Combined machine tool for metal cutting

Abstract

The invention discloses a combined machine tool for metal cutting. A machining center comprises a machine tool body, a long-stroke precision linear workbench, a spindle unit and three independently-configured gantry type cutting modules. The three gantry type cutting modules are sequentially arranged in the longitudinal direction of the workbench and arranged on the two sides of the workbench in a striding mode, each module comprises a rigid portal frame, a radial cutting power head installed on a cross beam, an X-axis servo driving mechanism and a Z-axis servo driving mechanism, structural parameters of all the gantry type cutting modules are independently adjustable, and the gantry type cutting modules can be provided with automatic tool changing devices or replaced with special process heads. The central numerical control system integrally controls the Y-axis positioning of the workbench, the movement of the main shaft unit and all feeding shafts of each gantry module, through the modularized independent gantry framework, the problems that a traditional combined machine tool is insufficient in rigidity, poor in flexibility and difficult to expand are solved, the unification of high efficiency, high precision, high flexibility and high expandability is achieved, and the working efficiency is improved. And the method is particularly suitable for batch flexible production of shaft and sleeve parts needing multiple radial procedures.

Description

Technical Field

[0001] This invention belongs to the technical field of metal cutting equipment, and specifically relates to a combination machine tool for metal cutting. Background Technology

[0002] In the field of modern mechanical manufacturing, for parts with multiple radial features such as milling grooves, drilling, tapping, and milling planes, the traditional processing methods are mainly divided into two types: one is to use multiple general-purpose machine tools (such as vertical machining centers, milling machines, and drilling machines) to perform process-distributed processing; the other is to design special multi-axis combination machine tools for specific products to perform assembly line processing.

[0003] While general-purpose machine tool processing is highly flexible, it has the following significant drawbacks: 1) Parts need to be clamped and transferred multiple times between different machine tools, and the conversion of positioning references leads to large cumulative errors, making it difficult to guarantee processing accuracy; 2) The production process is long, requiring a lot of equipment and personnel, resulting in low production efficiency and high management costs; 3) It is difficult to achieve precise coordination and efficient parallel processing of multiple processes.

[0004] Specialized multi-axis combination machine tools (such as multi-station rotary table machine tools or multi-spindle drilling and milling combination machines) improve the processing efficiency of specific products to a certain extent. However, these machine tools typically use a fixed layout shared frame (such as a single column or multi-spindle head), and their structural rigidity, thermal stability, and machining accuracy face challenges when faced with simultaneous heavy cutting by multiple tools. More importantly, their "rigid" mechanical structure results in extremely poor process flexibility. Once the product size series changes or the process flow is adjusted, large-scale, high-cost mechanical modifications or even redesign of the machine tool are required, making it unable to adapt to the modern production trend of multi-variety, small-batch production.

[0005] Furthermore, as manufacturing technologies develop towards intelligence and integration, the integration of specialized processes (such as laser marking and ultrasonic processing) or online quality inspection during manufacturing has become an urgent need to enhance product added value and ensure quality stability. Traditional modular machine tools, due to their enclosed and fixed structure, find it difficult to achieve convenient expansion and integration of such functions. Summary of the Invention

[0006] In view of the shortcomings of the prior art, the purpose of this invention is to provide a combination machine tool for metal cutting that can take into account high efficiency, high precision, high flexibility and strong scalability.

[0007] The technical solution adopted by this invention to solve its technical problem is: A combination machine tool for metal cutting includes a bed and further includes: A long-stroke precision linear worktable is located above the machine bed, and multiple machining stations for clamping workpieces are arranged longitudinally on the table surface. At least one set of spindle units that provide rotational power to the workpiece; Three independently configured gantry cutting modules are arranged sequentially along the longitudinal direction of the worktable and span across the bed on both sides of the worktable; each gantry cutting module includes a rigid gantry, a radial cutting power head mounted on the gantry beam, and a servo drive mechanism that drives the power head to perform transverse (X-axis) and vertical (Z-axis) feed. The three gantry cutting modules are spatially independent and spaced apart, and their radial cutting power heads can independently or collaboratively perform the same or different radial cutting operations on the corresponding machining stations on the worktable. A central CNC system integrates and controls the longitudinal (Y-axis) positioning of the worktable, the movement of each spindle unit, and all feed axes of the three gantry cutting modules, enabling parallel or serial machining of multiple stations and processes.

[0008] Preferably, each of the gantry cutting modules is equipped with a disc or chain tool magazine that can hold multiple tools and an automatic tool changer, so that each radial cutting power head can automatically change tools during the machining process and independently complete complex multi-process machining.

[0009] Preferably, the structural parameters of the three gantry cutting modules are independently adjustable, including the gantry span, beam height, and power head specifications, to adapt to the processing of workpieces of different sizes or process requirements.

[0010] Preferably, at least one of the radial cutting power heads of the gantry cutting module is replaced with a special process head, which includes one of a laser processing head, an ultrasonic vibration-assisted processing head, or an online inspection probe, enabling the machining center to have the capability for composite special machining or online quality monitoring.

[0011] Preferably, the central CNC system includes modular process programming functionality, which can configure and store machining programs for each independent gantry cutting module, and automatically call them according to the workpiece process flow during machining, thereby achieving flexible process path combinations.

[0012] Preferably, the central CNC system is also equipped with a collision interference prevention algorithm. This algorithm calculates the position of the power head, the tool length, and the position of the worktable of the three independently movable gantry cutting modules in real time, and provides early warning or stops the movement when spatial interference may occur.

[0013] Preferably, each of the gantry cutting modules is equipped with a high-precision adjustable foot pad and a leveling mechanism between its base and the bed, and can be individually leveled and aligned using a laser interferometer to ensure that the motion reference of the three modules is highly consistent with the machining coordinate system.

[0014] Preferably, each of the gantry cutting modules is equipped with an independent fully enclosed protective cover and chip recovery device, as well as an independent oil mist collection and coolant supply unit, to achieve isolation and environmental management of the processing area.

[0015] Preferably, the spindle unit is an electric spindle independently configured for each machining station, and at least some of the electric spindles have a C-axis function that rotates around its axis, enabling multi-axis linkage with the power head of any gantry cutting module to complete complex processes such as circumferential milling and spiral groove machining.

[0016] Preferably, the machining center also includes a bus-based distributed I / O control system, where each gantry cutting module acts as an independent intelligent slave station, possessing local motion control, sensor data processing, and fault diagnosis capabilities, and exchanging and cooperating with the central CNC system in real time via a high-speed industrial network.

[0017] The beneficial effects of this invention are as follows: By coordinating three independently configured gantry cutting modules with a multi-station worktable, this invention can achieve efficient batch processing of workpieces in a "parallel processing" mode (efficiency several times that of a single machine), and continuous composite processing of multiple complex radial operations on a single workpiece in a "parallel processing" mode (reducing clamping and improving accuracy). This architecture fundamentally solves the contradiction between efficiency and flexibility in traditional solutions.

[0018] The three gantry-type cutting modules are structurally completely independent, and their span, height, and power head model can all be adjusted or replaced independently. This makes the invention no longer a fixed-function "machine tool," but a "manufacturing platform" that can be quickly reconfigured according to changes in product families. Users can flexibly configure modules of different specifications and functions like building blocks, quickly responding to changes in production needs, and greatly reducing the cost and cycle of equipment upgrades and replacements.

[0019] It offers superior machining accuracy and stability: each gantry module employs an independent rigid frame, and a high-precision adjustable mechanism ensures consistent reference standards between them. This distributed, independent support structure, compared to traditional shared frames, has higher local rigidity and better thermal stability, effectively suppressing vibration coupling and thermal deformation caused by simultaneous multi-tool cutting, providing a solid mechanical foundation for high-precision machining. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of a metal cutting combination machine tool provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the overall structure of a gantry-type cutting module in a metal cutting combination machine tool according to an embodiment of the present invention. Detailed Implementation

[0021] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments are not intended to limit the present invention.

[0022] Example See Figure 1-2 As shown, a modular multi-axis radial composite machining center for the co-line production of quick-release pins and locating pins is described. The specific structure of the machining center in this embodiment is as follows: The machine tool's base is a heavy-duty bed 1, integrally cast or welded, which has good vibration damping and thermal stability. High-precision longitudinal guideways are provided on both sides of the upper part of the bed 1.

[0023] In the central area of ​​the bed 1, a long-stroke precision linear worktable 2 is installed. This worktable 2 is driven by a high-precision ball screw (or linear motor) driven by a high-torque servo motor, and can move at high speed and with precision along the longitudinal direction of the bed (defined as the Y-axis). Its movement accuracy is controlled by a grating ruler through a fully closed-loop feedback system.

[0024] A modular fixture base is fastened to the surface of the workbench 2 along the Y-axis. In this embodiment, three identical composite machining units are provided on the fixture base.

[0025] Each composite machining unit includes two quick-release pin hydraulic tensioning clamps and a positioning pin end face positioning elastic sleeve, which respectively constitute the "first type of clamping hole" and the "second type of clamping hole".

[0026] Directly below each clamping hole, there is an independent servo electric spindle 3, serving as a "spindle unit". This electric spindle 3 is integrated inside the worktable 2, with its axis pointing vertically upward (defined as the C-axis; some spindles have indexing and locking functions). Each electric spindle can be independently controlled in terms of speed and direction.

[0027] Three independent gantry cutting modules (4A, 4B, 4C) with the same structure but independently configurable functions sit sequentially on both sides of the worktable 2 along the Y-axis and are firmly installed on the bed 1.

[0028] Each gantry module includes: a. A rigid gantry frame 41: consisting of two side columns and a top crossbeam, employing a box-type structure with internal reinforcing ribs. b. An XZ-axis feed slide 42: mounted on the front guide rail of the crossbeam, driven by a servo motor for lateral (X-axis) movement. A vertical (Z-axis) feed ram is also mounted on this slide 42. c. A radial cutting power head 43: mounted at the end of the Z-axis ram. In this embodiment, the power heads of modules 4A and 4B are high-speed electric spindle milling power heads used for milling grooves; the power head of module 4C is a drilling and tapping power head used for drilling and tapping. d. A disc-type tool magazine 44 and an automatic tool changer: mounted on the side of the gantry crossbeam, allowing for automatic tool changing for the power head 43. For example, the tool magazine of module 4A can hold multiple milling cutters of different widths to accommodate different groove widths.

[0029] Sufficient safety distances are maintained between the three modules to ensure that there is no physical interference between their respective moving parts (such as the robotic arm and spindle) in any working state.

[0030] The machine tool is equipped with a central CNC system (such as an industrial PC based on an open CNC kernel). The control cabinet uses a distributed I / O control system based on the EtherCAT bus. Each gantry module (4A, 4B, 4C) and the table drive unit is an intelligent slave station, equipped with local drivers and I / O modules, responsible for motion control, sensor signal acquisition (such as tool breakage detection, temperature monitoring), and preliminary fault diagnosis within its unit.

[0031] The central CNC system runs dedicated control software, which includes: a. Modular process programming interface: Operators can program and store process parameters for "Gantry Module 4A - Milling Grooves", "Gantry Module 4B - Milling Grooves", and "Gantry Module 4C - Drilling / Tapping" respectively. b. Multi-axis collaborative scheduling module: Responsible for planning the movement sequence of worktable 2 on the Y-axis and directing the three gantry modules to execute the machining program at the correct time and to the correct workstation. c. Real-time collision interference prevention module: This module has a built-in 3D model of all moving parts of the machine tool, monitors the position of each axis in real time, and predicts the trajectory within the next few milliseconds through algorithms. Once a potential collision risk is detected (for example, the tool of a certain gantry module is not raised to a safe height when the worktable moves), it immediately stops and alarms. d. Dynamic load monitoring interface: Displays the real-time load current of each spindle and power head. When abnormal load fluctuations (such as tool wear) are detected, an alarm can be triggered.

[0032] The workflow of this embodiment is as follows: Preparation and clamping: The operator loads the blank into the two quick-release pin clamps and one locating pin clamp on station group 1 (front end of the worktable). At this time, station groups 2 and 3 are in the processing or waiting state.

[0033] Start-up and machining cycle: The central CNC system starts the machining program. Worktable 2 first moves rapidly, positioning station group 1 below gantry module 4A. The XZ axes of module 4A drive the designated milling cutter on its power head to perform a radial grooving operation on the first quick-release pin in station group 1. Simultaneously, its tool magazine can pre-select tools for the next operation.

[0034] After this process is completed, workbench 2 immediately moves, positioning station group 1 below gantry module 4B to slot the second quick-release pin; simultaneously, station group 2 is moved below module 4A to begin slotting the first quick-release pin of the second batch of workpieces. At this time, modules 4A and 4B are working simultaneously.

[0035] Subsequently, the workbench moves, positioning station group 1, which has already undergone slotting, below gantry module 4C, for drilling or chamfering of the positioning pins. At this time, station group 2 processes at module 4B, and station group 3 processes at module 4A. The three gantry modules operate in complete parallel.

[0036] Cycle and Unloading: After station group 1 completes the final process in module 4C, the workbench moves it back to the loading and unloading position. The operator unloads a finished quick-release pin and a locating pin, and loads a new blank. Meanwhile, stations 2 and 3 continue processing in subsequent modules, achieving uninterrupted production line operation.

[0037] The above embodiments of the present invention are not intended to limit the scope of protection of the present invention. The implementation of the present invention is not limited thereto. All other modifications, substitutions or alterations made to the above structure of the present invention based on the above content of the present invention, in accordance with ordinary technical knowledge and common practice in the field, without departing from the basic technical idea of ​​the present invention, shall fall within the scope of protection of the present invention.

Claims

1. A combination machine tool for metal cutting, characterized in that, Including a bed frame, characterized in that: it also includes: A long-stroke precision linear worktable is located above the machine bed, and multiple machining stations for clamping workpieces are arranged longitudinally on the table surface. At least one set of spindle units that provide rotational power to the workpiece; Three independently configured gantry cutting modules are arranged sequentially along the longitudinal direction of the worktable and span across the bed on both sides of the worktable; each gantry cutting module includes a rigid gantry, a radial cutting power head mounted on the gantry beam, and a servo drive mechanism that drives the power head to perform transverse (X-axis) and vertical (Z-axis) feed. The three gantry cutting modules are spatially independent and spaced apart, and their radial cutting power heads can independently or collaboratively perform the same or different radial cutting operations on the corresponding machining stations on the worktable. A central CNC system integrates and controls the longitudinal (Y-axis) positioning of the worktable, the movement of each spindle unit, and all feed axes of the three gantry cutting modules, enabling parallel or serial machining of multiple stations and processes.

2. The modular multi-axis radial composite machining center according to claim 1, characterized in that: Each of the gantry cutting modules is equipped with a disc or chain tool magazine that can hold multiple tools and an automatic tool changer, enabling each radial cutting power head to automatically change tools during the machining process and independently complete complex multi-process machining.

3. The modular multi-axis radial composite machining center according to claim 1, characterized in that: The structural parameters of the three gantry cutting modules are independently adjustable, including the gantry span, beam height, and power head specifications, to adapt to the processing of workpieces of different sizes or process requirements.

4. The modular multi-axis radial composite machining center according to claim 1 or 3, characterized in that: At least one of the radial cutting power heads of the gantry cutting module is replaced with a special process head, which includes one of a laser processing head, an ultrasonic vibration-assisted processing head, or an online inspection probe, enabling the machining center to have the capability for composite special machining or online quality monitoring.

5. The modular multi-axis radial composite machining center according to claim 1, characterized in that: The central CNC system includes modular process programming functionality, which can configure and store machining programs for each independent gantry cutting module, and automatically call them up during machining according to the workpiece process flow, thereby achieving flexible process path combinations.

6. The modular multi-axis radial composite machining center according to claim 5, characterized in that: The central CNC system is also equipped with a collision interference prevention algorithm. This algorithm calculates the position of the power head, the tool length, and the position of the worktable of the three independently movable gantry cutting modules in real time, and provides early warning or stops the movement when spatial interference may occur.

7. The modular multi-axis radial composite machining center according to claim 1, characterized in that: Each of the gantry cutting modules is equipped with high-precision adjustable leveling pads and a leveling mechanism between its base and the machine bed. It can also be individually leveled and aligned using a laser interferometer to ensure that the motion reference of the three modules is highly consistent with the machining coordinate system.

8. The modular multi-axis radial composite machining center according to claim 1, characterized in that: Each of the aforementioned gantry cutting modules is equipped with an independent fully enclosed protective cover and chip recovery device, as well as an independent oil mist collection and coolant supply unit, to achieve isolation and environmental management of the processing area.

9. The modular multi-axis radial composite machining center according to claim 1, characterized in that: The spindle unit is an electric spindle independently configured for each machining station, and at least some of the electric spindles have a C-axis function that rotates around its axis, enabling multi-axis linkage with the power head of any gantry cutting module to complete complex processes such as circumferential milling and spiral groove machining.

10. The modular multi-axis radial composite machining center according to claim 1, characterized in that: The machining center also includes a bus-based distributed I / O control system. Each gantry cutting module acts as an independent intelligent slave station, possessing local motion control, sensor data processing, and fault diagnosis capabilities. It also exchanges and collaborates with the central CNC system in real time via a high-speed industrial network.

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