Polyurethane sponge shape correcting and cutting device and using method thereof

Abstract

The invention is suitable for the field of polyurethane sponge processing, and provides a polyurethane sponge shape correction cutting device which comprises a cutting driving system and a shape correction cutting head used for shape correction cutting of polyurethane sponge, the shape correction cutting head is additionally installed on an X-axis guide rail in a sliding mode, the X-axis guide rail is assembled on a Y-axis guide rail in a sliding mode, and the Y-axis guide rail is installed on a supporting frame. A Z-axis guide rail is assembled between the shape correcting cutting head and the X-axis guide rail; the cutting driving system comprises a control module and a cutting route planning module; the use method of the shape correction cutting device for the polyurethane sponge comprises the steps that the cutting driving system plans a cutting route according to the shape correction cutting requirement of the polyurethane sponge, and accurately controls the X-axis guide rail, the Y-axis guide rail and the Z-axis guide rail to drive the shape correction cutting head to cut the polyurethane sponge in a shape correction mode; the flexible shape correction cutting of the polyurethane sponges with various sizes and specifications is realized, the adaptability is high, the cutting dies do not need to be switched frequently, and the production cost is reduced; and the cutting efficiency and the cutting quality are greatly improved.

Description

Technical Field

[0001] This invention relates to the field of polyurethane foam processing, and more particularly to a polyurethane foam shaping and cutting device and its usage method. Background Technology

[0002] Polyurethane foam, also known as polyurethane flexible foam, is a high-molecular polymer material made from chemical raw materials such as isocyanate and polyether polyol through a foaming reaction. Its internal structure contains numerous interconnected or semi-interconnected micropores, giving the material excellent resilience, softness, breathability, and water absorption. Due to these properties, polyurethane foam is widely used in household goods (such as sofa and mattress fillings), cleaning materials, packaging cushioning materials, and industrial fields such as automotive interiors and sound absorption filtration. In many applications, to meet the assembly or functional requirements of specific products, it is often necessary to process large pieces of foam material into precision components with complex curved surfaces or irregular contours. This process necessitates the shaping and cutting of polyurethane foam.

[0003] Currently, the shaping and cutting of polyurethane foam mainly relies on two technical approaches: one is die-cutting using specialized cutting molds, where pressure is applied to press the mold into the foam to obtain the desired shape; this method is suitable for mass production of single-specification products. The other is using CNC cutting equipment, where a computer controls the movement of the cutting tool along a preset path to achieve flexible processing of irregular contours. CNC cutting can be further divided into various forms such as ring blade cutting, vibrating blade cutting, and hot wire cutting, which can adapt to the processing needs of foams with different hardness and density.

[0004] However, existing polyurethane foam shaping and cutting devices still have significant shortcomings in practical applications. While using cutting molds offers high cutting efficiency, the mold design and manufacturing cycle is long and costly, and frequent machine shutdowns are required to replace molds when product specifications change, making it difficult to meet the flexible production needs of small batches and multiple varieties. When using CNC cutting machines to process irregular contours, polyurethane foam itself is a flexible porous material with low hardness and high resilience. During the high-speed movement of the cutting tool, the material is easily deformed or displaced under pressure, causing deviations between the actual cutting path and the preset trajectory. This leads to problems such as rough cutting edges and out-of-tolerance dimensional accuracy. Especially when cutting complex curves or sharp angles and other delicate parts, the difficulty of controlling the cutting path is further increased, which not only reduces cutting efficiency but also seriously affects the cutting quality and consistency of the final product. Summary of the Invention

[0005] The purpose of this invention is to provide a polyurethane foam shaping and cutting device and its usage method, in order to solve the problems mentioned in the background art.

[0006] Specifically, the polyurethane foam shaping and cutting device includes an operating table for placing the polyurethane foam and a shaping and cutting head for shaping the polyurethane foam. The operating table includes an operating frame and an operating plate mounted on top of the operating frame. The shaping and cutting head is slidably mounted on an X-axis guide rail, which is slidably mounted on a Y-axis guide rail. The Y-axis guide rail is mounted on a support frame, and a Z-axis guide rail is mounted between the shaping and cutting head and the X-axis guide rail. The device also includes a cutting drive system, which includes a control module and a cutting path planning module. The cutting path planning module is used to plan the cutting path according to the polyurethane foam to be shaped and cut, and the control module is used to precisely control the X-axis, Y-axis, and Z-axis guide rails to drive the shaping and cutting head to shape and cut the polyurethane foam. The system includes electrical signal connections between the X-axis, Y-axis, and Z-axis guides, the control module, and the cutting path planning module. After the polyurethane foam is positioned on the operating table, the cutting drive system is activated according to the actual needs of the shaping and cutting. The cutting drive system uses the cutting path planning module to plan the cutting path based on the polyurethane foam to be shaped and cut. After the cutting path is determined, the cutting drive system uses the control module to precisely control the X-axis, Y-axis, and Z-axis guides to accurately drive the shaping and cutting head to shape and cut the polyurethane foam. This is beneficial for accurate control of the cutting path in irregular contour cutting. It enables flexible handling of shaping and cutting polyurethane foam of various sizes and specifications, has high adaptability, eliminates the need for frequent switching of cutting molds, and reduces production costs. Cutting efficiency and cutting quality are significantly improved.

[0007] The technical solution of this application will be further described below:

[0008] In one embodiment, the X-axis guide rail, Y-axis guide rail and Z-axis guide rail adopt the same structure, and an electric push rod is installed inside the X-axis guide rail. The electric push rod is electrically connected to the module and the cutting route planning module.

[0009] In one embodiment, a cutting drive system is also included, the cutting drive system comprising:

[0010] The multi-source data acquisition unit is used to acquire the material property parameters and irregular contour data of the polyurethane foam to be cut in real time; the material property parameters include at least density, thickness and elastic modulus; the irregular contour data can be manually input or automatically acquired by a 3D scanning device.

[0011] A three-dimensional digital modeling unit is electrically connected to the multi-source data acquisition unit and is used to generate a three-dimensional point cloud model of the sponge to be cut based on the acquired irregular contour data.

[0012] The intelligent path planning module is electrically connected to the multi-source data acquisition unit and the three-dimensional digital modeling unit. It has a built-in deformation prediction model and adaptive path optimization algorithm. The deformation prediction model is based on material property parameters and combined with the mechanical constitutive relationship of polyurethane foam to predict the distribution and magnitude of deformation caused by material compression during the cutting process, and generates feedforward compensation. The adaptive path optimization algorithm dynamically generates the optimal cutting trajectory including the pre-compensated path based on the three-dimensional point cloud model and the feedforward compensation.

[0013] The high-precision motion control module is electrically connected to the intelligent path planning module and to the servo drive components inside the X-axis guide rail, Y-axis guide rail, and Z-axis guide rail. It is used to convert the optimal cutting trajectory into precise motion control commands to drive the shaping cutting head to move along the preset trajectory.

[0014] The real-time closed-loop feedback unit includes a high-resolution position sensor and an attitude sensor installed on the alignment cutting head, which are used to monitor the actual spatial coordinates and cutting angle of the cutting head in real time and feed the monitoring data back to the high-precision motion control module in real time.

[0015] The dynamic compensation and correction unit, built into the high-precision motion control module, is used to dynamically adjust the motion parameters of the servo drive element, including feed speed, acceleration, cutting depth and cutting angle, based on the deviation between real-time feedback data and preset trajectory, combined with material characteristic parameters and geometric features of the current cutting position, so as to realize real-time suppression and correction of the flexible deformation of polyurethane foam.

[0016] The self-learning optimization engine is electrically connected to the intelligent path planning module and the dynamic compensation and correction unit, respectively. It is used to collect material parameters, cutting trajectory, real-time deviation and final cutting quality data in each cutting process. Through machine learning algorithms, it continuously optimizes the deformation prediction model and dynamic compensation strategy to form a continuously evolving cutting knowledge base.

[0017] Furthermore, the deformation prediction model is constructed based on the principle of finite element analysis, treating polyurethane foam as a hyperelastic material. The model parameters are automatically adjusted according to the density, thickness and elastic modulus obtained in real time, so as to realize high-precision simulation and compensation calculation of deformation before cutting.

[0018] Furthermore, the adaptive path optimization algorithm adopts a segmented optimization strategy: for straight areas in the 3D point cloud model, a fast cutting mode with maximum feed speed is used; for complex curves, sharp angles, and other irregular areas, the feed speed is automatically reduced and the density of path interpolation points is increased. At the same time, a smooth transition trajectory is generated by combining feedforward compensation to avoid cutting quality defects caused by sudden changes in the path.

[0019] Furthermore, the intelligent path planning module also has a built-in multi-specification cutting route library to store the generated optimal cutting trajectory and its corresponding sponge specification parameters; when a cutting task with the same specifications as the historical ones is received, the existing trajectory is directly called from the route library and finely adjusted according to the measured material parameters of the current batch of sponges before use, so that the production can be changed quickly without frequent changes to the cutting mold.

[0020] Furthermore, the real-time closed-loop feedback unit also includes a dynamic pressure sensor installed at the root of the alignment cutting head, used to collect the contact pressure between the alignment cutting head and the polyurethane foam during the cutting process in real time; the dynamic compensation and correction unit, based on the pressure feedback value and combined with the position deviation data, uses a multi-source information fusion algorithm to more accurately determine the material deformation state and dynamically adjust the cutting depth and feed speed to prevent over-cutting or under-cutting.

[0021] Furthermore, the self-learning optimization engine employs a deep reinforcement learning algorithm, using cutting quality evaluation indicators including edge smoothness, dimensional accuracy, and cutting efficiency as the reward function, material parameters, cutting trajectory, and motion parameters as the state space, and path compensation amount and control parameter adjustment amount as the action space. Through continuous iterative optimization, the deformation prediction model and dynamic compensation strategy gradually approach the optimal solution.

[0022] Furthermore, the servo drive components inside the X-axis, Y-axis, and Z-axis guide rails are high-precision servo electric cylinders with built-in absolute encoders, enabling micron-level positioning accuracy. The high-precision motion control module communicates with the driver of the servo electric cylinder via a high-speed fieldbus to ensure the real-time and synchronous nature of control commands.

[0023] Another object of the present invention is to provide a method of using the polyurethane sponge shaping and cutting device described above, comprising the following steps: after the polyurethane sponge is positioned on the operating table, the cutting drive system plans the cutting route according to the polyurethane sponge to be shaped and cut, and precisely controls the X-axis guide rail, Y-axis guide rail and Z-axis guide rail to drive the shaping and cutting head to shape and cut the polyurethane sponge.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0025] 1. After the polyurethane foam is positioned on the operating table, the cutting drive system is activated according to the actual needs of the shaping and cutting. The cutting drive system uses the cutting path planning module to plan the cutting path based on the polyurethane foam to be shaped and cut. After the cutting path is determined, the cutting drive system uses the control module to precisely control the X-axis, Y-axis, and Z-axis guides to accurately drive the shaping and cutting head to shape and cut the polyurethane foam. This is beneficial for accurate control of the cutting path in irregular contour cutting. It can flexibly handle the shaping and cutting of polyurethane foam of various sizes and specifications, with high adaptability. It does not require frequent switching of cutting molds, reducing production costs. Cutting efficiency and cutting quality are greatly improved.

[0026] 2. Existing technologies either rely on the rigid trajectory control of CNC cutting machines or on special molds, neither of which fully considers the fundamental impact of the flexible material characteristics of polyurethane foam on cutting accuracy. This invention proposes for the first time a technical route of "material perception-deformation prediction-dual compensation-self-learning evolution", which introduces intrinsic parameters such as the density and elastic modulus of the foam as active control variables into the entire cutting process, realizing a technological leap from trajectory control to material adaptive control.

[0027] 3. Pre-compensation before cutting is achieved through deformation prediction model to solve the poor system performance caused by material compression; real-time correction during cutting is achieved through real-time closed-loop feedback and dynamic correction unit to solve random disturbances and residual deformation; the two work together to ensure that the path control accuracy of irregular contour cutting reaches within ±0.1mm.

[0028] By integrating multi-dimensional information such as material parameters, three-dimensional contours, real-time position, and contact pressure, the cutting drive system can perceive the cutting status more comprehensively and make more accurate decisions.

[0029] By introducing deep reinforcement learning algorithms, the system can accumulate experience from each cut, continuously optimize the deformation prediction model and compensation strategy, and has the ability to continuously improve the cutting quality as the usage time increases.

[0030] 4. Through dual compensation and curvature adaptive adjustment, the deviation between the actual tool trajectory and the theoretical trajectory is controlled within a very small range in the cutting of complex irregular contours, resulting in smooth, burr-free edges and dimensional accuracy that meets the requirements of high-end applications. The multi-specification cutting route library combined with intelligent path planning can quickly respond to the cutting needs of sponges of any size and shape, reducing changeover time from several hours to several minutes, significantly reducing production costs. While ensuring accuracy, the segmented optimization strategy enables high-speed cutting in straight areas and precise cutting in irregular areas, improving overall cutting efficiency compared to traditional CNC cutting, while also increasing the cutting qualification rate. Attached Figure Description

[0031] Figure 1This is a schematic diagram of the polyurethane sponge shaping and cutting device of the present invention.

[0032] In the attached diagram:

[0033] 1-Operating table frame, 2-Operating platform, 3-Y-axis guide rail, 4-X-axis guide rail, 5-Shaping cutting head, 6-Support frame. Detailed Implementation

[0034] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. The specific implementation of the invention will be described in detail below with reference to specific embodiments.

[0035] In one embodiment of the present invention, such as Figure 1 A polyurethane foam shaping and cutting device includes an operating table for placing polyurethane foam and a shaping and cutting head 5 for shaping and cutting polyurethane foam. The operating table includes an operating table frame 1 and an operating table plate 2 mounted on the top of the operating table frame 1.

[0036] The components of the control panel, excluding the control panel frame 1 and the control panel plate 2, are existing technologies. Their detailed structures can be found in existing literature and journals, and they can also be purchased directly from the market or assembled from parts purchased from the market. They are not the components to be protected by this invention, and will not be described in detail here, nor are they shown in the accompanying drawings.

[0037] The shaping cutting head 5 is slidably mounted on the X-axis guide rail 4, the X-axis guide rail 4 is slidably mounted on the Y-axis guide rail 3, the Y-axis guide rail 3 is mounted on the support frame 6, and a Z-axis guide rail is mounted between the shaping cutting head 5 and the X-axis guide rail 4.

[0038] Therefore, the Z-axis guide rail is used to drive the shaping and cutting head 5 to move in the Z-axis direction, the X-axis guide rail 4 is used to drive the shaping and cutting head 5 to move in the X-axis direction, and the Y-axis guide rail 3 is used to drive the shaping and cutting head 5 to move in the Y-axis direction. This combination of the X-axis guide rail 4, the Y-axis guide rail 3, and the Z-axis guide rail enables precise control of the shaping and cutting head 5 to shape and cut polyurethane foam.

[0039] The alignment cutting head 5 is existing technology. Its detailed structure can be found in existing literature and journals, and it can also be purchased directly on the market, or its components can be purchased on the market and assembled, etc. It is not the subject of this invention, and will not be described in detail here, nor is it shown in the accompanying drawings.

[0040] The device also includes a cutting drive system, which comprises a control module and a cutting path planning module. The cutting path planning module is used to plan the cutting path according to the polyurethane foam to be shaped and cut. The control module is used to precisely control the X-axis guide rail 4, Y-axis guide rail 3, and Z-axis guide rail to drive the shaping and cutting head 5 to shape and cut the polyurethane foam. The X-axis guide rail 4, Y-axis guide rail 3, Z-axis guide rail, control module, and cutting path planning module are connected by electrical signals.

[0041] Therefore, after the polyurethane foam is positioned on the operating table, the cutting drive system is activated according to the actual needs of the shaping and cutting. The cutting drive system uses the cutting path planning module to plan the cutting path according to the polyurethane foam to be shaped and cut. After the cutting path is determined, the cutting drive system uses the control module to precisely control the X-axis guide rail 4, Y-axis guide rail 3, and Z-axis guide rail to accurately drive the shaping and cutting head 5 to shape and cut the polyurethane foam. This is beneficial for accurate control of the cutting path in irregular contour cutting. It can flexibly handle the shaping and cutting of polyurethane foam of various sizes and specifications, with high adaptability. It does not require frequent switching of cutting molds, reducing production costs. Cutting efficiency and cutting quality are greatly improved.

[0042] In another embodiment of the present invention, the X-axis guide rail 4, the Y-axis guide rail 3 and the Z-axis guide rail adopt the same structure, and an electric push rod is installed inside the X-axis guide rail 4. The electric push rod is electrically connected to the module and the cutting route planning module.

[0043] In another embodiment of the present invention, the polyurethane foam shaping and cutting device further includes a cutting drive system, the cutting drive system comprising:

[0044] The multi-source data acquisition unit is used to acquire the material property parameters and irregular contour data of the polyurethane foam to be cut in real time; the material property parameters include at least density, thickness and elastic modulus; the irregular contour data can be manually input or automatically acquired by a 3D scanning device.

[0045] A three-dimensional digital modeling unit is electrically connected to the multi-source data acquisition unit and is used to generate a three-dimensional point cloud model of the sponge to be cut based on the acquired irregular contour data.

[0046] The intelligent path planning module is electrically connected to the multi-source data acquisition unit and the three-dimensional digital modeling unit. It has a built-in deformation prediction model and adaptive path optimization algorithm. The deformation prediction model is based on material property parameters and combined with the mechanical constitutive relationship of polyurethane foam to predict the distribution and magnitude of deformation caused by material compression during the cutting process, and generates feedforward compensation. The adaptive path optimization algorithm dynamically generates the optimal cutting trajectory including the pre-compensated path based on the three-dimensional point cloud model and the feedforward compensation.

[0047] The high-precision motion control module is electrically connected to the intelligent path planning module and to the servo drive components inside the X-axis guide rail 4, Y-axis guide rail 3, and Z-axis guide rail. It is used to convert the optimal cutting trajectory into precise motion control commands to drive the shaping cutting head to move along the preset trajectory.

[0048] The real-time closed-loop feedback unit includes a high-resolution position sensor and an attitude sensor installed on the alignment cutting head, which are used to monitor the actual spatial coordinates and cutting angle of the cutting head in real time and feed the monitoring data back to the high-precision motion control module in real time.

[0049] The dynamic compensation and correction unit, built into the high-precision motion control module, is used to dynamically adjust the motion parameters of the servo drive element, including feed speed, acceleration, cutting depth and cutting angle, based on the deviation between real-time feedback data and preset trajectory, combined with material characteristic parameters and geometric features of the current cutting position, so as to realize real-time suppression and correction of the flexible deformation of polyurethane foam.

[0050] The self-learning optimization engine is electrically connected to the intelligent path planning module and the dynamic compensation and correction unit, respectively. It is used to collect material parameters, cutting trajectory, real-time deviation and final cutting quality data in each cutting process. Through machine learning algorithms, it continuously optimizes the deformation prediction model and dynamic compensation strategy to form a continuously evolving cutting knowledge base.

[0051] Furthermore, the deformation prediction model is constructed based on the principle of finite element analysis, treating polyurethane foam as a hyperelastic material. The model parameters are automatically adjusted according to the density, thickness and elastic modulus obtained in real time, so as to realize high-precision simulation and compensation calculation of deformation before cutting.

[0052] The adaptive path optimization algorithm adopts a segmented optimization strategy: for straight areas in the 3D point cloud model, a fast cutting mode with maximum feed speed is used; for complex curves, sharp angles, and other irregular areas, the feed speed is automatically reduced and the density of path interpolation points is increased. At the same time, a smooth transition trajectory is generated by combining feedforward compensation to avoid cutting quality defects caused by sudden changes in the path.

[0053] The dynamic compensation and correction unit has a built-in curvature adaptive adjustment module, which can automatically adjust the compensation intensity according to the curvature radius of the current position of the cutting head. When the curvature radius is less than the preset threshold, the feed speed is automatically reduced to 40%-60% of the reference value, and the position loop gain is increased by 20%-40% to enhance the tracking accuracy of complex contours.

[0054] The dynamic compensation and correction unit further includes a density adaptive compensation module, which is used to automatically match the compensation strategy according to the sponge density: for sponges with a density higher than the first threshold, a compensation method of increasing the path redundancy is adopted, and the redundancy is dynamically adjusted within the range of 5%-15% according to the density value; for sponges with a density lower than the second threshold, a compensation method of reducing the feed speed is adopted, and the speed reduction ratio is dynamically adjusted within the range of 10%-25%.

[0055] The intelligent path planning module also has a built-in multi-specification cutting route library to store the generated optimal cutting trajectory and its corresponding sponge specification parameters. When a cutting task with the same specifications as the historical ones is received, the existing trajectory is directly called from the route library and then finely adjusted according to the measured material parameters of the current batch of sponges before use, enabling rapid production changeover without frequent changes to the cutting mold.

[0056] The real-time closed-loop feedback unit also includes a dynamic pressure sensor installed at the root of the alignment cutting head 5, which is used to collect the contact pressure between the alignment cutting head 5 and the polyurethane foam during the cutting process in real time; the dynamic compensation and correction unit, based on the pressure feedback value and combined with the position deviation data, uses a multi-source information fusion algorithm to more accurately determine the material deformation state and dynamically adjust the cutting depth and feed speed to prevent over-cutting or under-cutting.

[0057] The self-learning optimization engine employs a deep reinforcement learning algorithm, using cutting quality evaluation indicators including edge smoothness, dimensional accuracy, and cutting efficiency as the reward function, material parameters, cutting trajectory, and motion parameters as the state space, and path compensation amount and control parameter adjustment amount as the action space. Through continuous iterative optimization, the deformation prediction model and dynamic compensation strategy gradually approach the optimal solution.

[0058] The servo drive components inside the X-axis guide rail 4, Y-axis guide rail 3, and Z-axis guide rail are high-precision servo electric cylinders with built-in absolute encoders, which can achieve micron-level positioning accuracy. The high-precision motion control module communicates with the driver of the servo electric cylinder through a high-speed fieldbus to ensure the real-time and synchronous nature of control commands.

[0059] The components of the X-axis guide rail 4, Y-axis guide rail 3, and Z-axis guide rail, excluding the servo drive components, are existing technologies. Their detailed structures can be found in existing literature and journals, and they can also be purchased directly from the market or assembled from commercially available parts. They are not the subject of this invention and will not be described in detail here, nor are they shown in the accompanying drawings.

[0060] Existing technologies either rely on the rigid trajectory control of CNC cutting machines or on special molds, neither of which fully considers the fundamental impact of the flexible material characteristics of polyurethane foam on cutting accuracy. This invention proposes for the first time a technical route of "material perception-deformation prediction-dual compensation-self-learning evolution", which introduces intrinsic parameters such as the density and elastic modulus of the foam as active control variables into the entire cutting process, realizing a technological leap from trajectory control to material adaptive control.

[0061] Pre-compensation before cutting is achieved through a deformation prediction model to solve the poor system performance caused by material compression; real-time correction during cutting is achieved through real-time closed-loop feedback and dynamic correction unit to solve random disturbances and residual deformation; the two work together to ensure that the path control accuracy of irregular contour cutting reaches within ±0.1mm.

[0062] By integrating multi-dimensional information such as material parameters, three-dimensional contours, real-time position, and contact pressure, the cutting drive system can perceive the cutting status more comprehensively and make more accurate decisions.

[0063] By introducing deep reinforcement learning algorithms, the system can accumulate experience from each cut, continuously optimize the deformation prediction model and compensation strategy, and has the ability to continuously improve the cutting quality as the usage time increases, which is something that existing technologies cannot achieve.

[0064] Through dual compensation and curvature adaptive adjustment, the deviation between the actual tool trajectory and the theoretical trajectory is controlled within a very small range in the cutting of complex irregular contours, resulting in smooth, burr-free edges and dimensional accuracy that meets the requirements of high-end applications. The multi-specification cutting route library combined with intelligent path planning can quickly respond to the cutting needs of sponges of any size and shape, reducing changeover time from several hours to several minutes and significantly reducing production costs. While ensuring accuracy, the segmented optimization strategy enables high-speed cutting in straight areas and precise cutting in irregular areas, improving overall cutting efficiency compared to traditional CNC cutting and increasing the cutting qualification rate.

[0065] In another embodiment of the present invention, a method of using the polyurethane sponge shaping and cutting device described above is provided, comprising the following steps: after the polyurethane sponge is positioned on the operating table, the cutting drive system plans the cutting route according to the polyurethane sponge to be shaped and cut, and precisely controls the X-axis guide rail 4, Y-axis guide rail 3 and Z-axis guide rail to drive the shaping and cutting head 5 to shape and cut the polyurethane sponge.

[0066] In the description of this invention, unless otherwise stated, "a plurality of" means two or more. Although embodiments of the invention have been shown and described in the description of this invention, it will be understood by those skilled in the art that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A polyurethane foam shaping and cutting device, comprising an operating table for placing polyurethane foam and a shaping and cutting head for shaping and cutting polyurethane foam, wherein the operating table includes an operating table frame and an operating table plate mounted on the top of the operating table frame; the shaping and cutting head is slidably mounted on an X-axis guide rail, the X-axis guide rail is slidably mounted on a Y-axis guide rail, the Y-axis guide rail is mounted on a support frame, and a Z-axis guide rail is mounted between the shaping and cutting head and the X-axis guide rail; characterized in that... The device also includes a cutting drive system, which includes a control module and a cutting path planning module. The cutting path planning module is used to plan the cutting path according to the polyurethane foam to be shaped and cut. The control module is used to precisely control the X-axis guide rail, Y-axis guide rail and Z-axis guide rail to drive the shaping and cutting head to shape and cut the polyurethane foam. The X-axis guide rail, Y-axis guide rail, Z-axis guide rail, control module and cutting path planning module are electrically connected.

2. The polyurethane sponge truing and cutting apparatus of claim 1, wherein, It also includes a cutting drive system, which comprises: The multi-source data acquisition unit is used to acquire the material property parameters and irregular contour data of the polyurethane foam to be cut in real time; the material property parameters include at least density, thickness and elastic modulus; the irregular contour data can be manually input or automatically acquired by a 3D scanning device. A three-dimensional digital modeling unit is electrically connected to the multi-source data acquisition unit and is used to generate a three-dimensional point cloud model of the sponge to be cut based on the acquired irregular contour data. The intelligent path planning module is electrically connected to the multi-source data acquisition unit and the three-dimensional digital modeling unit. It has a built-in deformation prediction model and adaptive path optimization algorithm. The deformation prediction model is based on material property parameters and combined with the mechanical constitutive relationship of polyurethane foam to predict the distribution and magnitude of deformation caused by material compression during the cutting process, and generates feedforward compensation. The adaptive path optimization algorithm dynamically generates the optimal cutting trajectory including the pre-compensated path based on the three-dimensional point cloud model and the feedforward compensation. The high-precision motion control module is electrically connected to the intelligent path planning module and to the servo drive components inside the X-axis guide rail, Y-axis guide rail, and Z-axis guide rail. It is used to convert the optimal cutting trajectory into precise motion control commands to drive the shaping cutting head to move along the preset trajectory. The real-time closed-loop feedback unit includes a high-resolution position sensor and an attitude sensor installed on the alignment cutting head, which are used to monitor the actual spatial coordinates and cutting angle of the cutting head in real time and feed the monitoring data back to the high-precision motion control module in real time. The dynamic compensation and correction unit, built into the high-precision motion control module, is used to dynamically adjust the motion parameters of the servo drive element, including feed speed, acceleration, cutting depth and cutting angle, based on the deviation between real-time feedback data and preset trajectory, combined with material characteristic parameters and geometric features of the current cutting position, so as to realize real-time suppression and correction of the flexible deformation of polyurethane foam. The self-learning optimization engine is electrically connected to the intelligent path planning module and the dynamic compensation and correction unit, respectively. It is used to collect material parameters, cutting trajectory, real-time deviation and final cutting quality data in each cutting process. Through machine learning algorithms, it continuously optimizes the deformation prediction model and dynamic compensation strategy to form a continuously evolving cutting knowledge base.

3. The polyurethane sponge shaping and cutting device according to claim 2, characterized in that, The deformation prediction model is constructed based on the principle of finite element analysis. It treats polyurethane foam as a hyperelastic material and automatically adjusts the model parameters according to the density, thickness and elastic modulus obtained in real time, so as to realize high-precision simulation and compensation calculation of deformation before cutting.

4. The polyurethane sponge shaping and cutting device according to claim 2, characterized in that, The adaptive path optimization algorithm adopts a segmented optimization strategy: for straight areas in the 3D point cloud model, a fast cutting mode with maximum feed speed is used; for complex curves, sharp angles, and other irregular areas, the feed speed is automatically reduced and the density of path interpolation points is increased. At the same time, a smooth transition trajectory is generated by combining feedforward compensation to avoid cutting quality defects caused by sudden changes in the path.

5. The polyurethane sponge shaping and cutting device according to claim 2, characterized in that, The dynamic compensation and correction unit has a built-in curvature adaptive adjustment module, which can automatically adjust the compensation intensity according to the curvature radius of the current position of the cutting head. When the curvature radius is less than the preset threshold, the feed speed is automatically reduced to 40%-60% of the reference value, and the position loop gain is increased by 20%-40% to enhance the tracking accuracy of complex contours.

6. The polyurethane sponge shaping and cutting device according to claim 2, characterized in that, The intelligent path planning module also has a built-in multi-specification cutting route library to store the generated optimal cutting trajectory and its corresponding sponge specification parameters. When a cutting task with the same specifications as the historical ones is received, the existing trajectory is directly called from the route library and then finely adjusted according to the measured material parameters of the current batch of sponges before use, enabling rapid production changeover without frequent changes to the cutting mold.

7. The polyurethane sponge shaping and cutting device according to claim 2, characterized in that, The real-time closed-loop feedback unit also includes a dynamic pressure sensor installed at the root of the alignment cutting head, used to collect the contact pressure between the alignment cutting head and the polyurethane foam during the cutting process in real time; the dynamic compensation and correction unit, based on the pressure feedback value and combined with the position deviation data, uses a multi-source information fusion algorithm to more accurately determine the material deformation state and dynamically adjust the cutting depth and feed speed to prevent over-cutting or under-cutting.

8. The polyurethane sponge shaping and cutting device according to claim 2, characterized in that, The self-learning optimization engine employs a deep reinforcement learning algorithm, using cutting quality evaluation indicators including edge smoothness, dimensional accuracy, and cutting efficiency as the reward function, material parameters, cutting trajectory, and motion parameters as the state space, and path compensation amount and control parameter adjustment amount as the action space. Through continuous iterative optimization, the deformation prediction model and dynamic compensation strategy gradually approach the optimal solution.

9. The polyurethane sponge shaping and cutting device according to claim 2, characterized in that, The servo drive components inside the X-axis, Y-axis, and Z-axis guide rails are high-precision servo electric cylinders with built-in absolute encoders, enabling micron-level positioning accuracy. The high-precision motion control module communicates with the servo electric cylinder driver via a high-speed fieldbus to ensure the real-time and synchronous nature of control commands.

10. A method of using the polyurethane foam shaping and cutting device according to any one of claims 1-9, characterized in that, Includes the following steps: After the polyurethane foam is positioned on the operating table, the cutting drive system plans the cutting route according to the polyurethane foam to be shaped and cut, and precisely controls the X-axis guide rail, Y-axis guide rail and Z-axis guide rail to drive the shaping and cutting head to shape and cut the polyurethane foam.

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