specific functions, which describe the execution process of the computer program 193 in the soft magnetic core grinding compensation device 1.

[0166] The controller 19 can be a computing device such as a desktop computer, laptop, handheld computer, or cloud server. The soft magnetic core grinding compensation device may include, but is not limited to, a processor 191 and a memory 192. Those skilled in the art will understand that... Figure 4 This is merely an example of a soft magnetic core grinding and compensation device 1 and does not constitute a limitation on the soft magnetic core grinding and compensation device 1. It may include more or fewer components than shown in the figure, or combine certain components, or different components, such as input / output devices, network access devices, buses, etc.

[0167] The processor 191 can be a Central Processing Unit (CPU), but it can also be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor can be a microprocessor or any conventional processor.

[0168] In some embodiments, the memory 192 may be an internal storage unit of the controller 19, such as a hard disk or RAM of the controller 19. In other embodiments, the memory 192 may be an external storage device of the controller 19, such as a plug-in hard disk, smart media card (SMC), secure digital (SD) card, flash card, etc., equipped on the controller 19. Furthermore, the memory 192 may include both internal storage units and external storage devices of the controller 19. The memory 192 is used to store operating systems, applications, bootloaders, data, and other programs, such as the program code of computer programs. The memory 192 can also be used to temporarily store data that has been output or will be output.

[0169] In the above embodiments, the descriptions of each embodiment have different focuses. For parts that are not described in detail or recorded in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0170] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0171] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

Claims

1. A method for grinding and compensating soft magnetic cores, characterized in that, An application is made in a soft magnetic core grinding compensation device, the soft magnetic core grinding compensation device including a detection module, a pre-loading detection area, a transfer module, a position sensing module, and a processing station, the method including: The detection module is controlled to perform pre-grinding detection on the soft magnetic cores located in the pre-feeding detection area, and to screen out the soft magnetic cores to be processed that meet the preset conditions. The control module transfers the soft magnetic core to be processed from the pre-loading detection area to the processing station. After the position sensing module detects that the soft magnetic core to be processed has entered the processing station and is fixed, it acquires at least one set of monitoring parameters associated with the soft magnetic core to be processed. The at least one set of monitoring parameters includes the initial inductance parameter, initial surface state parameter, and grinding area environmental parameter of the soft magnetic core to be processed. Based on the initial inductance parameters, the initial surface state parameters, and the environmental parameters of the polishing area, the processing adaptation state of the soft magnetic core to be processed is determined; The grinding parameters of the soft magnetic core grinding compensation device are adjusted according to the processing adaptation state. The grinding parameters include grinding wheel feed parameters, cooling parameters, and fine grinding time parameters.

2. The soft magnetic core grinding compensation method as described in claim 1, characterized in that, The control module performs pre-grinding inspection on the soft magnetic cores located in the pre-feeding inspection area, and selects soft magnetic cores to be processed that meet preset conditions, including: The detection module is controlled to acquire an appearance image of the soft magnetic core and perform defect identification on the appearance image to obtain the degree of appearance defect of the soft magnetic core. The detection module is controlled to measure the key dimensions of the soft magnetic core, and the dimensional deviation value between the key dimensions and the preset processing dimension range is obtained. Select soft magnetic cores to be processed that have an appearance defect level less than a preset defect threshold and a size deviation value less than a preset size deviation threshold.

3. The soft magnetic core grinding compensation method as described in claim 1, characterized in that, The control of the transfer module to transfer the soft magnetic core to be processed from the pre-loading and detection area to the processing station includes: The transfer module obtains the real-time position information of the soft magnetic core to be processed in the pre-feeding detection area. The transfer module is controlled to move to the soft magnetic core to be processed according to the real-time location information, and the soft magnetic core to be processed is adapted and clamped according to the size of the soft magnetic core to be processed. The transfer module is controlled to detect in real time whether there are obstacles within the path range during the transfer process along the preset path; If an obstacle is detected, the transfer module is controlled to pause the transfer and record the position of the obstacle. Then, the transfer path is adjusted according to the preset obstacle avoidance rules. After adjusting the transfer path, the transfer module continues to transfer the clamped soft magnetic core to be processed to the designated placement position of the processing station.

4. The soft magnetic core grinding compensation method as described in claim 3, characterized in that, The processing station includes a fixture assembly; the step of detecting and fixing the soft magnetic core to be processed entering the processing station via the position sensing module includes: The position sensing module is controlled to detect the pressure signal at the designated placement position of the processing station. When the pressure signal reaches a preset pressure threshold, it is determined that the soft magnetic core to be processed has entered the processing station. The position sensing module is controlled to detect the position deviation of the soft magnetic core to be processed as it enters the processing station, and to obtain the position deviation data of the soft magnetic core to be processed. Based on the position deviation data, the clamping assembly is controlled to perform position correction on the soft magnetic core to be processed until the position deviation data is less than a preset position deviation threshold, after which the soft magnetic core to be processed is clamped and fixed.

5. The soft magnetic core grinding compensation method as described in claim 1, characterized in that, The acquisition of at least one set of monitoring parameters associated with the soft magnetic core to be processed, the at least one set of monitoring parameters including the initial inductance parameter, initial surface state parameter, and grinding area environmental parameter of the soft magnetic core to be processed, including: Based on the model of the soft magnetic core to be processed, the acquisition priority of the at least one set of monitoring parameters is determined; wherein, the initial inductance parameter is the first priority, the initial surface state parameter is the second priority, and the environmental parameter of the polishing area is the third priority. The soft magnetic core grinding compensation device is controlled to first collect the initial inductance parameters of the first priority. If the initial inductance parameters are within a preset effective range, the initial surface state parameters of the second priority are then collected. If the initial surface state parameters meet the preset quality requirements, then continue to collect the environmental parameters of the third priority grinding area; The collected initial inductance parameters, initial surface state parameters, and environmental parameters of the polishing area are correlated and matched to form a complete set of at least one monitoring parameter group.

6. The soft magnetic core grinding compensation method as described in claim 1, characterized in that, The soft magnetic core grinding compensation device also includes a parameter analysis module; the processing adaptation state includes a high adaptation state, a medium adaptation state, and a low adaptation state; determining the processing adaptation state of the soft magnetic core to be processed based on the initial inductance parameters, the initial surface state parameters, and the environmental parameters of the grinding area includes: The parameter analysis module receives the initial inductance parameters, the initial surface state parameters, and the environmental parameters of the polishing area, and preprocesses the initial inductance parameters, the initial surface state parameters, and the environmental parameters of the polishing area to obtain standardized inductance parameters, standardized surface state parameters, and standardized environmental parameters. The inductance matching degree is determined by comparing the standardized inductance parameters with a preset inductance reference range, the surface matching degree is determined by comparing the standardized surface state parameters with a preset surface quality standard, and the environmental matching degree is determined by comparing the standardized environmental parameters with a preset environmental matching range. The parameter analysis module is controlled to perform a comprehensive analysis of the inductance adaptation degree, the surface adaptation degree, and the environmental adaptation degree to obtain a comprehensive processing adaptation value; Based on the preset range in which the processing adaptation comprehensive value falls, the processing adaptation state of the soft magnetic core to be processed is determined: if the processing adaptation comprehensive value is in the first preset range, the processing adaptation state is determined to be the high adaptation state; if the processing adaptation comprehensive value is in the second preset range, the processing adaptation state is determined to be the medium adaptation state; if the processing adaptation comprehensive value is in the third preset range, the processing adaptation state is determined to be the low adaptation state; wherein, the lower limit of the first preset range is greater than the upper limit of the second preset range, and the lower limit of the second preset range is greater than the upper limit of the third preset range.

7. The soft magnetic core grinding compensation method as described in claim 6, characterized in that, The soft magnetic core grinding compensation device further includes a grinding parameter adjustment module and a grinding execution mechanism; the grinding parameters of the soft magnetic core grinding compensation device are adjusted according to the processing adaptation state, and the grinding parameters include grinding wheel feed parameters, cooling parameters, and fine grinding time parameters, including: The processing adaptation state is obtained, and the processing adaptation state and parameter adjustment strategy library are called. The strategy library is divided into a first parameter tuning rule corresponding to the high adaptation state, a second parameter tuning rule corresponding to the medium adaptation state, and a third parameter tuning rule corresponding to the low adaptation state according to the processing adaptation state. If the processing adaptation state is the high adaptation state, the grinding parameter adjustment module is controlled to adjust the grinding wheel feed parameter to the high efficiency range preset by the first parameter adjustment rule according to the first parameter adjustment rule, and then adjust the cooling parameter to the auxiliary range preset by the first parameter adjustment rule that matches the grinding wheel feed parameter, so as to keep the fine grinding time parameter within the benchmark range preset by the first parameter adjustment rule. If the processing adaptation state is the medium adaptation state, the grinding parameter adjustment module is controlled to adjust the fine grinding time parameter to the fine range preset by the second parameter adjustment rule according to the second parameter adjustment rule, and then adjust the grinding wheel feed parameter and the cooling parameter synchronously according to the linkage rule preset by the second parameter adjustment rule. If the processing adaptation state is the low adaptation state, the grinding parameter adjustment module is controlled to adjust the cooling parameter to the stable range preset by the third parameter adjustment rule according to the third parameter adjustment rule, then adjust the grinding wheel feed parameter to the low wear range preset by the third parameter adjustment rule, and finally adjust the fine grinding time parameter to the adaptation range according to the matching relationship preset by the third parameter adjustment rule and the final value of the grinding wheel feed parameter. Cross-validation is performed on the adjusted grinding wheel feed parameters, cooling parameters, and fine grinding time parameters to obtain parameter conflict results. If the parameter conflict results are that there are no parameter conflicts, the adjusted grinding wheel feed parameters, cooling parameters, and fine grinding time parameters are output to the grinding actuator.

8. The soft magnetic core grinding compensation method as described in claim 7, characterized in that, When the processing adaptation state is determined to be a low adaptation state, before adjusting the grinding parameters of the soft magnetic core grinding compensation device according to the low adaptation state, a low adaptation pre-verification is also included, which includes: The parameter analysis module generates pre-grinding parameters adapted to the low-fit state based on the initial inductance parameters and the initial surface state parameters. The feed speed of the grinding wheel in the pre-grinding parameters is less than the feed speed of the conventional grinding wheel in the soft magnetic core grinding compensation device, the fine grinding time of the pre-grinding parameters is less than the fine grinding time of the conventional grinding in the soft magnetic core grinding compensation device, and the cooling parameters of the pre-grinding parameters are consistent with the cooling parameters of the conventional grinding in the soft magnetic core grinding compensation device. The detection module is controlled to collect surface state parameters of the non-critical grinding area of ​​the soft magnetic core to be processed, and the surface state parameters of the non-critical grinding area are obtained; the non-critical grinding area is the edge redundant area on the soft magnetic core to be processed that does not affect the electrical performance and assembly accuracy. The grinding actuator is controlled to perform a pre-grinding operation on the non-critical grinding area of ​​the soft magnetic core to be processed according to the pre-grinding parameters; The detection module is controlled to re-acquire the surface state parameters of the non-critical grinding area to obtain the surface state parameters after pre-grinding. At the same time, the parameter analysis module is controlled to calculate the improvement rate between the surface state parameters of the non-critical grinding area and the surface state parameters after pre-grinding. If the improvement rate is greater than or equal to the preset improvement threshold, it is determined that the soft magnetic core to be processed can be qualified by adjusting the grinding parameters, and the grinding parameters of the soft magnetic core grinding compensation device are adjusted according to the low adaptation state. If the improvement rate is less than the preset improvement threshold, the transfer module is controlled to transfer the soft magnetic core to be processed to the non-conforming product temporary storage area, and the subsequent polishing process of the soft magnetic core to be processed is terminated.

9. A soft magnetic core grinding compensation device, characterized in that, An apparatus for grinding and compensating soft magnetic cores, comprising a detection module, a pre-feeding detection area, a transfer module, a position sensing module, and a processing station, wherein the apparatus includes: The detection unit is used to control the detection module to perform pre-grinding detection on the soft magnetic cores located in the pre-feeding detection area, and to screen out the soft magnetic cores to be processed that meet the preset conditions. The acquisition unit is used to control the transfer module to transfer the soft magnetic core to be processed from the pre-loading detection area to the processing station, and after the position sensing module detects that the soft magnetic core to be processed has entered the processing station and is fixed, it acquires at least one set of monitoring parameters associated with the soft magnetic core to be processed. The at least one set of monitoring parameters includes the initial inductance parameter, initial surface state parameter and grinding area environmental parameter of the soft magnetic core to be processed. The determining unit is used to determine the processing adaptation state of the soft magnetic core to be processed based on the initial inductance parameters, the initial surface state parameters, and the environmental parameters of the polishing area. The adjustment unit is used to adjust the grinding parameters of the soft magnetic core grinding compensation device according to the processing adaptation state. The grinding parameters include grinding wheel feed parameters, cooling parameters, and fine grinding time parameters.

10. A soft magnetic core grinding and compensation device, characterized in that, The device includes a detection module, a pre-loading detection area, a transfer module, a position sensing module, a processing station, and a controller. The controller is electrically connected to the detection module, the transfer module, and the position sensing module. The controller includes a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it implements the method as described in any one of claims 1 to 8.

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