Burr removing equipment for aluminum alloy die-casting parts

Abstract

The invention relates to the technical field of machine manufacturing, and discloses aluminum alloy die-casting part deburring equipment which comprises a rack, a rotating table, a pressing disc, a pressing disc lifting assembly, a rotating motor, a cutter feeding assembly and a torque limiting self-adaptive regulation and control system. The system includes a dynamic reference generation module that determines an expected torque reference based on cutting parameters; the multi-source load sensing module fuses the motor torque and the driver current to obtain real-time load feedback; the working condition nonlinear correction module is used for determining a working condition correction coefficient based on the pressing force and the burr thickness; the load adaptation degree evaluation module is used for quantifying the matching degree of the actual load and the corrected expected load; the safety margin evaluation module is used for evaluating a safety redundancy coefficient by integrating cutter wear, motor temperature and overload history; and the asymmetric torque amplitude limiting module dynamically calculates and adjusts a torque limiting value in real time. The torque protection threshold value can be adjusted in a self-adaptive mode, equipment safety is guaranteed, mistaken shutdown is avoided, and machining continuity and reliability are improved.

Description

Technical Field

[0001] This invention belongs to the field of mechanical manufacturing technology, and in particular relates to a deburring device for aluminum alloy die-cast parts. Background Technology

[0002] Aluminum alloy die casting is widely used in the production of automotive parts, with typical products including disc-shaped structural components such as wheel hubs and wheels. After die casting, irregular metal flashes inevitably remain on the parting surface and edge areas of the workpiece. These flashes are formed by metal overflow from the mold parting line, and their thickness exhibits significant non-uniformity along the circumference of the workpiece, and is greatly affected by fluctuations in process parameters such as die casting temperature and pressure. Due to the inherent high toughness and ductility of aluminum alloys, metal adhesion easily occurs at the tool-workpiece contact interface during flash removal by turning, leading to severe non-linear fluctuations in cutting force and load variations exceeding the normal range. Furthermore, due to differences in the stability of the die casting process, different batches of workpieces exhibit significant dispersion in flash geometry, material hardness, and surface condition. During continuous machining, tool wear gradually accumulates, and the clamping force of the clamping device may dynamically loosen. These factors combined significantly increase the dynamic uncertainty of the cutting process and substantially enhance the complexity of the working conditions.

[0003] Currently, most equipment uses a fixed torque limit value as a means of motor overload protection. This method has obvious limitations: if the threshold is set too low, frequent false shutdowns are easily triggered when the burr thickens locally or the material hardness fluctuates, interrupting the normal production cycle; if the threshold is set too high, it cannot effectively protect the spindle, tool, and transmission system when tool wear intensifies, clamping loosens, or abnormal impacts occur, posing a risk of equipment damage. Existing technology lacks the ability to dynamically perceive and adaptively adjust changes in cutting load, equipment status, and process conditions, making it difficult to balance machining continuity and equipment safety.

[0004] To address the aforementioned issues, this solution proposes an adaptive control system based on multi-parameter fusion. This system acquires process parameters, equipment status, and operating condition feedback in real time. Through fusion calculation, it dynamically adjusts the torque limit value of the tool feed motor, ensuring that the protection threshold can adapt to normal process changes such as burr fluctuations and material differences, while also tightening protection promptly under abnormal operating conditions. This achieves the adaptive control objective of "protecting the equipment without interrupting normal processing." Summary of the Invention

[0005] The purpose of this invention is to provide a deburring device for aluminum alloy die-cast parts, aiming to solve the above-mentioned problems.

[0006] This invention is implemented as follows: a deburring device for aluminum alloy die-cast parts, comprising a frame and a cutting tool, and a rotary table rotatably connected to the frame. A pressing plate is disposed above the rotary table. The device further includes: a pressing plate lifting assembly, disposed on the frame, for driving the pressing plate downwards and cooperating with the rotary table to fix the workpiece; a rotary motor, fixed to the bottom of the frame, for driving the rotary table to rotate along its axis; a cutting tool feed assembly, disposed on the frame, for driving the cutting tool feed; and a torque limiting adaptive control system, comprising: a dynamic reference generation module, configured to determine a expected torque reference based on the cutting tool feed speed, the rotary table motor speed, and the turning depth; and a multi-source load sensing module, configured to sense loads based on the tool feed. The system acquires real-time load feedback based on motor torque and tool feed motor driver current; a working condition nonlinearity correction module is configured to determine the working condition correction coefficient based on the pressing pressure of the pressing plate and the workpiece burr thickness; a load fit evaluation module is configured to determine the load fit degree through a load fit model based on the working condition correction coefficient, expected torque benchmark, and real-time load feedback; a safety margin evaluation module is configured to determine the safety redundancy coefficient based on the cumulative number of cutting operations, tool feed motor winding temperature, and historical overload alarm frequency; and an asymmetric torque limiting module is configured to dynamically calculate the target tool feed motor torque limit value based on the basic safety torque threshold, safety redundancy coefficient, and load fit degree, and adjust the tool feed motor torque limit parameters in real time.

[0007] A further technical solution involves configuring the dynamic reference generation module to: acquire the cutting tool feed rate, the rotary table motor speed, and the depth of cut; process the ratio of the cutting tool feed rate to the rotary table motor speed to obtain the feed per revolution; compare the feed per revolution and the depth of cut with the rated feed per revolution and the rated depth of cut, respectively, to obtain the feed rate index and the depth of cut index; and substitute the feed rate index and the depth of cut index into the formula. Obtain the expected torque benchmark ,in, The feed rate index. This is the turning depth index.

[0008] In a further technical solution, the multi-source load sensing module is configured to: acquire the tool feed motor torque and the tool feed motor driver current; process the ratios of the tool feed motor torque and the tool feed motor driver current with the motor's rated torque and the driver's rated current, respectively, to obtain the motor torque index and the driver current index; and substitute the motor torque index and the driver current index into the formula... Get real-time load feedback ,in, This refers to the motor torque index. For the driver current index, Torque weighting.

[0009] A further technical solution involves configuring the nonlinear correction module for the working condition as follows: acquiring the pressing pressure of the pressing plate and the workpiece burr thickness; performing ratio processing on the pressing pressure of the pressing plate and the workpiece burr thickness with the rated pressing pressure and the rated workpiece burr thickness, respectively, and limiting the upper limit of the ratio to 1 to obtain the workpiece pressing index and the workpiece burr thickness index; and substituting the workpiece pressing index and the workpiece burr thickness index into the formula. Obtain the working condition correction coefficient ,in, To press the pressure plate, The thickness of the workpiece burr.

[0010] In a further technical solution, the load adaptability evaluation module is configured to: obtain the operating condition correction coefficient, the expected torque benchmark, and the real-time load feedback; and substitute the operating condition correction coefficient, the expected torque benchmark, and the real-time load feedback into the formula. Get load adaptability ,in, Based on the expected torque, For real-time load feedback, The correction factor is used for the condition.

[0011] A further technical solution involves configuring the safety margin assessment module as follows: acquiring the cumulative number of cutting operations, the temperature of the tool feed motor winding, and the historical overload alarm frequency; comparing the cumulative number of cutting operations and the historical overload alarm frequency with the tool's rated number of operations and the maximum allowable alarm frequency, respectively, and limiting the ratio to a maximum of 1, to obtain the tool wear index and the overload alarm frequency index; comparing the difference between the tool feed motor winding temperature and the motor's normal operating temperature with the difference between the motor's maximum allowable temperature and the motor's normal operating temperature, and limiting the ratio to a maximum of 1, to obtain the tool feed motor winding temperature index; and substituting the tool wear index, the tool feed motor winding temperature index, and the overload alarm frequency index into the formula. Obtain the safety redundancy coefficient ,in, This is the tool wear index. This refers to the temperature index of the tool feed motor windings. This is the overload alarm frequency index.

[0012] In a further technical solution, the asymmetric torque limiting module is configured to: obtain a basic safe torque threshold, a safety redundancy coefficient, and a load adaptability; and substitute the basic safe torque threshold, safety redundancy coefficient, and load adaptability into the formula. Obtain the target tool feed motor torque limit value ,in, Based on the basic safe torque threshold, For safety redundancy coefficient, For load adaptability, , The underload directional attenuation coefficient has a value range of 0-1.

[0013] A further technical solution includes a vertically fixed guide rail on a frame, a slider slidably connected to the guide rail, a mounting frame fixed to the slider, a pressing plate rotatably connected to the mounting frame, and a cylinder fixed to the top of the frame, with the telescopic end of the cylinder connected to the mounting frame.

[0014] In a further technical solution, the cutting tool feed assembly includes a linear module fixed on a frame, the linear module is controlled by a servo motor, and the cutting tool is mounted on the linear module via a bracket.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0016] 1. Adaptive dynamic protection, balancing continuity and safety: By integrating multiple parameters to evaluate load matching and equipment safety margin in real time, the torque limit value is dynamically adjusted to avoid accidental shutdowns under normal working conditions such as burr fluctuations and material differences, and to tighten protection in a timely manner under abnormal working conditions such as tool wear and loose clamping, effectively balancing processing efficiency and equipment safety.

[0017] 2. Asymmetric adjustment mechanism to reduce false triggering: Differentiated adjustment strategies are adopted for overload and underload conditions. The underload direction is attenuated to avoid over-protection due to slight load fluctuations, thereby further improving the stability of equipment operation and the continuity of processing. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of a deburring device for aluminum alloy die-cast parts provided by the present invention;

[0019] Figure 2 The flowchart illustrates the operation of the torque limiting adaptive control system provided by this invention.

[0020] In the attached diagram: 1. Frame; 2. Rotary table; 3. Pressing plate; 4. Rotary motor; 5. Cutting blade; 6. Guide rail; 7. Slider; 8. Mounting bracket; 9. Linear module; 10. Servo motor; 11. Cylinder. Detailed Implementation

[0021] 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 and not intended to limit the invention.

[0022] The specific implementation of the present invention will be described in detail below with reference to specific embodiments.

[0023] like Figure 1 and Figure 2 As shown, an embodiment of the present invention provides a deburring device for aluminum alloy die-cast parts, including a frame 1, a cutting blade 5, and a rotary table 2 rotatably connected to the frame 1. A pressing plate 3 is disposed above the rotary table 2. The device also includes: a pressing plate lifting assembly, disposed on the frame 1, which controls the vertical movement of the pressing plate 3. This assembly can drive the pressing plate 3 downward, thereby firmly fixing the workpiece on the rotary table 2, and lifting the pressing plate 3 after processing for easy workpiece loading and unloading; a rotary motor 4, fixed to the bottom of the frame 1, which provides power to drive the rotary table 2 to rotate along its axis. By adjusting the speed of the rotary motor 4, the cutting speed of the workpiece can be controlled to adapt to different processing requirements; and a cutting blade feed assembly, disposed on the frame 1, which controls the feed motion of the cutting blade 5. This assembly can precisely control the movement of the cutting blade 5 towards the workpiece to achieve control over the cutting depth and cutting path of the deburring. During operation, the workpiece is placed on the rotary table 2. The pressure plate lifting assembly drives the pressing plate 3 to move downward. The pressing plate 3, together with the rotary table 2, fixes the workpiece. The rotary motor 4 drives the rotary table 2 to rotate along its axis. The rotary table 2 drives the workpiece and the pressing plate 3 to rotate. The cutting tool feed assembly drives the cutting tool 5 to feed. The cutting tool 5 cuts the rotating workpiece, thereby removing the burrs from the workpiece.

[0024] Torque limiting adaptive control system, the torque limiting adaptive control system includes:

[0025] The dynamic reference generation module is configured to determine the expected torque reference based on the cutting tool feed rate, rotary table motor speed, and depth of cut. For example, this module can output a corresponding expected torque value based on the input feed rate, motor speed, and depth of cut using a pre-established lookup table or a simple linear interpolation model. These lookup tables or models can be obtained based on empirical data or theoretical calculations. This method can provide a preliminary expected load reference, but it may not accurately reflect nonlinear variations under all operating conditions.

[0026] A multi-source load sensing module is configured to obtain real-time load feedback based on the tool feed motor torque and the tool feed motor driver current. For example, this module can directly measure the motor output torque using a torque sensor mounted on the tool feed motor, while simultaneously measuring the motor driver output current using a current sensor. These sensors convert analog signals into digital signals and transmit them to the control system. This approach provides real-time load information, but data from a single sensor may not fully reflect the complex characteristics of the cutting load, and the accuracy and response speed of the sensor itself can affect the accuracy of the feedback.

[0027] The nonlinear correction module is configured to determine a correction coefficient based on the clamping pressure of the pressing plate and the burr thickness of the workpiece. For example, this module can measure the clamping pressure of the pressing plate using a pressure sensor and measure the burr thickness of the workpiece visually or with a simple thickness gauge. Then, based on these measurements, a correction coefficient is calculated using preset empirical rules or a simple piecewise function. For example, the correction coefficient increases when the clamping pressure is below a certain threshold; it also increases when the burr thickness is large. This method can make preliminary adjustments to the expected torque reference to accommodate some common operating condition variations, but its precision and accuracy may be limited.

[0028] The load fit assessment module is configured to determine the load fit degree based on the operating condition correction factor, the expected torque benchmark, and real-time load feedback using a load fit model. For example, this module can simply calculate the absolute difference between the real-time load feedback and the corrected expected torque benchmark, and then compare this difference with the expected torque benchmark to determine if they are close. If the difference is within a preset allowable range, the load fit degree is considered high; otherwise, the fit degree is low. This simple comparison method can preliminarily determine the load matching situation, but it may not be able to distinguish between different abnormal situations such as excessively high or low loads.

[0029] The safety margin assessment module is configured to determine the safety redundancy coefficient based on the cumulative number of machining operations performed by the cutting tool, the temperature of the tool feed motor windings, and the frequency of historical overload alarms. For example, this module can record the cumulative number of machining operations by the cutting tool using a counter, monitor the motor winding temperature using a temperature sensor, and record the number of overload alarms through the system log. Then, based on this data, the safety redundancy coefficient is calculated using a simple threshold judgment or a linear decay model. For example, when the cumulative number of machining operations exceeds a certain threshold, the safety redundancy coefficient decreases; when the motor temperature is too high, the safety redundancy coefficient also decreases. This method can provide a preliminary assessment of the equipment's safety status, but it may not fully consider all factors affecting the safety margin.

[0030] The asymmetric torque limiting module is configured to dynamically calculate the target tool feed motor torque limit value based on a basic safe torque threshold, a safety redundancy coefficient, and load adaptability, and adjust the tool feed motor torque limit parameters in real time. For example, the module can preset a fixed basic safe torque threshold, and then adjust this basic threshold using simple multiplication or addition operations based on the safety redundancy coefficient and load adaptability. For instance, when the safety redundancy coefficient is low or the load adaptability is poor, the basic threshold is multiplied by a coefficient less than 1, thereby reducing the torque limit value. This method enables dynamic adjustment of the torque limit value, but its adjustment strategy may be relatively simple and cannot fully utilize the advantages of multi-parameter fusion.

[0031] The aforementioned technical solution significantly improves the performance of deburring equipment for aluminum alloy die-cast parts by introducing a torque-limiting adaptive control system. Traditional equipment generally uses a fixed torque limit value as a means of motor overload protection. This method has obvious limitations when facing complex and variable actual working conditions such as uneven deburr thickness, material fluctuations, and tool wear. For example, when local thickening of the deburr causes a sudden increase in cutting load, if the fixed threshold is set too low, it will frequently trigger false shutdowns, interrupting the normal production cycle; if it is set too high, it cannot effectively protect the spindle, tool, and transmission system when tool wear intensifies, clamping loosens, or abnormal impacts occur, posing a risk of equipment damage.

[0032] This application further proposes that the dynamic benchmark generation module is configured as follows:

[0033] The system acquires the cutting tool feed rate, rotary table motor speed, and depth of cut. The cutting tool feed rate refers to the speed at which the cutting tool 5 moves along the feed direction during machining. This speed can be obtained in real-time through encoder feedback from the servo motor 10 of the cutting tool feed assembly, displacement sensor of the linear module 9, or controller command parameters. The rotary table motor speed refers to the rotational speed of the rotary motor 4 that drives the rotary table 2. This speed can be obtained in real-time through encoder feedback from the rotary motor 4, inverter output frequency, or controller command parameters. The depth of cut refers to the depth to which the cutting tool 5 penetrates the workpiece material. This depth can be obtained through initial position setting of the cutting tool 5, displacement feedback from the linear module 9, or pre-scanning of the workpiece burr thickness using a vision system.

[0034] The ratio of the cutting tool feed rate to the rotary table motor speed is processed to obtain the feed per revolution. This step aims to convert the linear velocity form of the cutting tool feed rate into a unit feed rate related to the rotation of rotary table 2. Its purpose is to eliminate the influence of rotary table 2 speed variations on feed rate evaluation, making feed rates at different speeds comparable, thus more accurately reflecting the amount of material removed per unit rotation angle. For example, this can be calculated by dividing the cutting tool feed rate by the rotary table motor speed, or by conversion using a kinematic model within the controller.

[0035] The feed per revolution and depth of cut are compared with the rated feed per revolution and rated depth of cut, respectively, to obtain the feed rate index and depth of cut index. The rated feed per revolution refers to the standard feed rate corresponding to one revolution of the cutting tool 5 under the design or calibration conditions of the equipment. This parameter is usually preset by the equipment manufacturer based on tool performance, material properties, and machining requirements, and stored in the control system. The rated depth of cut refers to the standard depth of cut that the cutting tool 5 can withstand under the design or calibration conditions of the equipment. This parameter is also preset by the equipment manufacturer and is used to measure the ratio of the current depth of cut to the equipment's capacity. The purpose of this step is to dimensionlessly process the actual feed per revolution and depth of cut, making them proportionate to the rated values. Through this indexation, the relative contribution of the current cutting parameters to the expected load can be quantified. For example, the feed rate index can be expressed as the actual feed per revolution divided by the rated feed per revolution, and the depth of cut index can be expressed as the actual depth of cut divided by the rated depth of cut. This processing method allows parameters from different devices or operating conditions to be compared and calculated within a range of 0 to 1.

[0036] Substitute the feed rate index and depth of cut index into the formula. Obtain the expected torque benchmark This step uses a mathematical model to combine the quantified feed rate index and depth of cut index to calculate a target torque benchmark. The purpose of this formula is to use the feed rate index... and turning depth index The product of these factors reflects the combined effect of cutting volume or material removal rate on torque load. A larger product indicates a higher expected load. Simultaneously, a min function is used to limit the result to within 1, ensuring that the expected torque baseline does not exceed the theoretical maximum value. This avoids abnormal baseline values ​​due to extreme parameter combinations, thus guaranteeing the rationality of subsequent torque limit calculations. This baseline value... It is a normalized value. , Approaching 0 indicates that the expected load is extremely low. A value approaching 1 indicates that the expected load is close to the rated upper limit. Wherein, The feed rate index. This is the turning depth index.

[0037] This application's solution precisely quantifies the impact of cutting parameters on the load to ensure that the expected torque benchmark accurately reflects the actual expected load, thus providing a reliable reference for subsequent adaptive torque limitation control. The module first acquires key parameters such as the cutting tool feed rate, rotary table motor speed, depth of cut, rated feed per revolution, and rated depth of cut. These parameters are fundamental data describing the current cutting state and equipment capabilities. To eliminate the interference of rotary table speed variations on feed rate evaluation, the system ratios the cutting tool feed rate to the rotary table motor speed to obtain the feed per revolution, making the feed rates comparable across different speeds. Subsequently, this feed per revolution and depth of cut are compared with preset rated feed per revolution and rated depth of cut, respectively, to generate a feed rate index. and turning depth index This indexation process transforms actual cutting parameters into dimensionless relative values, intuitively reflecting the ratio of current cutting intensity to the equipment's rated capacity. Finally, these two indices are substituted into the formula. Calculate the expected torque reference This formula comprehensively considers the combined effects of feed rate and depth of cut on cutting load through a product relationship, and uses a min function to impose an upper limit on the result, ensuring that the reference value is within a reasonable range. Through this series of processes, the dynamic reference generation module can dynamically and accurately predict the expected torque load under the current working condition based on real-time cutting parameters, providing a dynamic reference point for the torque limit adaptive control system that changes with the working condition. This effectively solves the problem that traditional fixed torque limit values ​​cannot adapt to complex and variable cutting conditions.

[0038] The following example illustrates how the dynamic reference generation module can be integrated into the CNC system of the aluminum alloy die-casting parts deburring equipment 1 or a standalone industrial controller. The controller can obtain the cutting tool feed rate in real time from the servo driver of the cutting tool feed assembly, the rotary table motor speed from the driver of the rotary motor 4, and the turning depth through the CNC program or sensors. The rated feed per revolution and rated turning depth can be pre-stored as system parameters in the controller's memory. For example, suppose at a certain moment, the controller obtains a cutting tool feed rate of 1000 mm / min, a rotary table motor speed of 500 rpm, and a turning depth of 0.5 mm. Simultaneously, the system's preset rated feed per revolution is 2 mm / rev, and the rated turning depth is 1 mm. First, the controller divides the cutting tool feed rate (1000 mm / min) by the rotary table motor speed (500 rpm) to obtain a feed per revolution of 2 mm / rev. Then, it calculates the feed rate index. The actual feed per revolution (2 mm / rev) divided by the rated feed per revolution (2 mm / rev) yields the result. =1. Calculate the depth of cut index. The actual depth of cut (0.5 mm) divided by the rated depth of cut (1 mm) yields the result. =0.5. Finally, substitute these two exponents into the formula. At this point, the expected torque reference A value of 0.5 indicates that the expected load under the current cutting condition is 50% of the rated load. This dynamically calculated baseline value will serve as an important input for the subsequent torque limit adaptive control system, guiding the system to make more precise torque limit adjustments.

[0039] Through the above technical solution, the dynamic reference generation module of this application can dynamically and accurately calculate the expected torque reference based on real-time cutting parameters. This effectively solves the problem that traditional fixed torque limit values ​​cannot adapt to complex working conditions such as uneven burr thickness and material property fluctuations during the deburring process of aluminum alloy die-cast parts. By processing the ratio of the cutting tool feed rate to the rotary table motor speed, the interference of speed changes on feed rate evaluation is eliminated, allowing the feed rate index and depth of cut index to more accurately reflect the cutting intensity. Furthermore, by substituting these indices into specific formulas, the combined influence of feed rate and depth of cut on the cutting load is comprehensively considered, and the reference value is reasonably limited, ensuring the accuracy and stability of the expected torque reference. This enables the torque limit adaptive control system to obtain a dynamic reference that is highly matched with the actual cutting conditions, thereby minimizing frequent downtime caused by misjudgment while ensuring equipment safety, and significantly improving the continuity and efficiency of machining.

[0040] This application further proposes that the multi-source load sensing module be configured as follows:

[0041] This section describes how to obtain the torque of the tool feed motor and the current of the tool feed motor driver. The tool feed motor torque refers to the real-time torque value output by the tool feed motor during actual cutting. It can be obtained by direct measurement using a torque sensor integrated on the motor shaft, or by estimation using parameters such as current, voltage, and speed within the servo driver. The tool feed motor driver current refers to the real-time current value output by the driver that drives the tool feed motor during operation. It can be obtained through precise measurement using a Hall effect current sensor built into the driver, or by acquiring internal monitoring data through the driver's communication interface with the host computer.

[0042] The torque of the tool feed motor and the current of the tool feed motor driver are compared with the rated torque of the motor and the rated current of the driver, respectively, to obtain the motor torque index and the driver current index. The rated torque of the motor refers to the maximum torque that the tool feed motor can output stably and continuously under design conditions. This value is usually specified by the motor manufacturer in its product specifications and pre-configured in the control system. The rated current of the driver refers to the maximum current that the driver can output stably and continuously under design conditions. This value is usually specified by the driver manufacturer in its product specifications and pre-configured in the control system. The ratio processing involves comparing the real-time acquired torque of the tool feed motor with the rated torque of the motor, and comparing the tool feed motor driver current with the rated current of the driver. This normalization process eliminates the influence of different physical dimensions, converting the actual load state into a dimensionless index between 0 and 1, facilitating subsequent unified calculations and comparisons. For example, when the actual torque reaches 70% of the rated torque, the ratio is 0.7. The motor torque index represents the ratio of the current actual output torque of the tool feed motor to its rated torque. This index directly reflects the load level of the motor under current operating conditions; a higher value indicates that the load is closer to the rated upper limit. The driver current index represents the ratio of the current output current of the tool feed motor driver to its rated current. This index also directly reflects the load level of the driver under current operating conditions; a higher value indicates that the driver load is closer to the rated upper limit.

[0043] Substitute the motor torque index and the driver current index into the formula. Get real-time load feedback Real-time load feedback It is a normalized value between 0 and 1, used to quantify the current actual load level of the device. , A value close to 0 indicates that the equipment is almost unloaded. A value approaching 1 indicates that the equipment is close to its rated load. This value serves as a crucial input for the subsequent torque-limiting adaptive control system, providing a reliable basis for dynamic system adjustments. This refers to the motor torque index. For the driver current index, The output torque weight, ranging from 0 to 1, is an adjustable parameter used in subsequent fusion calculations to balance the contributions of the tool feed motor torque and the tool feed motor driver current to the real-time load feedback. This weight can be preset based on actual machining experience, for example, by adjusting it through the system configuration interface, or dynamically optimized according to different materials and cutting conditions. For example, when... When set to 0.8, it means that the torque index accounts for 80% of the weight in the real-time load feedback, while the current index accounts for 20%. This fusion method can comprehensively consider the two key indicators of motor output torque and driver current, thereby obtaining a more comprehensive and accurate real-time load assessment result.

[0044] This application's solution overcomes the limitations of single-parameter sensing by acquiring multiple parameters, including tool feed motor torque, tool feed motor driver current, motor rated torque, driver rated current, and torque weight. The module first preprocesses the real-time acquired tool feed motor torque and driver current by comparing them with preset motor rated torque and driver rated current, thereby normalizing the real-time data of different physical dimensions into dimensionless motor torque and driver current indices. This normalization process allows load information from different sources to be compared and fused on a unified scale. Subsequently, these normalized indices are substituted into a weighted fusion formula. Among them, torque weight This allows the system to flexibly adjust the contribution ratios of torque and current in the final real-time load feedback based on actual operating conditions or experience. Through this weighted fusion, the system can generate a real-time load feedback between 0 and 1. This value can comprehensively and accurately reflect the current actual load status of the equipment, among which A value close to 0 indicates that the equipment is almost unloaded. A value approaching 1 indicates that the equipment is close to its rated load. This application's solution effectively avoids load assessment biases that can result from relying on a single parameter by integrating two key and complementary parameters: tool feed motor torque and driver current. Motor torque directly reflects the magnitude of the cutting force, while driver current reflects the actual electrical state of the motor. Combining the two provides more robust load information. This multi-source sensing mechanism provides more accurate and reliable real-time load feedback for the torque-limited adaptive control system, enabling the subsequent load fit assessment module to make judgments based on more accurate data. This, in turn, guides the asymmetric torque limiting module to dynamically calculate and adjust the target tool feed motor torque limit value. Therefore, this solution significantly improves the adaptability and protection accuracy of the entire deburring equipment under complex and variable working conditions, ensuring that the equipment effectively removes burrs while minimizing the risk of accidental shutdowns and equipment damage.

[0045] The following is a concrete example to illustrate this. Suppose that during the deburring process of die-cast aluminum alloy parts, the multi-source load sensing module needs to evaluate the load on the tool feed motor in real time. First, the system acquires the current torque of the tool feed motor, for example, 5 Nm, and the current of the tool feed motor driver, for example, 10 A. Simultaneously, the system has preset the rated torque of the tool feed motor to 10 Nm and the rated current of the driver to 20 A. Furthermore, based on experience or debugging results, torque weighting... It is set to 0.7. Next, the multi-source load sensing module performs ratio processing. It compares the real-time tool feed motor torque of 5 Nm to the motor's rated torque of 10 Nm to obtain the motor torque index. =5 / 10=0.5. Simultaneously, the ratio of the real-time tool feed motor driver current of 10 amps to the driver's rated current of 20 amps is used to obtain the driver current index. =10 / 20=0.5. Finally, substitute these indices into the weighted fusion formula: Based on the above calculations, real-time load feedback is achieved. The value was set to 0.5. This value intuitively indicates that the current tool feed motor is operating at approximately 50% of its rated load. This real-time load feedback value is then passed to other modules in the torque limit adaptive control system, such as the load fit assessment module, for further condition assessment and dynamic adjustment of the torque limit value.

[0046] Through the above technical solution, the multi-source load sensing module of this application can effectively solve the problem of incomplete load sensing by traditional single-parameter sensing. By comprehensively considering the two complementary physical quantities of tool feed motor torque and driver current, and performing normalization and weighted fusion, the system can obtain a more comprehensive, accurate, and robust real-time load feedback. This multi-source fusion mechanism significantly improves the accuracy and reliability of load sensing, avoiding misjudgments caused by fluctuations in a single parameter or measurement errors. Therefore, it provides high-quality input data for the torque-limiting adaptive control system, enabling subsequent load fit assessments and asymmetric torque limiting decisions to be based on more realistic and stable load information. This not only improves the equipment's adaptability to complex conditions during the deburring process of aluminum alloy die-cast parts (such as uneven deburring thickness and changes in material toughness), reducing unnecessary downtime, but also enhances the equipment's ability to identify abnormal conditions (such as tool wear and loose clamping), thereby more effectively protecting the spindle, tools, and transmission system, balancing machining continuity and equipment safety.

[0047] This application further proposes that the nonlinearity correction module for operating conditions is configured as follows:

[0048] The pressing pressure of the pressing plate and the burr thickness of the workpiece are obtained. The pressing pressure of the pressing plate refers to the actual pressure value applied by the pressing plate 3 when pressing the workpiece. This pressure can be obtained in real time by a pressure sensor (e.g., a piezoelectric sensor, strain gauge sensor, or hydraulic / pneumatic sensor) installed on the pressing plate 3 or its drive mechanism. The burr thickness of the workpiece refers to the actual thickness of the burrs or flash at the edge of the workpiece to be processed. This thickness can be obtained by pre-scanning the workpiece before it enters the processing area using a non-contact measurement sensor (e.g., a laser displacement sensor, a vision measurement system), or estimated by combining an empirical model with workpiece batch information.

[0049] The pressing pressure and workpiece burr thickness are compared to the rated pressing pressure and rated workpiece burr thickness, respectively. A min function is used to limit the upper limit of the ratio to 1, yielding the workpiece pressing index and workpiece burr thickness index. The rated pressing pressure refers to the ideal pressing pressure reference value set by the equipment under design or standard operating conditions to ensure stable workpiece clamping. This value is usually determined during equipment debugging or process parameter setting. The rated workpiece burr thickness refers to the expected or acceptable maximum thickness reference value of the workpiece burr under standard die-casting processes. This value is used to assess the severity of the current workpiece burr. This step converts physical quantities of different dimensions into dimensionless relative indices, facilitating subsequent unified calculations and comparisons. To avoid excessive nonlinear effects from extreme values ​​on subsequent calculations, the system further uses a min function to limit the upper limit of the ratio to 1, ensuring that the workpiece pressing index and workpiece burr thickness index can stably and reasonably reflect the relative severity of the operating conditions. The workpiece pressing index, the ratio of the pressing pressure to the rated pressing pressure, after limiting, reflects the relative adequacy of the workpiece pressing state. The workpiece burr thickness index is the ratio of the workpiece burr thickness to the rated workpiece burr thickness. After being limited, it reflects the relative level of the severity of the workpiece burr.

[0050] Substitute the workpiece compression index and the workpiece burr thickness index into the formula. Obtain the working condition correction coefficient This formula uses nonlinear functions (max and exp) to adjust the workpiece clamping index. and workpiece burr thickness index Convert to working condition correction factor .in, This indicates the degree of insufficient clamping force. This indicates the severity of the burr thickness. The max function is used to select the more severe condition as the dominant factor. The introduction of the exponential function exp(-x) allows for a correction factor when the condition is less severe. The changes are gradual, but when the severity of the working conditions increases, It will rapidly approach 1, thus achieving sensitive response to harsh operating conditions and nonlinear amplification correction. Operating condition correction coefficient. It is a dimensionless coefficient between 0 (inclusive) and 1 (exclusive), quantifying the severity of the current cutting condition. When When the value approaches 0, it indicates sufficient clamping force and minimal workpiece burr thickness, indicating ideal working conditions and no significant adjustment is needed for the expected load; when When the value approaches 1, it indicates that the clamping force is severely insufficient or the workpiece burr thickness is extremely large, the working conditions are harsh, and the expected load should be significantly increased to match the actual cutting difficulty. Among these, To press the pressure plate, The thickness of the workpiece burr.

[0051] The working condition nonlinear correction module of this application provides a key correction basis for the torque-limited adaptive control system by dynamically sensing and quantifying the actual difficulty of the cutting condition. This module first acquires the clamping pressure of the pressing plate 3 and the burr thickness of the workpiece in real time. These parameters directly reflect the current clamping stability of the workpiece and the potential magnitude of the cutting load. By comparing the actual measured values ​​with preset rated values ​​and using a min function to limit the upper limit of the ratio to 1, the system can uniformly transform parameters of different physical quantities into dimensionless workpiece clamping indices and workpiece burr thickness indices. This normalization process not only eliminates dimensional differences but, more importantly, avoids excessive nonlinear effects of extreme measured values ​​on subsequent calculations through amplitude limiting, ensuring that the indices can stably and reasonably reflect the relative severity of the working condition. Subsequently, these indices are substituted into a carefully designed nonlinear correction formula. This formula uses a max function to identify the more severe working condition factor between insufficient clamping force and severe burr thickness. Then, the most severe factor is nonlinearly amplified using an exponential function, and finally, the working condition correction coefficient is calculated. The ingenious aspect of this nonlinear processing lies in the fact that when the operating conditions approach the ideal state, the correction coefficient... A value close to 0 indicates that no significant adjustment to the expected load is needed; however, when operating conditions deteriorate significantly, the correction factor... The value will rapidly approach 1, indicating that the system needs to significantly increase the expected load to cope with the substantial increase in actual cutting difficulty. Through this mechanism, the nonlinear correction module can accurately quantify the actual difficulty of the current cutting condition and convert it into a correction coefficient with nonlinear response characteristics. This correction coefficient is then passed to the load fit evaluation module, working together with the expected torque benchmark and real-time load feedback. This allows the torque limit adaptive control system to more accurately assess the degree of matching between the actual load and the corrected expected load, thereby effectively improving the equipment's adaptability and safety to complex and variable working conditions while ensuring machining continuity. This dynamic, nonlinear correction capability enables the equipment to intelligently distinguish between normal process fluctuations and abnormal working conditions, avoiding the problems of accidental shutdowns or insufficient protection caused by traditional fixed thresholds, and significantly improving the intelligence and reliability of deburring machining.

[0052] In one specific implementation, the nonlinear correction module can be integrated into the controller of the torque limiting adaptive control system, which can be an industrial PC or a high-performance PLC. To obtain the pressing pressure of the pressing plate, a high-precision pressure sensor can be installed on the hydraulic or pneumatic drive cylinder of the pressing plate 3. This sensor converts the analog signal into a digital signal and transmits it to the controller. For the workpiece burr thickness, a laser displacement sensor can be installed above or to the side of the workpiece before it enters the processing area of ​​the rotary table 2. This sensor calculates the average or maximum burr thickness by scanning the workpiece edge contour and transmits the data to the controller. The rated pressing pressure and rated workpiece burr thickness are stored as preset parameters in the controller's memory. For example, the rated pressing pressure can be set to 500N, and the rated workpiece burr thickness can be set to 0.5mm. After receiving the real-time pressing pressure (e.g., 400N) and real-time burr thickness (e.g., 0.8mm), the controller performs a ratio calculation. For example, the pressing force ratio = 400N / 500N = 0.8. The burr thickness ratio = 0.8mm / 0.5mm = 1.6. Next, a min function is applied to these ratios, limiting the upper limit to 1. Therefore, the workpiece clamping index... The workpiece burr thickness index is 0.8. The minimum value is min(1.6,1) = 1. Finally, the controller substitutes these two exponents into the formula. Perform the calculations. First, calculate... =1-0.8=0.2. Then calculate... =1. The final operating condition correction factor is obtained. =1-0.3679=0.6321. This calculation... A value of 0.6321 indicates that the current operating conditions are relatively harsh (the burr thickness is large), requiring a significant upward adjustment of the expected load to ensure the stability and safety of the cutting process. This coefficient is then passed to the load fit evaluation module to more accurately determine the degree of matching between the actual load and the corrected expected load.

[0053] Through the above technical solution, the working condition nonlinear correction module of this application can accurately obtain key working condition parameters such as the pressing pressure of the pressing plate and the workpiece burr thickness. Combined with rated values, it performs ratio processing and min function limiting, effectively unifying parameters of different dimensions into dimensionless workpiece pressing index and workpiece burr thickness index. This avoids excessive influence of extreme values ​​on the correction coefficient, ensuring the rationality and stability of the index. More importantly, by substituting these indices into a nonlinear formula containing a max function and an exponential function, this solution can achieve nonlinear and sensitive quantification of the severity of working conditions. When the pressing force is sufficient and the burr thickness is extremely small, the working condition correction coefficient approaches 0, indicating that there is no need to significantly adjust the expected load. However, when the pressing force is severely insufficient or the burr thickness is extremely large, the working condition correction coefficient will rapidly approach 1, thereby significantly increasing the expected load to match the actual cutting difficulty. This nonlinear correction mechanism enables the torque limit adaptive control system to more accurately assess the actual cutting load, effectively distinguish between normal process fluctuations and abnormal working conditions, and avoid the problems of insufficient protection under severe working conditions or frequent false shutdowns under ideal working conditions caused by traditional fixed thresholds. Therefore, this solution significantly improves the equipment's adaptability to complex and variable working conditions, effectively protects the spindle, cutting tools, and transmission system while ensuring continuous processing, and improves the equipment's operational reliability and processing efficiency.

[0054] This application further proposes that the load adaptability assessment module be configured as follows:

[0055] Obtain the operating condition correction factor, expected torque reference, and real-time load feedback; the operating condition correction factor, expected torque reference, and real-time load feedback are all calculated as described above.

[0056] Substitute the operating condition correction factor, the expected torque reference, and the real-time load feedback into the formula. Get load adaptability , , A value close to 1 indicates that the actual load is highly consistent with the corrected expected load, suggesting a smooth cutting process without abnormal impacts, severe tool wear, or loose clamping. A value close to 0 indicates a significant deviation between the actual load and the corrected expected load (potentially, the actual load is much higher than expected, resulting in overload; or much lower than expected, such as tool breakage or empty cutting), suggesting a serious anomaly that requires tightening the protection. Based on the expected torque, For real-time load feedback, The formula is a condition correction factor. This formula incorporates real-time load feedback. Compared with the expected torque reference after operating condition correction The comparison quantifies the relative deviation between the two. This represents the dynamic expected load after considering the influence of actual working conditions (such as burr thickness, clamping force, etc.). The ratio of the absolute value of the difference between the two values ​​to the corrected expected load is calculated, and a min function is used to limit the upper limit of this ratio to 1 to avoid extreme deviations that could distort the calculation results. Finally, subtracting this ratio from 1 yields the load fit degree, which is between 0 and 1. This calculation method can accurately reflect the degree of matching between the actual load and the corrected expected load, providing a quantitative basis for subsequent torque limit adjustments.

[0057] Load adaptability The value range is [0,1], and its magnitude directly reflects the stability and abnormal conditions of the cutting process. When When the value approaches 1, it indicates that the actual load is highly consistent with the corrected expected load. This usually means that the cutting process is smooth, without abnormal impacts, severe tool wear, or workpiece clamping looseness. Conversely, when... When the value approaches 0, it indicates a significant deviation between the actual load and the corrected expected load, suggesting a possible serious anomaly, such as the actual load being much higher than expected (overload) or much lower than expected (e.g., tool breakage, empty cutting). This explicit numerical mapping relationship allows the system to intuitively and reliably determine the current cutting state and take corresponding protective measures accordingly.

[0058] This application's solution solves the problem of accurately quantifying the deviation between the actual load and the corrected expected load by precisely calculating the load fit, thereby reliably identifying abnormalities in the cutting process. Specifically, the module first obtains the working condition correction coefficient, the expected torque reference, and real-time load feedback. These parameters comprehensively reflect the working conditions, theoretical expectations, and actual measurements of the cutting process, providing a comprehensive input basis for subsequent calculations. Then, the load fit is calculated by substituting these parameters into a specific formula. The formula adjusts the expected torque reference according to the working condition correction coefficient to ensure that the expected load takes into account changes in actual working conditions. Next, the absolute value of the relative deviation between the actual load and the adjusted expected load is calculated, and the minimum value between this value and 1 is taken to avoid excessive deviation leading to calculation distortion. Finally, the load fit is obtained by subtracting this value from 1, achieving standardization of the result within the range of 0 to 1, effectively distinguishing between normal and abnormal states. This calculation method based on relative deviation, which particularly emphasizes dynamically adjusting the expectation according to the working condition correction coefficient, can accurately capture abnormalities such as overload or underload, providing a reliable criterion for torque limitation. In this way, the load adaptability assessment module can provide key decision-making basis for the torque limit adaptive control system, enabling the system to respond more intelligently to various changes in the cutting process, thereby ensuring machining continuity while effectively protecting the equipment.

[0059] The following is a concrete example. Suppose that in a deburring device for aluminum alloy die-cast parts, the load fit assessment module receives the following parameters: expected torque reference. 0.6, real-time load feedback The working condition correction factor is 0.9. The value is 0.2. Substitute these values ​​into the formula. Perform the calculations. First, calculate the corrected expected load: =0.72. Then calculate the relative deviation between the actual load and the corrected expected load: =0.25. Since 0.25 is less than 1, therefore min(0.25,1) = 0.25. Finally, the load fit is... =1-0.25=0.75. At this time, A value of 0.75 indicates that there is a certain deviation between the actual load and the corrected expected load, but it is still within an acceptable range. There may be slight fluctuations in the cutting process or the load may be slightly higher than expected. The system can make fine adjustments based on this value without immediately triggering the shutdown protection.

[0060] Through the above technical solution, the load fit assessment module can accurately quantify the deviation between the actual cutting load and the corrected expected load, thereby reliably identifying abnormal situations in the cutting process, such as overload or underload. This provides an accurate basis for the torque limit adaptive control system, enabling the system to dynamically adjust the torque limit value of the tool feed motor according to real-time changes in the cutting state. When the load fit is high, the system can maintain a normal machining rhythm; when the load fit decreases, the system can promptly identify potential risks and tighten protection, effectively avoiding accidental shutdowns and equipment damage, thus significantly improving the operational safety and stability of the equipment while ensuring machining continuity.

[0061] This application further proposes that the safety margin assessment module be configured as follows:

[0062] The system acquires the cumulative number of machining operations by the cutting tool, the temperature of the tool feed motor windings, and the frequency of historical overload alarms. These parameters are fundamental data for assessing the equipment's safety status, reflecting the degree of cutting tool wear, the thermal load and potential risks of the tool feed motor, and abnormal situations encountered during equipment operation. The cumulative number of machining operations by the cutting tool can be recorded by an internal counter in the equipment control system, incrementing at the end of each machining cycle; alternatively, cutting tool wear can be indirectly assessed using external sensors (such as a vision recognition system) and converted into an equivalent number of machining operations. The temperature of the tool feed motor windings is typically measured in real time using a thermistor or thermocouple built into the motor windings, converting the analog signal into a digital signal for the controller to read. The frequency of historical overload alarms is recorded by the equipment control system, with the corresponding counter incrementing each time a tool feed motor overload alarm occurs.

[0063] The cumulative number of machining operations and historical overload alarm frequencies are compared with the tool's rated number of machining operations and the maximum allowable alarm frequency, respectively. A min function is then used to limit the ratio to an upper limit of 1 to obtain the tool wear index and overload alarm frequency index. This step transforms the raw count data into a dimensionless index between 0 and 1, standardizing the dimensions of different parameters for easier subsequent unified calculation and evaluation. The min function limit ensures the index does not exceed 1, preventing unreasonable impacts on subsequent calculations in extreme cases (such as overuse).

[0064] The difference between the tool feed motor winding temperature and the motor's normal operating temperature is compared with the difference between the motor's maximum allowable temperature and its normal operating temperature. This ratio is then limited to an upper limit of 1 using a min function to obtain the tool feed motor winding temperature index. This step transforms the actual temperature state of the tool feed motor into a standardized index, reflecting the risk level of the current temperature relative to its safe operating range. This relative difference processing method more accurately reflects the risk of the tool feed motor's thermal load, rather than a simple absolute temperature value.

[0065] The rated number of machining operations for the cutting tool, the maximum permissible alarm frequency, the maximum permissible temperature of the motor, and the normal operating temperature of the motor are used as benchmarks to standardize the actual measured values. These parameters are usually stored as factory settings for the equipment or component in the non-volatile memory of the control system, such as EEPROM or flash memory.

[0066] Substituting the tool wear index, the tool feed motor winding temperature index, and the overload alarm frequency index into the formula Obtain the safety redundancy coefficient This step combines three independent risk indices into a unified safety redundancy coefficient through multiplication. The key feature of this formula is that any increase in any risk index (approaching 1) leads to a significant decrease in the safety redundancy coefficient, thus enabling a multi-dimensional risk assessment. In the controller or processing unit, this multiplication formula can be executed using floating-point arithmetic; for example, the corresponding calculation logic can be implemented using programming languages ​​such as C / C++ or Python. , A value close to 1 indicates that the cutting tool is new, the motor temperature is low, there is no overload history, there is sufficient safety redundancy, and a more lenient torque limit is allowed. A value approaching 0 indicates severe tool wear, high motor temperature, frequent overload alarms, and near-complete exhaustion of safety redundancy. Torque must be strictly limited to prevent damage. This is the tool wear index. This refers to the temperature index of the tool feed motor windings. This is the overload alarm frequency index.

[0067] The proposed solution utilizes a safety margin assessment module to dynamically evaluate the equipment's safety margin, providing a precise basis for adaptive adjustment of torque limits. This module first acquires key parameters such as the cumulative number of machining operations by the cutting tool, the temperature of the tool feed motor windings, and the historical overload alarm frequency. These parameters directly reflect the cutting tool's lifespan, the thermal load status of the tool feed motor, and the abnormal history of equipment operation, forming the basis for quantifying safety risks. Simultaneously, it acquires reference values ​​such as the tool's rated machining operations, the maximum permissible alarm frequency, the motor's maximum permissible temperature, and the motor's normal operating temperature, providing a benchmark for subsequent standardization processing. Next, the cumulative number of machining operations and the historical overload alarm frequency are compared with the tool's rated machining operations and the maximum permissible alarm frequency, respectively. The ratio is then capped at 1 using a min function to obtain the tool wear index and the overload alarm frequency index. This processing method standardizes the raw data into a dimensionless exponent between 0 and 1, ensuring the comparability of different parameters in subsequent calculations and avoiding the excessive influence of extreme values ​​on the evaluation results. Similarly, the difference between the tool feed motor winding temperature and the motor's normal operating temperature is compared with the difference between the motor's maximum allowable temperature and its normal operating temperature. This ratio is then limited to a maximum of 1 using a min function to obtain the tool feed motor winding temperature index. This relative difference processing method more accurately reflects the risk level of the tool feed motor's thermal load. Finally, these three standardized indices are substituted into the multiplication formula. Calculate the safety redundancy coefficient The ingenuity of this multiplication formula lies in the fact that when any risk index approaches 1 (indicating high risk), the safety redundancy coefficient... This will significantly reduce risks, ensuring that the system can promptly tighten protection in any situation, such as severe tool wear, high temperature of the tool feed motor, or frequent overload alarms. Conversely, when all risk indices approach 0 (indicating low risk), the safety redundancy coefficient... Approaching a value of 1 allows the system to operate under more lenient torque limits. Through this multi-factor collaborative evaluation mechanism, the safety margin assessment module provides the torque limit adaptive control system with precise and dynamic safety status information, enabling the entire system to intelligently adjust its protection strategy based on the actual health condition of the equipment.

[0068] The following is a concrete example. Suppose that a safety margin assessment module is running in a deburring equipment for aluminum alloy die-cast parts.

[0069] As a specific implementation, when the equipment is in normal operation, the cutting tool is new, the cumulative machining count is 1000 cycles (the rated machining count of the tool is 100,000 cycles), the tool feed motor winding temperature is 40°C (the normal operating temperature of the motor is 35°C, and the maximum allowable temperature of the motor is 80°C), and the historical overload alarm frequency is 0 times (the maximum allowable alarm frequency is 10 times). At this time, the tool wear index is... The calculation is 1000 / 100000 = 0.01. (Tool feed motor winding temperature index) The calculation is (40-35) / (80-35) = 5 / 45 ≈ 0.11. Overload alarm frequency index. The calculation is 0 / 10 = 0. Substituting these exponents into the formula, we get a safety redundancy coefficient of 0.88. At this point, the safety redundancy coefficient is relatively high, indicating that the equipment is in good condition and allows for more lenient torque limits.

[0070] In another specific implementation, after the equipment has been running for a period of time, the cutting tool has become severely worn, with a cumulative machining cycle of 90,000 times. The temperature of the tool feed motor winding has risen to 60°C due to prolonged high-load operation, and two overload alarms have recently occurred. At this point, the tool wear index... The calculation is 90000 / 100000 = 0.9. (Tool feed motor winding temperature index) The calculation is (60-35) / (80-35) = 25 / 45 ≈ 0.56. Overload alarm frequency index. The calculation is 2 / 10 = 0.2. Substituting these exponents into the formula, we obtain the safety redundancy coefficient. 0.035. At this point, the safety redundancy factor has decreased significantly, indicating that the equipment has a high risk and torque needs to be strictly limited to prevent further damage.

[0071] Through the above technical solution, the safety margin assessment module can provide a comprehensive, dynamic, and quantitative assessment of the equipment's safety status. This module overcomes the limitations of traditional fixed threshold or single-factor assessments by comprehensively considering multiple factors such as the degree of cutting tool wear, the temperature of the tool feed motor windings, and the frequency of historical overload alarms. When the equipment is in good condition (e.g., new cutting tool, low tool feed motor temperature, no overload history), the safety redundancy coefficient is high, allowing the torque limit adaptive control system to operate under a more relaxed torque limit. This reduces accidental shutdowns caused by normal process changes such as burr fluctuations or material differences, ensuring the continuity and efficiency of processing. Conversely, when the equipment condition deteriorates (e.g., severely worn cutting tool, high temperature of the tool feed motor, frequent overload alarms), the safety redundancy coefficient rapidly decreases, prompting the torque limit adaptive control system to tighten the torque limit in a timely manner. This effectively protects the spindle, cutting tool, and transmission system from damage, avoiding equipment failure and production interruptions, and significantly improving the equipment's operational reliability and service life. This adaptive protection mechanism achieves the goal of maximizing processing efficiency while ensuring equipment safety.

[0072] This application further proposes that the asymmetric torque limiting module is configured as follows:

[0073] Obtain the basic safe torque threshold, safety redundancy factor, and load adaptability. The basic safe torque threshold is a baseline protection value set for the tool feed motor, ensuring that the torque limit will not fall below a preset safety level under any operating condition to prevent irreversible damage to the equipment. This threshold can be set based on the rated torque of the tool feed motor, the mechanical strength of the transmission system, and empirical values ​​for machining aluminum alloy die-cast parts. For example, it can be set as a percentage of the motor's rated torque or determined through experimental testing. The safety redundancy factor and load adaptability are obtained from the steps described above.

[0074] Substituting the basic safe torque threshold, safety redundancy factor, and load adaptability into the formula Obtain the target tool feed motor torque limit value ,in, Based on the basic safe torque threshold, For safety redundancy coefficient, For load adaptability, , This is an underload directional attenuation coefficient with a value range of 0-1, specifically designed to handle underload situations. Its function is to attenuate the adjustment range of the torque limit value when the actual load is lower than the expected load, preventing excessive tightening of the torque limit due to slight underload, thereby reducing false triggering of protection. Target tool feed motor torque limit value. It is dynamically calculated based on the above parameters and is used to adjust the torque limit parameters of the tool feed motor in real time to achieve precise protection of the tool feed motor.

[0075] The solution in this application uses an asymmetric torque limiting module to limit the basic safe torque threshold. Safety redundancy coefficient Load adaptability and underload directional attenuation coefficient By combining these methods, the torque limit value of the target tool feed motor can be dynamically calculated. This module first acquires various parameters output by the dynamic benchmark generation module, multi-source load sensing module, operating condition nonlinearity correction module, load adaptability assessment module, and safety margin assessment module. Among these, the basic safety torque threshold... This serves as a benchmark for torque limiting, ensuring the basic safety of the equipment. Safety redundancy factor. and load adaptability These factors work together on the reference value to dynamically adjust the torque limit. When the safety redundancy factor... High (e.g., new cutting tools, low motor temperature, no overload history) and load adaptability At higher loads (e.g., when the actual load closely matches the expected load), the attenuation term in the formula will be smaller, resulting in a lower target torque limit. A relatively loose safety margin is adopted to maintain the continuity of processing. Conversely, when the safety redundancy factor is... Low (e.g., severe tool wear, high motor temperature, frequent overload alarms) or load mismatch At lower loads (e.g., when the actual load deviates significantly from the expected load, indicating an anomaly), the attenuation term increases, causing the target torque limit value to be lowered. Tightening ensures timely protection of the equipment. Specifically, this module introduces a directional coefficient. This achieves asymmetric adjustment of torque limit. Under real-time load... Greater than or equal to the corrected expected load When this occurs, it indicates a potential risk of overload. When the value is 1, the torque limit will be tightened normally based on safety redundancy and load adaptation. However, when the real-time load... Less than the corrected expected load When this occurs, it indicates a possible underload situation. The value is the underload directional attenuation coefficient. (A value less than 1) means that the adjustment range of the torque limit value will be attenuated in the underload direction, thereby avoiding over-tightening the protection due to slight underload and reducing accidental shutdowns. Through this asymmetric dynamic adjustment mechanism, the module can accurately balance processing continuity and equipment safety, so that the torque limit can adapt to normal process changes such as burr thickness fluctuations and material differences during the deburring of aluminum alloy die-cast parts, and can also tighten the protection in time under abnormal working conditions such as tool wear, clamping loosening, or abnormal impact, to prevent equipment damage.

[0076] In one specific implementation, the asymmetric torque limiting module can be implemented by an embedded controller or industrial PC, which receives output data from a safety margin assessment module, a load fit assessment module, a multi-source load sensing module, and a nonlinearity correction module. For example, a basic safety torque threshold. It can be preset to 80% of the rated torque of the tool feed motor and fine-tuned through equipment debugging. Underload directional attenuation coefficient. The setting can be based on the cutting characteristics of aluminum alloy materials and empirical values ​​for the deburring process; for example, setting it to 0.6 allows for a certain degree of underload fluctuation. When the controller receives the safety redundancy factor... A value of 0.8 (indicating good equipment condition) indicates a load adaptability score. A value of 0.95 (indicating high load matching) and real-time load Slightly higher than the revised expected load When, direction coefficient Taking 1, the calculated target torque limit value This will be relatively lenient, allowing the equipment to continue operating stably. Conversely, if the safety redundancy factor is... A drop to 0.3 (indicating severe tool wear) indicates a decrease in load adaptability. A drop to 0.2 (indicating a significant discrepancy between actual and expected load, potentially indicating an abnormal surge), and the real-time load... Much higher than the revised expected load Then the direction coefficient Still take 1, but because and The value is low, and the calculated target torque limit value This will tighten significantly, thus triggering the protection mechanism promptly. If the real-time load... Much lower than the revised expected load (For example, tool breakage leading to air cutting), then the direction coefficient Taking 0.6 will tighten the torque limit, but because The tightening effect is less than that under overload conditions, thus avoiding an overreaction to slight underload.

[0077] Through the above technical solution, this application enables dynamic and asymmetric adjustment of the torque limit value of the tool feed motor. This allows the equipment to maintain processing continuity when facing normal process changes such as cutting load fluctuations and workpiece differences commonly encountered during the deburring of aluminum alloy die-cast parts, avoiding production interruptions due to accidental protection triggering. Simultaneously, in abnormal operating conditions requiring protection, such as accelerated tool wear, loose clamping, or abnormal impacts, the system can promptly tighten the torque limit, effectively protecting the spindle, tool, and transmission system, significantly reducing the risk of equipment damage. This refined torque limiting strategy greatly improves the processing efficiency and operational reliability of the deburring equipment for aluminum alloy die-cast parts.

[0078] like Figure 1 As shown, in a preferred embodiment of the present invention, the pressure plate lifting assembly includes a guide rail 6 vertically fixed on the frame 1, a slider 7 slidably connected on the guide rail 6, a mounting frame 8 fixed on the slider 7, the pressing plate 3 being rotatably connected to the mounting frame 8, and a cylinder 11 fixedly provided on the top of the frame 1, the telescopic end of the cylinder 11 being connected to the mounting frame 8.

[0079] In this embodiment of the invention, the vertically fixed guide rail 6 on the frame 1 is a device for guiding mechanical components to move along a specific path. Its installation direction is perpendicular to the horizontal plane and it is firmly connected to the frame 1. The guide rail 6 can be a linear guide rail, such as a ball linear guide rail, roller linear guide rail, or sliding linear guide rail. It can be fixed by bolting, welding, or riveting to firmly install the guide rail body onto the corresponding structural surface of the frame 1. The main function of the guide rail 6 is to provide precise vertical guidance for the lifting and lowering movement of the pressing plate 3, ensuring the straightness and consistency of its movement trajectory, thereby ensuring that the clamping force can be applied evenly and stably to the workpiece, avoiding uneven clamping caused by lateral or tilting offsets. The slider 7, slidably connected to the guide rail 6, is a moving component that works in conjunction with the guide rail 6, moving on the guide rail 6 by sliding or rolling. The slider 7 can form a sliding pair with the guide rail 6, for example, using a sliding bearing or bushing made of polymer material, or using rolling elements such as ball bearings or roller bearings to cooperate with the guide rail to form a rolling pair. The slider 7 functions to achieve smooth lifting and lowering of the pressing plate 3, effectively reducing frictional resistance during movement and preventing jamming and impact, thus ensuring the smoothness and reliability of the clamping action. The mounting bracket 8 fixed to the slider 7 is a structural component used to support and connect other parts. It is firmly fixed to the slider 7 and moves with it. The mounting bracket 8 can be a metal plate, support, or box structure, securely connected to the slider 7 by bolts, pins, or welding. As an intermediate connector between the pressing plate 3 and the slider 7, the mounting bracket 8 provides a stable support platform, significantly enhancing the structural rigidity of the entire pressing plate lifting assembly and effectively preventing deformation or shaking due to force when clamping the workpiece. The pressing plate 3 is rotatably connected to the mounting bracket 8. The pressing plate 3 is the component that directly contacts the workpiece and applies clamping force. Rotational connection means that the pressing plate 3 can rotate or swing relative to the mounting bracket 8 within a certain range. Rotational connection can be achieved through ball joints, universal joints, bolt connections with elastic washers, or bearing connections, allowing the pressing plate 3 to make small-angle adaptive adjustments when contacting the workpiece. This rotating connection allows the pressing plate 3 to be finely adjusted according to the unevenness or burr thickness of the workpiece surface when in contact with it, ensuring a uniform distribution of clamping force and avoiding local over-pressure or under-pressure. The pressing plate 3 can be moved up and down by the extension and retraction of the cylinder 11.

[0080] like Figure 1 As shown, in a preferred embodiment of the present invention, the cutting tool feed assembly includes a linear module 9 fixed on the frame 1, the linear module 9 is controlled by a servo motor 10, and the cutting tool 5 is mounted on the linear module 9 by a bracket.

[0081] In this embodiment of the invention, the linear module 9 is a mechanical device that provides precise linear motion. Its core function is to convert rotary motion into linear motion, ensuring smoothness and positioning accuracy. The linear module 9 can be fixed to the frame 1 to provide stable support and rigidity, reducing vibration and deformation that may occur during cutting. Common types of linear modules include ball screw modules, synchronous belt modules, or linear motor modules. Ball screw modules convert rotary motion into linear motion through ball screw pairs, featuring high precision, high rigidity, and strong load-bearing capacity. Synchronous belt modules achieve linear motion through synchronous belts and pulleys, offering advantages such as high speed, long stroke, and relatively low cost. Linear motor modules directly achieve linear motion through electromagnetic force, offering advantages such as fast response speed, high positioning accuracy, and no mechanical wear. The servo motor 10 is a motor capable of precisely controlling speed, position, and torque, typically used in conjunction with an encoder to form a closed-loop control system. By controlling the linear module 9 through the servo motor 10, precise control and rapid response of the cutting tool 5's feed motion can be achieved. The servo motor 10 can adjust its speed and torque in real time according to control commands, thereby precisely controlling the moving speed and position of the linear module 9. Besides the servo motor, a stepper motor or DC motor can also be used for control. Stepper motors control the step angle through pulse signals to achieve open-loop or closed-loop position control, suitable for applications with high precision requirements but relatively low speed and dynamic response requirements; DC motors control speed by changing voltage or current, but usually require additional feedback mechanisms to achieve precise position control. However, the servo motor 10 has significant advantages in such applications due to its high precision, high response speed, and good dynamic performance. The bracket is a connecting component used to securely fix the cutting tool 5 to the linear module 9. The bracket design should ensure that the cutting tool 5 remains stable during high-speed cutting and under cutting forces, avoiding loosening or vibration, thereby ensuring machining accuracy and tool life. The bracket can adopt various structural forms; for example, it can be designed as an integrated structure, directly connected to the slider of the linear module 9; or it can be a split structure, where the cutting tool 5 is fixed to the bracket by bolts, clamps, or dovetail joints, and then the bracket is installed on the linear module 9. In addition, the choice of materials for the support is also crucial. High-strength, high-rigidity materials, such as alloy steel or aluminum alloy, are usually selected to withstand cutting loads and suppress vibration.

[0082] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A deburring device for aluminum alloy die-cast parts, comprising a frame and a cutting tool, and a rotary table rotatably connected to the frame, wherein a pressing plate is disposed above the rotary table, characterized in that, Also includes: The pressure plate lifting assembly is mounted on the frame and is used to move the pressure plate downwards and, in conjunction with the rotary table, fix the workpiece. A rotary motor, fixed to the bottom of the frame, is used to drive the rotary table to rotate around its axis; The cutting tool feed assembly, mounted on the frame, is used to drive the cutting tool to feed. Torque limiting adaptive control system, the torque limiting adaptive control system includes: The dynamic reference generation module is configured to determine the expected torque reference based on the cutting tool feed rate, the rotary table motor speed, and the depth of cut. The multi-source load sensing module is configured to obtain real-time load feedback based on the tool feed motor torque and the tool feed motor driver current. The nonlinear correction module is configured to determine the correction coefficient based on the pressing pressure of the pressing plate and the workpiece burr thickness. The load fit assessment module is configured to determine the load fit based on the operating condition correction factor, the expected torque benchmark, and the real-time load feedback through the load fit model. The safety margin assessment module is configured to determine the safety redundancy coefficient based on the cumulative number of cutting operations, the temperature of the tool feed motor winding, and the frequency of historical overload alarms. The asymmetric torque limiting module is configured to dynamically calculate the target tool feed motor torque limit value based on the basic safe torque threshold, safety redundancy coefficient, and load adaptability, and adjust the tool feed motor torque limit parameters in real time.

2. The deburring equipment for aluminum alloy die-cast parts according to claim 1, characterized in that, The dynamic benchmark generation module is configured as follows: Obtain the cutting tool feed rate, rotary table motor speed, and depth of cut; The ratio of the cutting tool feed rate to the rotary table motor speed is processed to obtain the feed per revolution; The feed per revolution and depth of cut are compared with the rated feed per revolution and rated depth of cut, respectively, to obtain the feed rate index and depth of cut index. Substitute the feed rate index and depth of cut index into the formula. Obtain the expected torque benchmark ,in, The feed rate index. This is the turning depth index.

3. The deburring equipment for aluminum alloy die-cast parts according to claim 1, characterized in that, The multi-source load sensing module is configured as follows: Obtain the tool feed motor torque and the tool feed motor driver current; The ratios of the tool feed motor torque and the tool feed motor driver current to the motor rated torque and the driver rated current are respectively processed to obtain the motor torque index and the driver current index. Substitute the motor torque index and the driver current index into the formula. Get real-time load feedback ,in, This refers to the motor torque index. For the driver current index, Torque weighting.

4. The deburring equipment for aluminum alloy die-cast parts according to claim 1, characterized in that, The nonlinear correction module for the operating condition is configured as follows: Obtain the pressing pressure of the pressing plate and the burr thickness of the workpiece; The pressing pressure of the pressing plate and the workpiece burr thickness are respectively compared with the rated pressing pressure and the rated workpiece burr thickness. After limiting the upper limit of the ratio to 1, the workpiece pressing index and the workpiece burr thickness index are obtained. Substitute the workpiece compression index and the workpiece burr thickness index into the formula. Obtain the working condition correction coefficient ,in, To press the pressure plate, The thickness of the workpiece burr.

5. The deburring equipment for aluminum alloy die-cast parts according to claim 1, characterized in that, The load adaptability assessment module is configured as follows: Obtain operating condition correction factors, expected torque reference, and real-time load feedback; Substitute the operating condition correction factor, the expected torque reference, and the real-time load feedback into the formula. Get load adaptability ,in, Based on the expected torque, For real-time load feedback, The correction factor is used for the condition.

6. The deburring equipment for aluminum alloy die-cast parts according to claim 1, characterized in that, The safety margin assessment module is configured as follows: Acquire the cumulative number of machining operations by the cutting tool, the temperature of the tool feed motor winding, and the historical overload alarm frequency; The cumulative number of cutting operations and the historical overload alarm frequency are compared with the rated number of cutting operations and the maximum allowable alarm frequency, respectively. After limiting the upper limit of the ratio to 1, the tool wear index and the overload alarm frequency index are obtained. The difference between the temperature of the tool feed motor winding and the normal operating temperature of the motor is processed into the ratio of the difference between the maximum allowable temperature of the motor and the normal operating temperature of the motor, and the upper limit of the ratio is limited to 1 to obtain the temperature index of the tool feed motor winding. Substituting the tool wear index, the tool feed motor winding temperature index, and the overload alarm frequency index into the formula Obtain the safety redundancy coefficient ,in, This is the tool wear index. This refers to the temperature index of the tool feed motor windings. This is the overload alarm frequency index.

7. The deburring equipment for aluminum alloy die-cast parts according to claim 5, characterized in that, The asymmetric torque limiting module is configured as follows: Obtain the basic safe torque threshold, safety redundancy coefficient, and load adaptability; Substituting the basic safe torque threshold, safety redundancy factor, and load adaptability into the formula Obtain the target tool feed motor torque limit value ,in, Based on the basic safe torque threshold, For safety redundancy coefficient, For load adaptability, , The underload directional attenuation coefficient has a value range of 0-1.

8. The deburring equipment for aluminum alloy die-cast parts according to claim 1, characterized in that, The pressure plate lifting assembly includes a vertically fixed guide rail on the frame, a slider slidably connected to the guide rail, a mounting frame fixed to the slider, a pressure plate rotatably connected to the mounting frame, and a cylinder fixed to the top of the frame, with the telescopic end of the cylinder connected to the mounting frame.

9. The deburring equipment for aluminum alloy die-cast parts according to claim 1, characterized in that, The cutting tool feed assembly includes a linear module fixed on the frame, the linear module is controlled by a servo motor, and the cutting tool is mounted on the linear module via a bracket.

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