Multi-station collaborative part total-sequence machining method and integrated type combined machining center

Abstract

The invention relates to a multi-station collaborative part total-sequence machining method and an integrated combined machining center. The method comprises the steps that a three-dimensional digital twinning body including static layout and dynamic time sequence is constructed based on a unified coordinate system; carrying out global optimization by taking minimization of the maximum completion time as a target and taking spatial interference-free as a constraint, and generating an initial operation sequence and a pose; workpiece characteristics and pose deviation are detected in real time in the machining process, and working condition data are synchronously collected; triggering process compensation and interference early warning in parallel based on the deviation; the accurate compensation amount is calculated through the dynamic compensation model fusing the multi-source data, and an instruction is broadcasted to a subsequent station; and the target station executes compensation, the layout management module performs interference check, and a result is fed back to the central control system to iteratively update the model and rescheduling unexecuted jobs. The machining center comprises a casting base and a vertical turning unit, a vertical machining unit and a horizontal machining unit which are integrated on the casting base. Dynamic optimization and interference prevention of the whole machining process are achieved, and precision, efficiency and safety are improved.

Description

Technical Field

[0001] This application relates to the field of mechanical equipment technology, and in particular to a multi-station collaborative full-sequence machining method for parts and an integrated composite machining center. Background Technology

[0002] In modern manufacturing, composite machining technology has received widespread attention and application to improve production efficiency and processing accuracy. However, traditional composite machining centers are limited by their structural design and functional integration, typically employing a single spindle or possessing only limited composite machining capabilities, making it difficult to meet the overall demand for multi-process, multi-angle, and high-efficiency machining of complex workpieces. Especially when dealing with large or irregularly shaped workpieces, it is often necessary to integrate multiple processes such as turning, milling, and drilling within the same machining flow, and to operate from different directions. For example, complex multi-faceted parts such as pump and valve bodies often have multiple ports, cavities, and flow channels in different directions, requiring high-precision hole machining, planar milling, thread turning, and sealing surface finishing on multiple spatial surfaces.

[0003] Currently, traditional equipment for machining pump and valve bodies generally follows a production model of multiple clamping, multi-machine collaboration, or frequent transfer between processes. However, due to the irregular shape and large casting tolerances of pump and valve body blanks, it is difficult to achieve high-precision initial positioning during clamping. This leads to deviations between the tool path and the actual workpiece surface during subsequent machining, directly affecting machining accuracy and surface quality. Furthermore, machining errors caused by tool wear, machine tool thermal deformation, and cutting force fluctuations are difficult to monitor and compensate for in real time. Existing technologies largely rely on post-processing inspection and manual correction, failing to achieve dynamic error closed-loop control during machining, thus limiting product yield.

[0004] Furthermore, the lack of online detection and adaptive adjustment capabilities for the real-time position and orientation of workpieces makes it difficult to achieve highly flexible and fully automated continuous processing. This not only significantly increases production cycle and cost, but also introduces cumulative errors due to repeated positioning, which seriously affects the final processing accuracy. Moreover, each process is usually executed serially, making it impossible to achieve true parallel processing, which restricts further improvement in overall efficiency.

[0005] Therefore, we propose a multi-station collaborative full-sequence machining method for parts and an integrated composite machining center. Summary of the Invention

[0006] The main purpose of this application is to solve the problems of insufficient global collaborative optimization capability, lag in precision control and interference avoidance, insufficient data utilization, and insufficient equipment integration in the existing technology of multi-station collaborative machining, and to provide a multi-station collaborative full-sequence machining method for parts and an integrated composite machining center.

[0007] To achieve the above objectives, this application provides a multi-station collaborative full-sequence machining method for parts, comprising the following steps;

[0008] S10. Based on a unified global valve body coordinate system, construct a three-dimensional manufacturing scene digital twin that includes at least the workpiece, all processing stations and mold components, and the digital twin includes static layout and dynamic process sequence information.

[0009] S20. Set the minimum system maximum completion time as the global optimization goal, and take the minimum safe distance and no spatial interference of all mold components in all process sequences as the hard constraint to generate the initial collaborative operation sequence, process parameters and spatial pose set of each component;

[0010] S30. During the process execution, the real-time machining feature values ​​and actual spatial pose of the workpiece are obtained at the preset detection nodes, and multi-factor working condition data in the machining domain are collected simultaneously.

[0011] S40. Based on the real-time processing feature values ​​and the deviation between the actual spatial pose and the theoretical values, process compensation determination and spatial interference warning are triggered in parallel.

[0012] S50. After triggering process compensation, the precise compensation amount is calculated based on the dynamic compensation model that integrates machining feature deviation, spatial pose deviation and working condition data; the compensation amount and the verified spatial pose data are encapsulated into an adjustment instruction and broadcast to the subsequent target machining station and layout management module.

[0013] The target processing station performs local compensation adjustments according to the instructions, while the layout management module performs spatial interference checks based on the updated pose data; and feeds the execution and check results back to the central control system to iteratively update the model parameters and perform local rescheduling optimization on the unexecuted work sequences.

[0014] S60. Repeatedly execute the steps from online detection to iterative optimization until all processing steps are completed.

[0015] Preferably, in step S20, the minimum safety distance is set to a fixed value for rigid components, while for components including elastic and / or thermally deformable components, the value is obtained through finite element simulation pre-calculation based on the material properties and operating condition data in the digital twin.

[0016] Preferably, in step S50, when the layout management module performs spatial interference checks, it decomposes the continuous motion of the components into a set of discrete static state views based on time-equal interval sampling for interference analysis.

[0017] Preferably, in step S50, the dynamic compensation model is expressed as:

[0018] ;

[0019] in, For compensation amount, For processing feature deviation, This is the pose deviation vector. For sensitivity factor, As an environmental coupling factor, These are model constants; the environmental coupling factor It is calculated from operating condition data of temperature, vibration and spindle power.

[0020] Preferably, the environmental coupling factor The expression is:

[0021] ;

[0022] in, For real-time operating condition data, For calibration values, The weighting coefficients are initially derived from the regression analysis results of historical processed data and are dynamically updated via a recursive algorithm during online operation.

[0023] Preferably, it also includes a manufacturing resource digital twin library, which is used to associate and store theoretical values, measured values, deviation data, operating condition data, compensation amounts, and interference check results of the processing process;

[0024] Before calculating the compensation amount, the central control system queries historical processing data of the same type in the database to calibrate the dynamic compensation model.

[0025] Preferably, when a spatial interference warning is triggered or spatial interference is detected, the central control system invokes the real-time rescheduling engine to adjust the component pose or insert micro-waiting time as intervention means to re-optimize and reschedule the remaining processes in a spatiotemporal manner.

[0026] Preferably, the acquisition of the multi-condition data specifically involves:

[0027] Data is acquired through an integrated measurement unit, where dimensional features are obtained through a contact probe, surface topography and 3D point cloud are obtained through a machine vision sensor, and spatial pose is calculated by matching a reference sphere with the machine tool probe. The measurement data are then validated using a multivariate statistical process control method based on Mahalanobis distance.

[0028] To achieve the above objectives, this application provides an integrated composite machining center, including a casting base on which a vertical turning unit, a horizontal machining unit, and a vertical machining unit are integrated and mounted.

[0029] The vertical turning unit includes a spindle chuck located at the center of the casting base, and the spindle chuck is connected to a servo motor with C-axis indexing function;

[0030] The vertical machining unit includes a support rod that is vertically fixed to the side of the casting base. The support rod is provided with a Z-axis slide that slides in the vertical direction. A vertical machining spindle and a chip turning tool holder are mounted side by side on the Z-axis slide.

[0031] The horizontal machining unit includes a Y-axis slide that spans the casting base and moves vertically along the side of the support rod. An X-axis slide that slides horizontally is provided on the Y-axis slide, and a horizontal machining spindle is mounted on the X-axis slide.

[0032] Preferably, both the vertical machining spindle and the horizontal machining spindle are BT interface spindles, and the vertical machining unit and the horizontal machining unit are each equipped with an independent disc-type tool magazine; the casting base is provided with a circulating cooling channel, and the circulating cooling channel is connected to a thermal balance control system.

[0033] The beneficial effects of the technical solution of this invention are as follows:

[0034] By constructing a digital twin, combining static layout with dynamic timing information, and using the minimization of the system's maximum completion time as the global optimization objective, combined with spatial interference-free hard constraints, global optimization of the initial job sequence, process parameters, and pose is achieved. More importantly, during processing, deviations can be detected in real time, process compensation and spatial interference warnings can be triggered in parallel, and precise compensation amounts can be calculated based on the dynamic compensation model to adjust subsequent workstations and locally reschedule unexecuted job sequences. This enables real-time dynamic optimization and adjustment of the processing process, significantly improving processing efficiency and accuracy, and reducing the scrap rate.

[0035] By using digital twins, all mold components are spatially free from interference constraints throughout the entire process sequence. During process execution, the layout management module performs spatial interference checks based on the updated pose data. Furthermore, when a spatial interference warning is triggered, the real-time rescheduling engine can be invoked to intervene. This effectively avoids potential interference risks in multi-station collaborative processing, ensures equipment and personnel safety, and reduces downtime.

[0036] A dynamic compensation model was introduced, which integrates machining feature deviations, spatial pose deviations, and multi-factor operating data to calculate more accurate compensation amounts. Simultaneously, by iteratively executing online detection and optimization steps and updating model parameters, the system acquires self-learning and adaptive capabilities, significantly improving machining accuracy and the system's intelligence level. The construction of a digital twin library of manufacturing resources further supports the accumulation of historical data and model calibration, enhancing the system's robustness.

[0037] By integrating vertical turning, vertical machining, and horizontal machining units onto a single cast base, this machining center achieves a compact integration of multiple machining modes. The C-axis indexing function of the spindle chuck, the parallel mounting of the vertical machining spindle and the chip holder, and the configuration of the horizontal machining spindle enable this machining center to perform full-sequence, multi-faceted, and multi-process composite machining of complex parts. This significantly improves equipment utilization and machining flexibility, reduces changeover time, and lowers the floor space required.

[0038] High-precision transmission components such as roller linear guides and ball screw drives are employed to ensure the accuracy and stability of each axis's movement. The combination of a circulating cooling channel and a thermal balance control system effectively controls the equipment's thermal deformation, further guaranteeing machining accuracy. Attached Figure Description

[0039] Figure 1 This is a schematic diagram of the structure of a multi-station collaborative vertical and horizontal integrated composite machining center in one embodiment of this application.

[0040] The realization of the purpose, functional features and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0041] The embodiments of this application are described in detail below. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0042] Furthermore, descriptions using terms such as "first" and "second" in this application are for descriptive purposes only (e.g., to distinguish identical or similar elements) and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "first" or "second" may explicitly or implicitly include at least one feature. Additionally, technical solutions from different embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If a combination of technical solutions is contradictory or impossible to implement, such a combination should be considered nonexistent and not within the scope of protection claimed in this application.

[0043] like Figure 1 As shown, the present invention provides a multi-station collaborative full-sequence machining method for parts, characterized by comprising the following steps:

[0044] S10. Based on a unified global valve body coordinate system, construct a 3D digital twin of the manufacturing scene, which includes at least the workpiece, all machining stations, and mold components. The digital twin includes static layout and dynamic process sequence information. Specifically, in this step, a unified global coordinate system is first established, for example, using a fixed point in the machining center as the origin, defining the X, Y, and Z axes. Under this coordinate system, the entire manufacturing scene is digitally modeled to construct a high-fidelity digital twin. This digital twin includes not only the geometric information of physical entities (such as the 3D model of the workpiece, the geometric models of each machining station (such as turning, milling, drilling units, etc.), and the 3D models of mold components such as tools, fixtures, and robots), but also the physical properties of these entities (such as material properties, mass, and inertia).

[0045] Furthermore, the digital twin also integrates static layout information and dynamic process sequence information.

[0046] Static layout information refers to the initial fixed position and posture of each machining station and mold component in the global coordinate system. Dynamic process timing information refers to the execution sequence and time nodes of each process during the entire part machining process, as well as the motion trajectory and spatial pose changes of each mold component (such as cutting tools, fixtures, robot end effectors, etc.) at different process stages. Through digital twins, every detail of the machining process in the physical world can be reflected in real time, providing accurate digital mapping for subsequent optimization, control, and early warning.

[0047] S20. After constructing the digital twin, use optimization algorithms (such as genetic algorithms, particle swarm optimization, reinforcement learning, etc.) to perform global planning on the entire processing process, and set minimizing the maximum completion time of the system as the global optimization objective;

[0048] Among them, minimizing the maximum system completion time is the global optimization objective, which is the shortest time required from the start of the first process to the completion of the last process.

[0049] Meanwhile, to ensure the safety and reliability of the machining process, the requirement that "all mold components must meet the minimum safe distance for spatial non-interference throughout the entire process sequence" is set as a hard constraint. This means that at any given time, the distance between any two mold components (including workpieces, cutting tools, fixtures, machine tool parts, etc.) must be greater than or equal to the preset minimum safe distance.

[0050] In a preferred embodiment, the minimum safety distance is set to a fixed value, such as 5 mm or 10 mm, for rigid components (e.g., machine tool bed, fixture body). For components involving elasticity and / or thermal deformation (e.g., slender cutting tools, thin-walled workpieces, machine tool spindles subject to thermal expansion), the value is obtained through finite element simulation pre-calculation based on material properties and operating condition data in the digital twin. For example, for a cutting tool operating at high temperatures, its thermal expansion can be obtained through finite element analysis, thereby dynamically adjusting its minimum safety distance to avoid interference during actual machining.

[0051] In summary, this global optimization can generate an initial set of collaborative operation sequences (i.e., the execution order of each process at different workstations), process parameters (such as cutting speed, feed rate, depth of cut, etc.), and the spatial pose set of each component throughout the machining process. These initial schemes are the optimal solutions obtained based on theoretical models and preset conditions.

[0052] S30. In actual processing, for real-time monitoring and adjustment, data collection is required at key preset detection nodes (e.g., after each key process is completed, or at regular processing intervals). Real-time processing characteristic values ​​include, but are not limited to, workpiece dimensions, morphology, and surface roughness. Actual spatial pose refers to the actual position and orientation of the workpiece at the processing station.

[0053] Simultaneously, multi-factor operating data within the machining domain are collected. This data reflects the machining environment and equipment operating status, such as: machine tool spindle temperature, ambient temperature, coolant temperature, etc.; vibration acceleration and frequency of each axis of the machine tool, etc.; spindle power, feed axis power, etc.; as well as coolant flow rate, pressure, and tool wear status, etc.

[0054] In a preferred embodiment, the acquisition of the multi-factor operating data specifically involves: acquiring data through an integrated measurement unit, wherein dimensional features are obtained through a contact probe, surface topography and 3D point cloud are obtained through a machine vision sensor, and spatial pose is calculated by matching a reference sphere with the machine tool probe. For example, a laser scanner can be used to acquire the 3D point cloud data of the workpiece, and by comparing it with a CAD model, dimensional and topographic deviations can be quickly obtained. The contact probe can provide high-precision measurement of critical dimensions. The reference sphere, in conjunction with the machine tool probe, can accurately calibrate the actual pose of the workpiece in the machine tool coordinate system.

[0055] To ensure the reliability of the measurement data, a multivariate statistical process control method based on Mahalanobis distance was used for confidence verification. Mahalanobis distance can comprehensively consider the correlation between multiple variables, effectively identify outlier data points, and thus improve data quality.

[0056] S40. Compare the real-time data obtained in step S30 with the theoretical values ​​in the digital twin, and calculate the deviation.

[0057] Specifically, when the deviation between real-time processing feature values ​​(such as dimensions and morphology) and theoretical values ​​exceeds a preset threshold, a process compensation decision is triggered. This indicates that the current process parameters may need to be adjusted to ensure processing accuracy.

[0058] When the deviation between the actual spatial pose and the theoretical pose is analyzed in real time using a digital twin, combined with the geometric models of each component and the minimum safe distance, a spatial interference warning is triggered if interference is predicted to occur in subsequent movements, or if the current pose deviation has caused the component spacing to fall below the preset safe distance. Process compensation determination and spatial interference warning are triggered in parallel and can be performed simultaneously without affecting each other.

[0059] S50. After triggering process compensation, the precise compensation amount is calculated based on the dynamic compensation model that integrates machining feature deviation, spatial pose deviation and working condition data; the compensation amount and the verified spatial pose data are encapsulated into an adjustment instruction and broadcast to the subsequent target machining station and layout management module.

[0060] S60. Repeatedly execute the steps from online detection to iterative optimization until all processing steps are completed.

[0061] In a preferred embodiment, the dynamic compensation model is expressed as:

[0062] ;

[0063] in, For compensation amount, For processing feature deviation, This is the pose deviation vector. For sensitivity factor, As an environmental coupling factor, These are model constants; the environmental coupling factor It is calculated from operating condition data of temperature, vibration and spindle power.

[0064] Furthermore, the dynamic compensation model adopts a multi-input, single-output nonlinear model, which can comprehensively consider the influence of multiple factors on machining accuracy. Machining feature deviation. The pose deviation vector directly reflects the degree of deviation of the processing result. It reflects the deviation of the workpiece or tool position and orientation, while the environmental coupling factor E introduces multi-factor operating data (such as temperature, vibration, and spindle power) in the machining domain into the model to reflect the impact of environmental changes on the machining process.

[0065] In a more preferred embodiment, the environmental coupling factor The expression is:

[0066] ;

[0067] in, For real-time operating condition data, For calibration values, These are the weighting coefficients.

[0068] The initial values ​​of the weighting coefficients are derived from regression analysis results of historical machining data and are dynamically updated during online operation using recursive algorithms (such as recursive least squares). This indicates that the model can continuously learn and optimize based on actual machining conditions, improving the accuracy of compensation. The calculated precise compensation amounts (e.g., fine-tuning of toolpaths, fine-tuning of spindle speeds, etc.) and the updated spatial pose data, after verification (e.g., re-verification of no interference using a digital twin), are encapsulated into adjustment instructions. These instructions are broadcast over the network to subsequent target machining stations (i.e., machining units containing processes that have not yet been executed) and the layout management module.

[0069] The target machining station performs local compensation adjustments according to instructions, such as adjusting the toolpath, correcting the feed rate or spindle speed, to correct machining feature deviations. Simultaneously, the layout management module performs spatial interference checks based on the updated pose data.

[0070] In a preferred embodiment, when performing spatial interference checks, the layout management module decomposes the continuous motion of components into a set of discrete static state views based on time-equal sampling for interference analysis. For example, a 1-second continuous motion is decomposed into 100 static snapshots with 0.01-second intervals, and interference detection is performed on each snapshot to more accurately capture potential interference.

[0071] The execution and inspection results are then fed back to the central control system. Based on this feedback, the central control system iteratively updates the model parameters (e.g., sensitivity factors, environmental coupling factors, model constants, and weighting coefficients in the environmental coupling factor of the dynamic compensation model) and performs local rescheduling optimization on unexecuted job sequences. Local rescheduling optimization refers to fine-tuning the execution order and resource allocation of remaining processes based on the current situation and adjustment instructions, without changing the overall optimization objective, to adapt to the new processing state.

[0072] like Figure 1 As shown, the present invention provides an integrated composite machining center, including a casting base 100 cast from high-quality cast iron material, and a vertical turning unit 300, a horizontal machining unit 400 and a vertical machining unit 200 integratedly mounted on the casting base 100.

[0073] The vertical turning unit 300 is used for turning rotary parts. It includes a spindle chuck 301 located at the center of the casting base 100. The spindle chuck 301 is a workpiece clamping and rotating component, capable of stably clamping workpieces of various shapes.

[0074] To achieve high-precision turning and indexing functions, the spindle chuck 301 is connected to a servo motor 302 with C-axis indexing capability. The servo motor 302 drives the spindle chuck 301 to perform continuous rotary cutting motion or precise angular indexing motion via a high-precision transmission mechanism (such as a synchronous belt pulley mechanism 303 or a gear transmission mechanism). The C-axis indexing function allows the workpiece to be positioned at any angle during turning, thereby enabling combined machining operations such as milling and drilling in conjunction with the vertical machining spindle 201, greatly expanding the functionality of the turning unit.

[0075] The vertical machining unit 200 is used for vertical milling, drilling, tapping, and other machining operations on workpieces, and can also be used with the spindle chuck 301 for turning. It includes a support rod 202 vertically fixed to the side of the casting base 100. The support rod 202 is also made of high-rigidity cast iron and is firmly connected to the casting base 100 through precision machining, ensuring the verticality and stability of the vertical machining unit 200. A Z-axis slide 203 that slides vertically is provided on the support rod 202. The Z-axis slide 203 is mounted on the front of the support rod 202 via a high-precision guide rail (e.g., a roller linear guide 11) and is driven by a ball screw transmission mechanism 500 to achieve precise feed motion in the Z1 axis direction (vertical direction). A vertical machining spindle 201 and a chip-turning tool holder 205 are mounted side-by-side on the Z-axis slide 203. The vertical machining spindle 201 is the core component for milling, drilling, and other machining operations. Its spindle interface (e.g., BT40 interface) can mount various cutting tools. The turning tool holder 205 is used to mount turning tools, and it can be used for turning operations when the spindle chuck 301 rotates. This parallel mounting method allows the vertical machining unit 200 to flexibly switch machining modes, improving the utilization rate of the equipment.

[0076] The horizontal machining unit 400 is used for horizontal milling, drilling, tapping, and other machining operations on the workpiece. It includes a Y-axis slide 401 that spans the casting base 100 and moves vertically along the support rod 202. The Y-axis slide 401 is mounted on the side of the support rod 202 via guide rails and is driven by a ball screw transmission mechanism 500 to achieve precise feed motion in the Y-axis direction (vertical direction). An X-axis slide 402 that slides horizontally is provided on the Y-axis slide 401.

[0077] Furthermore, the X-axis slide 402 is mounted on the Y-axis slide 401 via a high-precision guide rail and is driven by a ball screw transmission mechanism 500 to achieve precise feed motion in the X-axis direction (horizontal direction). A horizontal machining spindle 403 is mounted on the X-axis slide 402. The horizontal machining spindle 403 works in conjunction with the vertical machining spindle 201 to machine different sides of the workpiece, achieving multi-faceted machining and further improving machining flexibility.

[0078] Through the above structure, this embodiment achieves a high degree of integration of vertical turning, vertical machining, and horizontal machining. In actual machining, the workpiece is clamped on the spindle chuck 301 at a time, and the vertical machining spindle 201 and the horizontal machining spindle 403 can machine the workpiece separately or in concert according to machining requirements. For example, the vertical machining unit 200 can first perform top milling, and then the horizontal machining unit 400 can perform side drilling. At the same time, the spindle chuck 301 performs C-axis indexing, and the turning tool holder 205 is used for turning, thereby realizing multi-process, multi-angle, and multi-face machining of complex parts, significantly improving machining efficiency and accuracy.

[0079] In one embodiment, both the vertical machining spindle 201 and the horizontal machining spindle 403 are BT40 interface spindles.

[0080] The BT40 interface is an industry standard interface with good versatility and rigidity, and is compatible with mainstream cutting tools on the market, making it convenient for users to select and replace cutting tools.

[0081] Furthermore, the vertical machining unit 200 and the horizontal machining unit 400 are each equipped with an independent disc-type tool magazine. This independent tool magazine design allows the two machining units to automatically change tools independently without interference, further improving machining efficiency. While one unit is machining, the other unit can prepare the next tool in advance, reducing tool change waiting time.

[0082] In one embodiment, the Z-axis slide 203 is mounted on the front of the support rod 202 via roller linear guides 11. Compared to traditional sliding guides, the roller linear guides 11 have higher load-bearing capacity, rigidity, and motion accuracy, and a lower coefficient of friction, ensuring the smoothness and positioning accuracy of the Z-axis slide 203 in the vertical direction. The two ends of the Y-axis slide 401 are mounted to the sides of the support rod 202 via guide rail pairs. These guide rail pairs also employ high-precision roller linear guides to ensure the stability and rigidity of the Y-axis slide 401 in the vertical direction, effectively resisting cutting forces during machining.

[0083] In one embodiment, the spindle chuck 301 and the servo motor 302 are connected by a synchronous belt pulley mechanism 303 or a gear transmission mechanism.

[0084] Specifically, the synchronous belt pulley mechanism 303 has advantages such as smooth transmission, low noise, and no need for lubrication; while the gear transmission mechanism has advantages such as high transmission power, compact structure, and precise transmission ratio. Both transmission methods can ensure that the power of the servo motor 302 is efficiently and accurately transmitted to the spindle chuck 301. The servo motor 302 controls the spindle chuck 301 to perform continuous rotary cutting motion or precise angular indexing motion through the CNC system. The CNC system can precisely control the speed and angle of the servo motor 302 according to the machining program, thereby realizing high-precision turning and C-axis indexing functions to meet the machining requirements of complex parts.

[0085] In one embodiment, the X-axis slide 402, the Y-axis slide 401, and the Z-axis slide 203 are all connected to a ball screw transmission mechanism 500. The ball screw transmission mechanism 500 has advantages such as high transmission efficiency, low friction, high positioning accuracy, and small backlash, and is a commonly used transmission method in high-precision CNC machine tools.

[0086] The two ends of the ball screw transmission mechanism 500 are fixed to the corresponding support members by connecting bearings. The connecting bearings have extremely high rotational accuracy and rigidity, which can effectively eliminate the axial movement of the screw, ensure the positioning accuracy and repeatability of each axis movement, and thus guarantee the overall machining accuracy of the machining center.

[0087] In one embodiment, the casting base 100 has a circulating cooling channel inside. The circulating cooling channel is integrally formed during the casting of the casting base 100, or formed through precision machining.

[0088] The circulating cooling channels cover key areas inside the casting base 100 and are connected to a thermal balance control system via piping. This system uses circulating coolant to precisely control the temperature of the casting base 100, effectively removing heat generated during processing and compensating for the effects of ambient temperature changes, thereby minimizing thermal deformation of the equipment. This is crucial for long-term, high-precision machining, ensuring the machining center maintains stable machining accuracy under various operating conditions.

[0089] In the actual machining process, the workpiece is first firmly clamped on the spindle chuck 301. The CNC system coordinates the actions of each machining unit according to the preset machining program. For example, for a complex part that requires turning the outer diameter, milling the plane, and drilling:

[0090] Turning stage: Servo motor 302 drives spindle chuck 301 to rotate at high speed, and Z-axis slide 203 of vertical machining unit 200 drives turning tool holder 205 to move to a suitable position for external turning or end face turning.

[0091] Vertical Milling / Drilling Stage: After turning, the spindle chuck 301 precisely indexes the workpiece to a specified angle using the C-axis indexing function. The Z-axis slide 203 of the vertical machining unit 200 drives the vertical machining spindle 201 (which has been automatically loaded with milling cutters or drills via a disc-type tool magazine) to perform milling or drilling. During this process, the X-axis slide 402 and Y-axis slide 401 can remain stationary or be finely adjusted to assist in positioning.

[0092] Horizontal milling / drilling stage: If the workpiece side needs to be machined, the spindle chuck 301 performs C-axis indexing again, oriented the side to be machined toward the horizontal machining unit 400. The Y-axis slide 401 and X-axis slide 402 move together to move the horizontal machining spindle 403 (which has been automatically loaded with the appropriate tool via its independent disc-type tool magazine) to the machining position for side milling or drilling.

[0093] Throughout the process, the movement of each axis is ensured to have high precision and high rigidity by the ball screw transmission mechanism 500 and the connecting bearings. The circulating cooling channel and thermal balance control system inside the casting base 100 work continuously to ensure that the temperature of the equipment remains stable during long-term operation and to avoid the impact of thermal deformation on machining accuracy.

[0094] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover a non-exclusive inclusion, such that a process, apparatus, article, or multi-station collaborative full-sequence machining method that includes a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, apparatus, article, or multi-station collaborative full-sequence machining method. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, apparatus, article, or multi-station collaborative full-sequence machining method that includes that element.

[0095] The above description is only a preferred embodiment of this application and does not limit the patent scope of this application. Any equivalent structural or procedural changes made based on the content of this application's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this application.

Claims

1. A multi-station collaborative full-sequence machining method for parts, characterized in that, Includes the following steps; S10. Based on a unified global valve body coordinate system, construct a three-dimensional manufacturing scene digital twin that includes at least the workpiece, all processing stations and mold components, and the digital twin includes static layout and dynamic process sequence information. S20. Set the minimum system maximum completion time as the global optimization goal, and take the minimum safe distance and no spatial interference of all mold components in all process sequences as the hard constraint to generate the initial collaborative operation sequence, process parameters and spatial pose set of each component; S30. During the process execution, the real-time machining feature values ​​and actual spatial pose of the workpiece are obtained at the preset detection nodes, and multi-factor working condition data in the machining domain are collected simultaneously. S40. Based on the real-time processing feature values ​​and the deviation between the actual spatial pose and the theoretical values, process compensation determination and spatial interference warning are triggered in parallel. S50. After triggering process compensation, the precise compensation amount is calculated based on the dynamic compensation model that integrates machining feature deviation, spatial pose deviation and working condition data; the compensation amount and the verified spatial pose data are encapsulated into an adjustment instruction and broadcast to the subsequent target machining station and layout management module. The target processing station performs local compensation adjustments according to the instructions, while the layout management module performs spatial interference checks based on the updated pose data; and feeds the execution and check results back to the central control system to iteratively update the model parameters and perform local rescheduling optimization on the unexecuted work sequences. S60. Repeatedly execute the steps from online detection to iterative optimization until all processing steps are completed.

2. The multi-station collaborative full-sequence machining method for parts according to claim 1, characterized in that, In step S20, the minimum safety distance is set to a fixed value for rigid components, while for components including elastic and / or thermally deformable components, the value is obtained through finite element simulation pre-calculation based on the material properties and operating condition data in the digital twin.

3. The multi-station collaborative full-sequence machining method for parts according to claim 1, characterized in that, In step S50, when the layout management module performs spatial interference checks, it decomposes the continuous motion of the components into a set of discrete static state views based on time-equal interval sampling for interference analysis.

4. The multi-station collaborative full-sequence machining method for parts according to claim 3, characterized in that, In step S50, the dynamic compensation model is expressed as: ； in, For compensation amount, For processing feature deviation, This is the pose deviation vector. For sensitivity factor, As an environmental coupling factor, These are model constants; the environmental coupling factor It is calculated from operating condition data of temperature, vibration and spindle power.

5. The multi-station collaborative full-sequence machining method for parts according to claim 4, characterized in that, The environmental coupling factor The expression is: ； in, For real-time operating condition data, For calibration values, The weighting coefficients are initially derived from the regression analysis results of historical processed data and are dynamically updated via a recursive algorithm during online operation.

6. The multi-station collaborative full-sequence machining method for parts according to claim 1, characterized in that, It also includes a manufacturing resource digital twin library, which is used to associate and store theoretical values, measured values, deviation data, operating condition data, compensation amounts, and interference check results of the processing process; Before calculating the compensation amount, the central control system queries historical processing data of the same type in the database to calibrate the dynamic compensation model.

7. A multi-station collaborative full-sequence machining method for parts according to claim 6, characterized in that, When a spatial interference warning is triggered or spatial interference is detected, the central control system invokes the real-time rescheduling engine to adjust the component pose or insert micro-waiting time as intervention methods to re-optimize and schedule the remaining processes in a spatiotemporal manner.

8. The multi-station collaborative full-sequence machining method for parts according to claim 7, characterized in that, The acquisition of the multi-condition data is specifically as follows: Data is acquired through an integrated measurement unit, where dimensional features are obtained through a contact probe, surface topography and 3D point cloud are obtained through a machine vision sensor, and spatial pose is calculated by matching a reference sphere with the machine tool probe. The measurement data are then validated using a multivariate statistical process control method based on Mahalanobis distance.

9. An integrated composite machining center for implementing the multi-station collaborative full-sequence machining method for parts according to any one of claims 1-8, comprising a casting base, characterized in that, The casting base is equipped with a vertical turning unit, a horizontal machining unit, and a vertical machining unit. The vertical turning unit includes a spindle chuck located at the center of the casting base, and the spindle chuck is connected to a servo motor with C-axis indexing function; The vertical machining unit includes a support rod that is vertically fixed to the side of the casting base. The support rod is provided with a Z-axis slide that slides in the vertical direction. A vertical machining spindle and a chip-turning tool holder are mounted side by side on the Z-axis slide. The horizontal machining unit includes a Y-axis slide that spans the casting base and moves vertically along the side of the support rod. An X-axis slide that slides horizontally is provided on the Y-axis slide, and a horizontal machining spindle is mounted on the X-axis slide.

10. The integrated composite machining center according to claim 9, characterized in that, Both the vertical and horizontal machining spindles are BT interface spindles, and each of the vertical and horizontal machining units is equipped with an independent disc-type tool magazine; the casting base has a circulating cooling channel inside, and the circulating cooling channel is connected to a thermal balance control system.

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