Integrated automatic centering device for track beam drilling and intelligent leveling method of integrated automatic centering device

Abstract

The invention discloses an integrated automatic centering device for track beam drilling and an intelligent leveling method of the integrated automatic centering device, and particularly relates to the technical field of engineering machinery track beam machining. The integrated automatic centering device comprises an adjustable machine tool and a first movable supporting base; a variable supporting base is placed below the alignment punching mechanism, the two ends of the variable supporting base are slidably connected with a first movable supporting base and a second movable supporting base correspondingly, and a three-area supporting layout is constructed through the variable supporting base and the first movable supporting base and the second movable supporting base at the two ends. The device is adaptive to long and short track beams, solves the problem that the two ends of the long beam are suspended and are not supported, and provides a basic framework for automatic alignment and leveling. The root problems of deflection deformation caused by suspension of the long beam without a support and precision failure after leveling can be eliminated; special tools do not need to be designed and manufactured for track beams with different lengths and different section special shapes.

Description

Integrated automatic centering device and intelligent leveling method for drilling tracks Technical Field

[0001] This application relates to the field of engineering machinery track beam processing technology, and more specifically, this application relates to an integrated automatic centering device for drilling track beams and its intelligent leveling method. Background Technology

[0002] Track beams are core load-bearing and moving components of heavy construction machinery such as excavators and bulldozers. They are large, irregularly shaped welded structural parts, characterized by large spans, irregular cross-sectional shapes, uncontrollable welding deformation, and high drilling precision requirements. In the drilling process of track beams, the workpiece's positioning support, posture leveling, and anti-vibration locking directly determine the drilling accuracy, hole diameter tolerance, and hole wall quality. Existing publication number CN112325111B discloses an assembled automatic leveling device and leveling method, including a guide rail section, a CNC leveling section, a load-bearing platform section, and a pneumatic support section. The guide rail section is located on top of the load-bearing platform section; the CNC leveling section is located on the side of the load-bearing platform section; the pneumatic support section is located on the bottom surface of the load-bearing platform section and is electrically connected to the CNC leveling section. Under the control of the CNC leveling section, the support length of the pneumatic support section is adjusted to achieve horizontal adjustment of the load-bearing platform section. In the process of developing this application, the inventors discovered the following problems with the existing technology: In the existing technology, the drilling and processing of track beams mostly uses special fixed fixtures for positioning and support. Such fixtures can only be adapted to a single specification of track beam. When changing production, the fixtures need to be redesigned and manufactured. At the same time, due to the influence of welding deformation, the bottom surface of track beams is mostly an irregular shape. Traditional fixed fixtures cannot achieve full-fit conformal support, which easily leads to false support. During the drilling process, the workpiece is prone to cutting vibration, causing problems such as hole position displacement, hole diameter deviation, and non-compliance of hole wall roughness. Furthermore, the existing adjustable multi-point support fixtures are mostly single-point independent adjustments, which cannot achieve multi-area collaborative closed-loop leveling. They rely on the operator's manual dial gauge and experience operation, and cannot achieve automated and intelligent full-area attitude correction. Moreover, the existing support mechanisms are mostly mechanical or hydraulic structures. After adjustment, the locking rigidity is insufficient, the shock resistance is poor, and the hydraulic structure also has the problems of medium leakage and high maintenance costs, making it difficult to adapt to long-term continuous processing conditions.

[0003] Therefore, an integrated automatic centering device for drilling track beams and its intelligent leveling method are proposed to address the above problems. Summary of the Invention

[0004] In order to overcome the above-mentioned defects of the prior art, this application provides an integrated automatic centering device for drilling track beams and its intelligent leveling method to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, this application provides the following technical solution: an integrated automatic alignment centering device for drilling tracks, comprising an adjustable machine tool and a first movable support base. The adjustable machine tool includes an alignment and drilling mechanism, below which is a variable support base. The first movable support base and a second movable support base are slidably connected to both ends of the variable support base, respectively. A three-zone support layout is constructed through the variable support base and the first and second movable support bases at both ends, adapting to tracks of varying lengths and solving the problem of unsupported ends on long tracks. The first mobile support base includes a sliding base, a placement bracket, and a variable fixing component. The placement bracket is fixedly connected to the top of the sliding base, and the variable fixing component is fixedly connected to the top of the placement bracket. The sliding base is the core component of the first mobile support base. The sliding base enables the sliding adjustment of the work position to adapt to different beam lengths. The placement bracket provides stable load-bearing for the support structure. The variable fixing component is the core functional unit, which realizes the conformal fitting support for the suspended section of the track beam. It symmetrically cooperates with the second mobile support base to complete the end-to-end supplementary support.

[0006] Preferably, the conformal fixing assembly includes a barrier box, a rigid skeleton support rod, a sealing partition plate, and a magnetorheological fluid placement box. The barrier box provides arrangement protection and limitation for multiple sets of support rods. The rigid skeleton support rods are arranged at equal intervals inside the barrier box, and the equally spaced rigid skeleton support rods are multi-point support execution units. The bottom of the rigid skeleton support rods is fixedly connected to the sealing partition plate, which achieves sealed isolation between the upper and lower structures. The bottom of the sealing partition plate is sealed and connected to the magnetorheological fluid placement box, which provides a sealed containment space for the magnetorheological fluid and is the core carrier of conformal locking.

[0007] Preferably, the magnetorheological fluid placement tank has a reserved placement cavity inside, which provides a sealed flow containment space for the magnetorheological fluid. The sealing partition plate is located in the placement cavity of the magnetorheological fluid placement tank and a composite isolation membrane is placed therein. The tubular composite isolation membrane with one end sealed is located at the center of the four sets of support rods. When compressed, it can accommodate the expansion of the flowing magnetorheological fluid and fill the irregular gap between the bottom surface of the track beam and the support rods, achieving full fit and conformal support. The composite isolation membrane is tubular and sealed at one end, and the composite isolation membrane is located at the center of the four sets of rigid skeleton support rods.

[0008] Preferably, the magnetorheological fluid is placed in the placement cavity of the magnetorheological fluid placement box. The placement cavity is filled with magnetorheological fluid and sealed by a partition plate. There is no air in the placement cavity. The air-free, fully filled magnetorheological fluid ensures that there is no compressibility margin when under pressure, realizing pressure transmission and flow filling. The sealed structure prevents medium leakage. The base of the magnetorheological fluid placement box is fixedly connected to an electromagnetic actuator. The electromagnetic actuator provides an external main magnetic field to the magnetorheological fluid, realizing rapid and reversible liquid-solid conversion and completing the rigid locking of the support structure.

[0009] Preferably, the rigid frame support rod includes a tube, an extrusion head, a lifting adjustment column, a limiting column, a limiting ring, and an extrusion magnetic actuator. The tube and the lifting adjustment column are the main load-bearing components. The extrusion head is fixedly connected to the top of the tube and directly contacts the bottom surface of the workpiece. The lifting adjustment column is connected to the bottom of the tube. Limiting columns are fixedly connected to the four sides of the tube. The limiting columns and the limiting ring ensure the straightness of the lifting and avoiding radial deviation. The limiting ring is connected through the column of the limiting column. The extrusion magnetic actuator is fixedly connected to the bottom of the lifting adjustment column, and the extrusion magnetic actuator provides a carrier for the auxiliary magnetic field. The rigid frame support rod also includes an extrusion cavity tube, an electric push rod, and a connecting column. The electric push rod is fixedly connected to the bottom of the extrusion cavity tube. The electric push rod drives the support rod to achieve lifting and lowering, providing an execution unit for intelligent leveling. The pushing end of the electric push rod is fixedly connected to the connecting column.

[0010] Preferably, the extrusion magnetic actuator includes a docking ring, a magnetic coil, and an extrusion box. The docking ring docks with the lifting adjustment column. The magnetic coil is placed at the bottom of the docking ring, and the extrusion box is placed at the bottom of the magnetic coil. The sealed extrusion box provides protection and sealing space for the magnetic coil, preventing the magnetorheological fluid from seeping in and damaging the coil. After the magnetic coil is energized, it generates an auxiliary superimposed magnetic field, which works with the main actuator to enhance the curing effect and improve the locking rigidity. The extrusion box and the docking ring are sealed together.

[0011] Preferably, the variable support base includes a lifting placement seat and a support frame assembly group. The lifting placement seat can realize the benchmark adjustment of the main support height to adapt to track beams with different cross-sectional heights. The support frame assembly group is placed inside the lifting placement seat. The internal support frame assembly group has the same structural design as the variable fixing assembly, realizing multi-point conformal support of the main load-bearing section of the track beam. It cooperates with the support bases at both ends to form a full-area support system. The support frame assembly group and the variable fixing assembly have the same structure.

[0012] Preferably, the sliding base includes a docking base plate, slide rails, and clamping limiters. The docking base plate provides a mounting foundation for the upper structure. The bottom slide rails cooperate with the limiting grooves of the sliding base plate to ensure the straightness and smoothness of the sliding adjustment of the support base. Slide rails are fixedly connected to both sides of the bottom end of the docking base plate. Clamping limiters are fixedly connected between the two sets of slide rails. Three sets of clamping limiters are provided. The three sets of clamping limiters can clamp the locking strip to achieve reliable locking after the work position is adjusted, and prevent the work position from shifting during processing.

[0013] Preferably, the alignment and drilling mechanism includes a lifting bracket, a mounting bracket is fixedly connected to the top of the lifting bracket, and a drilling machine body is slidably connected to one side of the mounting bracket; the bottom of the variable support base, the first movable support base and the second movable support base are provided with sliding base plates, and the sliding base plate is provided with a limit groove at one end of the clamping limiter, and a locking strip is provided inside the limit groove.

[0014] Preferably, the integrated intelligent leveling method for drilling track beams is characterized by the following steps: Step 1: According to the length specifications of the track beam to be processed, adjust the relative positions of the first movable support base and the second movable support base on the sliding base plate, so that the variable support base corresponds to supporting the main body section of the track beam, and the first movable support base and the second movable support base respectively correspond to supporting the suspended sections at both ends of the track beam, thus completing the pre-positioning of the support station; Step 2: Hoist the track beam to be processed onto the pre-positioned variable support base and the first movable support base. Above the seat and the second movable support base, the track beam, under the action of gravity, presses down on the rigid skeleton support rods in the conformal fixing components at each support position. The compressed rigid skeleton support rods drive the compression magnetic actuator downwards into the placement cavity of the magnetorheological fluid placement box, compressing the magnetorheological fluid in the placement cavity, causing the magnetorheological fluid to flow into the composite isolation membrane, filling the fitting gap between the bottom surface of the track beam and each rigid skeleton support rod, completing the initial conformal fitting support of the track beam; Step 3: Obtain the spatial coordinates and reference attitude data of the track beam surface to be processed through the alignment and drilling mechanism, and calculate the track beam surface to be processed. The perpendicularity deviation with the drill bit axis of the drilling machine body is addressed by adjusting the lifting height of the corresponding rigid frame support rods in each support station based on the deviation data. Through multi-zone coordinated height adjustment, the attitude deviation of the track beam is corrected, ensuring that the surface of the track beam to be processed is perpendicular to the drill bit axis of the drilling machine body, thus completing the full-area intelligent leveling. Step 4: After leveling, the electromagnetic actuator of the magnetorheological fluid placement box and the extrusion magnetic actuator corresponding to each rigid frame support rod are simultaneously activated to apply a magnetic field of preset intensity to the magnetorheological fluid in the placement cavity, causing the magnetorheological fluid to instantly change from a liquid to a solid state, completing the rigid frame support. The position locking of the strut and the conformal rigid wrapping limit of the bottom surface of the track beam form a full-area rigid support system; Step 5: Start the drilling machine body of the alignment and drilling mechanism, and perform drilling operations on the track beam according to the preset processing program. During the entire drilling process, the magnetic field is continuously loaded to maintain the solidified and locked state of the magnetorheological fluid and suppress the track beam attitude deviation caused by drilling vibration; Step 6: After the drilling operation is completed, disconnect the power supply of the electromagnetic actuator and the extrusion magnetic actuator. The magnetic field disappears, the magnetorheological fluid returns to the liquid state, the rigid frame support rod is reset and unlocked, and the processed track beam is hoisted and removed to complete a single processing cycle.

[0015] The technical effects and advantages of this application are as follows: 1. Compared with the prior art, the integrated automatic centering device and intelligent leveling method for drilling track beams, this invention constructs a three-zone support structure through a variable support base and a first movable support base and a second movable support base that can be slidably adjusted according to the length specifications of the track beam to be processed. It can not only adapt to the centralized and stable support of short track beams, but also provide supplementary support for the suspended sections at both ends of long track beams. It can eliminate the root cause problems of bending deformation and accuracy failure after leveling caused by the unsupported suspension of long beams; there is no need to design and manufacture special tooling for track beams of different lengths and cross-sectional shapes.

[0016] 2. Compared with existing technologies, this integrated automatic centering device and intelligent leveling method for drilling track beams utilizes the millisecond-level reversible solid-liquid conversion characteristics of magnetorheological fluid to achieve a flexible conformal fit while simultaneously enabling seamless connection for rigid solidification and locking: During the leveling phase, the magnetorheological fluid remains liquid, completely avoiding interference with the height adjustment of the support rods and ensuring leveling flexibility; after leveling, the magnetorheological fluid instantly transforms from liquid to solid by synchronously loading dual magnetic fields through an electromagnetic actuator and a compression magnetic actuator, achieving absolute locking of the positions of all rigid frame support rods and preventing height rebound. Furthermore, a composite isolation membrane forms a wrap-around rigid support that perfectly matches the irregularly shaped welded bottom surface of the track beam, replacing traditional point-contact support. Compared to traditional point-contact support, the effective support contact area is significantly increased, significantly improving support rigidity and seismic resistance. Attached Figure Description

[0017] Figure 1 is a schematic diagram of the overall structure of this application; Figure 2 is a schematic diagram of the adjustable machine tool of this application; Figure 3 is a schematic diagram of the sliding base plate of this application; Figure 4 is a schematic diagram of the first movable support base of this application; Figure 5 is a schematic diagram of the variable fixing component of this application; Figure 6 is a front view of the first movable support base of this application; Figure 7 is a schematic diagram of the sealing partition plate of this application; Figure 8 is a schematic diagram of the sliding base of this application; Figure 9 is a cross-sectional view of the first movable support base of this application; Figure 10 is a schematic diagram of the rigid skeleton support rod of this application; Figure 11 is a cross-sectional view of the rigid skeleton support rod of this application; Figure 12 is a schematic diagram of the unfolded structure of the extrusion magnetic actuator of this application.

[0018] The attached figures are labeled as follows: 1. Adjustable machine tool; 2. Alignment and drilling mechanism; 3. Variable support base; 4. First movable support base; 5. Second movable support base; 6. Lifting bracket; 7. Mounting bracket; 8. Drilling machine body; 9. Sliding base plate; 10. Limiting groove; 11. Locking strip; 12. Sliding base; 13. Placement bracket; 14. Variable fixing component; 15. Lifting placement seat; 16. Support frame assembly group; 17. Barrier box; 18. Rigid frame support rod; 19. 20. Sealed partition plate; 21. Magnetorheological fluid placement box; 22. Placement cavity; 23. Composite isolation membrane; 24. Magnetorheological fluid; 25. Electromagnetic actuator; 26. Docking base plate; 27. Slide rail; 28. Clamping limiter; 29. ​​Tube body; 30. Extrusion head; 31. Lifting adjustment column; 32. Limiting column; 33. Limiting ring; 34. Extrusion magnetic actuator; 35. Extrusion cavity tube; 36. Electric push rod; 37. Connecting column; 38. Docking ring; 39. Magnetic coil; 30. Extrusion box. Detailed Implementation

[0019] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0020] Example 1: An integrated automatic alignment centering device for drilling tracks, as shown in Figures 1 to 12. This integrated automatic alignment centering device for drilling tracks includes an adjustable machine tool 1 and a first movable support base 4. The adjustable machine tool 1 includes an alignment and drilling mechanism 2. A variable support base 3 is placed below the alignment and drilling mechanism 2. The first movable support base 4 and a second movable support base 5 are slidably connected to both ends of the variable support base 3, respectively. The first movable support base 4 includes a sliding base 12, a placement bracket 13, and a variable fixing assembly 14. The placement bracket 13 is fixedly connected above the sliding base 12, and a fixed component is fixedly connected to the top of the placement bracket 13. After the operator inputs the length and cross-sectional parameters of the track beam to be processed into the human-machine interface of the central controller, the central controller pre-generates the three-zone support station layout parameters: the variable support base 3 serves as the main support area, corresponding to the main load-bearing section of the track beam; the first movable support base 4 and the second movable support base 5 serve as the end-end supplementary support areas, respectively corresponding to the suspended sections at both ends of the track beam, completely eliminating unsupported suspended areas and adapting to both long and short track beams; the central controller issues an unlocking command to the clamping limiters 27 of the first movable support base 4 and the second movable support base 5, and the clamping limiters 27 release from the locking bar. The clamping engagement of 11 releases the sliding lock of the two movable support bases. As shown in Figure 1, the central controller is located on the outside of the machine tool in Figure 1. The central controller drives the two movable support bases to slide along the limiting groove 10 of the sliding base plate 9. During the sliding process, the slide rail 26 at the bottom of the mating base plate 25 slides with the limiting groove 10 to ensure the straightness of the sliding process and avoid position deviation. During the sliding process, the grating ruler displacement sensor on the sliding base plate 9 collects the sliding displacement and relative distance data of the two movable support bases in real time through the reading head fixed at the bottom of the sliding base 12, and synchronously feeds it back to the central controller. When the relative distance reaches the preset target value, The central controller immediately issues a stop command to complete the coarse positioning of the support station; the central controller issues a locking command to the clamping limiter 27, the clamping end of the clamping limiter 27 clamps the locking strip 11, and completes the position locking of the two movable support bases; during the locking process, the clamping force pressure sensor inside the clamping limiter 27 collects the clamping force data in real time and feeds it back to the central controller synchronously. When the clamping force reaches the preset safety locking threshold, the central controller confirms that the locking is completed, so as to avoid the base sliding during the drilling process and causing loss of leveling accuracy; the travel limit sensors at both ends of the limit groove 10 monitor the sliding travel throughout the process to prevent the support base from sliding beyond the travel and causing equipment collision;The lifting and lowering placement seat 15 of the variable support base 3 is adjusted to the preset reference support height. Simultaneously, the dual-axis tilt sensors on the top surfaces of the variable support base 3, the first movable support base 4, and the second movable support base 5 collect the reference levelness data of each support station in real time and upload it synchronously to the central controller as the relative reference for subsequent leveling calculations. This completes the station reservation for the leveling pre-leveling step.

[0021] Example 2 further elaborates on the scheme in Example 1 based on Example 1, and combines the following specific working method, as shown in Figures 1 to 12, and details are described below: As a preferred embodiment, the variable fixing component 14 includes a barrier box 17, a rigid skeleton support rod 18, a sealing partition plate 19, and a magnetorheological fluid placement box 20. The rigid skeleton support rod 18 is arranged equidistantly inside the barrier box 17. The bottom of the rigid skeleton support rod 18 is fixedly connected to the sealing partition plate 19, and the bottom of the sealing partition plate 19 is sealed to the magnetorheological fluid placement box 20.

[0022] In a preferred embodiment, the magnetorheological liquid placement box 20 has a reserved placement cavity 21 inside. A temperature sensor is fixedly installed on the inner wall of the placement cavity 21 of the magnetorheological liquid placement box 20 to detect the working temperature of the magnetorheological liquid 23 in real time, so as to avoid the temperature change affecting the curing performance of the magnetorheological liquid. A sealing partition plate 19 is located in the placement cavity 21 of the magnetorheological liquid placement box 20, and a composite isolation membrane 22 is placed therein. The composite isolation membrane 22 is tubular and sealed at one end. The composite isolation membrane 22 is located at the center of the four sets of rigid skeleton support rods 18.

[0023] The track beam to be processed is lowered to the three pre-positioned support bases using hoisting equipment. Under its own weight, the track beam presses down on the rigid skeleton support rods 18 within the variable fixing components 14 of each support position. The pressed-down rigid skeleton support rods 18 drive the extrusion magnetic actuators 33 at their bottom ends to descend and enter the placement chamber 21 of the magnetorheological fluid placement box 20. The magnetorheological fluid 23 in the extrusion placement chamber 21 is in liquid state. The extruded magnetorheological fluid 23 flows and fills the composite isolation membrane 22 at the center of the four sets of rigid skeleton support rods 18, forming a composite membrane. The isolation membrane 22 expands under hydraulic pressure, completely filling the irregular gap between the bottom surface of the track beam and the extrusion heads 29 of each rigid frame support rod 18, achieving initial conformal fit with the irregularly shaped welded bottom surface of the track beam. During the fitting process, the pull rod-type linear displacement sensor between the limiting ring 32 of each rigid frame support rod 18 and the tube body 28 collects the downward stroke data of the support rod in real time and feeds it back to the central controller synchronously. At the same time, the thin film-type contact pressure sensor embedded on the upper end face of the extrusion head 29 of each rigid frame support rod 18 collects the pressure data of the support rod in real time. The contact pressure data between the track beam and the bottom surface is simultaneously uploaded to the central controller. Based on the dual-dimensional data of displacement and pressure, the central controller completes the pre-adjustment and fit determination: when the contact pressure of a certain support rod is detected to be 0 and the downward stroke does not change, it is determined that the point is a false support. The central controller immediately sends an upward command to the electric push rod 35 corresponding to the support rod. The electric push rod 35 pushes the connecting column 36 and the lifting adjustment column 30 upward, driving the tube body 28 and the extrusion head 29 to rise until the contact pressure sensor detects the preset fit pressure, thus eliminating the false support. When the contact pressure of all support rods reaches the preset fitting threshold and the displacement data is stable without sudden changes, the central controller determines that the initial conformal fitting and pre-leveling are completed. All support points are completely in contact with the bottom surface of the track beam, with no suspension or false support. During this process, the electromagnetic actuator 24 and the magnetic coil 38 are kept in a de-energized state, and the magnetorheological fluid 23 remains liquid. The magnetic actuator 33 can move freely up and down in the placement cavity 21 when squeezed, and the magnetorheological fluid 23 can flow freely in the placement cavity 21 without interfering with the lifting and lowering adjustment of the rigid frame support rod 18.

[0024] In a preferred embodiment, the magnetorheological fluid 23 is placed in the placement cavity 21 of the magnetorheological fluid placement box 20. The placement cavity 21 is filled with the magnetorheological fluid 23 and sealed by a partition plate, so there is no air inside the placement cavity 21. An electromagnetic actuator 24 is fixedly connected to the base of the magnetorheological fluid placement box 20. Magnetic flux sensors are fixedly installed on the side of the electromagnetic actuator 24 and on each rigid frame support rod 18 of the magnetorheological fluid placement box 20 to detect the magnetic field strength applied to the magnetorheological fluid 23 in real time, realize closed-loop control of the magnetic field strength, and ensure stable locking rigidity. A dual-axis tilt sensor of the main spindle fixed on the spindle box of the drilling machine body 8 collects the verticality data of the drill spindle axis in real time and uploads it to... The central controller, serving as the absolute reference for this leveling process, eliminates the impact of machine tool installation errors and spindle offset on leveling accuracy. Position encoders on the XYZ axis feed mechanism of the drilling machine body 8 collect the spatial coordinates of the spindle in real time and synchronously feed them back to the central controller. This provides machine tool coordinate system calibration for the scanning points of the 3D laser contour sensor, ensuring each scanning point corresponds to a unique spatial coordinate. The central controller drives the drilling machine body 8 to move the 3D laser contour sensor, performing a continuous full-segment scan along the surface to be machined on the track beam. This acquires the 3D spatial coordinates, contour data, flatness data, and hole position reference data of all points on the surface to be machined, establishing a global 3D attitude model of the track beam surface to be machined. The central controller then converts the acquired workpiece 3D attitude model... The model uses data fusion calculations based on the absolute reference for perpendicularity of the main shaft and the relative reference for the horizontality of the support surfaces of each support station to calculate the pitch deviation, yaw deviation, and flatness deviation between the track beam to be processed surface and the drill bit axis. Simultaneously, it identifies the flexural deformation in the middle and the warping deformation at both ends of the long track beam, providing accurate data for generating leveling strategies. As a preferred implementation, the rigid frame support rod 18 includes a tube body 28, an extrusion head 29, a lifting adjustment column 30, a limiting column 31, a limiting ring 32, and an extrusion magnetic actuator 33. The extrusion head 29 is fixedly connected to the top of the tube body 28. Thin-film contact pressure sensors are embedded in the upper surface of the extrusion head 29 of the rigid frame support rod 18 to detect the contact pressure between the support rod and the bottom surface of the track beam in real time. The force is used to determine whether the fit is complete and whether there is any false support. At the same time, it monitors the pressure fluctuation caused by cutting vibration during the processing to achieve uniform control of support force and vibration monitoring. The bottom end of the tube body 28 is connected to the lifting adjustment column 30. The four sides of the tube body 28 are fixedly connected to the limit column 31. The column body of the limit column 31 is connected to the limit ring 32. The limit ring 32 of the rigid frame support rod 18 and the tube body 28 are both fixedly installed with a pull rod type linear displacement sensor. The measuring rod is fixedly connected to the bottom end of the tube body 28, and the shell is fixedly connected to the limit ring 32. It is used to detect the lifting stroke and current height position of the corresponding rigid frame support rod 18 in real time, and provide height closed-loop feedback for intelligent leveling. The bottom end of the lifting adjustment column 30 is fixedly connected to the extrusion magnetic actuator 33.Based on the calculated attitude deviations, the central controller divides the track beam into three control zones corresponding to the three support positions, generating a multi-zone collaborative leveling strategy: the main control zone corresponds to the support frame assembly group 16 of the variable support base 3, responsible for correcting the flatness deviation and intermediate deflection of the main track beam section; the left control zone corresponds to the variable fixed assembly 14 of the first movable support base 4, responsible for correcting the pitch and yaw deviations of the left end of the track beam and the warping deformation of the left end overhang section; the right control zone corresponds to the second movable support base... The variable-fixed component 14 of component 5 is responsible for correcting the pitch and yaw deviations of the right end of the track beam and the warping deformation of the right end suspended section; the central controller sends the target lifting height command to the electric push rod 35 corresponding to each rigid frame support rod 18 in each control zone. The linkage of components in the leveling execution process is as follows: after receiving the control command, the electric push rod 35 pushes the connecting column 36 and the lifting adjustment column 30 to perform precise lifting and lowering actions, and simultaneously drives the tube body 28 and the extrusion head 29 to lift and lower, adjusting the support height of the corresponding points; the limiting columns fixed on the four sides of the tube body 28 The 31 and the limiting ring 32 slide together throughout the entire process to ensure the straightness of the support rod during lifting and lowering, avoiding radial offset that could cause the height adjustment accuracy to fail. Each rigid frame support rod 18 corresponds to a pull-rod type linear displacement sensor, which collects the actual lifting height of the support rod in real time and simultaneously feeds it back to the central controller, forming a closed-loop control of the height of a single support rod. The central controller compares the difference between the actual height and the target height in real time and dynamically adjusts the feed amount of the electric push rod 35 until the height error is controlled within the preset accuracy range. During height adjustment, each rigid frame support rod 18 corresponds to a thin-film contact pressure sensor, which collects the support pressure data at that point in real time and simultaneously feeds it back to the central controller, forming a closed-loop control of the support force: when the support force of a support rod exceeds a preset threshold, the central controller immediately stops the lifting action of that support rod to avoid excessive support force causing plastic deformation of the workpiece; when the support force is lower than the preset fitting threshold, the height of the support rod is finely adjusted to ensure fitting support, achieving uniform force distribution at each support point throughout the process and preventing internal stress rebound of the workpiece during leveling.

[0025] Throughout this process, the electromagnetic driver 24 and the magnetic coil 38 are kept de-energized, and the magnetorheological fluid 23 remains in a liquid state, without interfering with the height adjustment of the rigid frame support rod 18.

[0026] The rigid frame support rod 18 also includes an extrusion chamber tube 34, an electric push rod 35, and a connecting column 36. The bottom of the extrusion chamber tube 34 is fixedly connected to the electric push rod 35, and the pushing end of the electric push rod 35 is fixedly connected to the connecting column 36.

[0027] After the first round of leveling is completed, the central controller drives the three-dimensional laser contour sensor again to perform a second full-section scan of the track beam surface to be processed. At the same time, the dual-axis tilt sensor of the main spindle and the dual-axis tilt sensor of the support surface collect the reference data again. The central controller recalculates the perpendicularity deviation and flatness deviation between the surface to be processed and the drill bit axis. The central controller judges the leveling effect: if the deviation value meets the preset processing accuracy requirements, it is determined that the full-area intelligent fine leveling is completed; if the deviation value does not meet the requirements, the central controller automatically identifies the deviation area and the deviation amount, generates a secondary correction leveling strategy, and sends adjustment instructions to the rigid frame support rod 18 of the corresponding area again, repeating the above leveling execution process until the deviation value fully meets the processing accuracy requirements.

[0028] In a preferred embodiment, the extrusion magnetic actuator 33 includes a docking ring 37, a magnetic coil 38, and an extrusion box 39. The magnetic coil 38 is placed at the bottom of the docking ring 37, and the extrusion box 39 is placed at the bottom of the magnetic coil 38. The extrusion box 39 and the docking ring 37 are sealed together. After the central controller confirms that the leveling is completed, it synchronously sends a power-on start command to the electromagnetic actuator 24 in the magnetorheological liquid placement box 20 and the magnetic coils 38 of the extrusion magnetic actuator 33 corresponding to all rigid frame support rods 18, applying a magnetic field synchronously on both sides. After the device 24 is powered on, a main magnetic field is applied to the magnetorheological fluid 23 in the entire placement cavity 21; after the magnetic flux coil 38 is powered on, an auxiliary superimposed magnetic field is applied to the magnetorheological fluid 23 around the corresponding support rod. After the two magnetic fields are superimposed, the magnetorheological fluid 23 in the placement cavity 21 changes from liquid to high viscosity solid, completing the double locking. At this time, the solid magnetorheological fluid 23 completely locks the upper and lower positions of all the extrusion magnetic flux actuators 33, thereby completely locking the support height of all rigid skeleton support rods 18, and completely fixing the posture of the leveled workpiece, so that there will be no height rebound or displacement deviation. The magnetorheological fluid 23 filled in the composite isolation membrane 22 is simultaneously cured, forming a rigid wrapping limit that perfectly matches the irregular contour of the bottom surface of the track beam. It forms an integrated full-area rigid support system with the rigid frame support rod 18, completely eliminating the fitting gap. During the locking process, the magnetic flux sensors next to the electromagnetic actuator 24 and the magnetic coil 38 collect magnetic field strength data in real time and feed it back to the central controller to form a closed-loop control of magnetic field strength. The central controller dynamically adjusts the drive current to ensure that the magnetic field strength is always maintained above the curing threshold, ensuring the stability of the locking rigidity. The temperature sensor on the inner wall of the placement cavity 21 collects the working temperature of the magnetorheological fluid 23 in real time. When the temperature exceeds the preset range, the central controller automatically adjusts the drive current or starts the heat dissipation device to avoid the temperature change from affecting the curing performance of the magnetorheological fluid and to ensure the long-term stability of the locking effect. After locking is completed, the central controller collects the support status data again through the contact pressure sensor and the linear displacement sensor to confirm that all support rods have no displacement, the support force has no sudden change, and the workpiece posture is completely consistent with the state after leveling, thus completing the full rigid consolidation of the leveling accuracy.

[0029] In a preferred embodiment, the variable support base 3 includes a lifting placement seat 15 and a support rod assembly group 16. The support rod assembly group 16 is placed inside the lifting placement seat 15. The support rod assembly group 16 and the variable fixing assembly 14 have the same structure.

[0030] After the central controller confirms that the locking is complete, it sends a start command to the main body 8 of the drilling machine. The main body 8 of the drilling machine performs drilling operations on the track beam according to the preset processing program. During the entire drilling process, the central controller maintains continuous power supply to the electromagnetic driver 24 and the magnetic coil 38 to maintain the solidified and locked state of the magnetorheological fluid 23 and suppresses drilling cutting vibration through the full-area rigid support system. During the processing, all thin-film contact pressure sensors collect pressure fluctuation data at each support point in real time, and the central controller monitors the vibration amplitude in real time. When the vibration amplitude exceeds the preset threshold, the central controller immediately increases the driving current of the electromagnetic driver 24 and the magnetic coil 38 to enhance the magnetic field strength, further enhance the solidification rigidity of the magnetorheological fluid 23, enhance the vibration resistance, suppress the workpiece posture deviation caused by vibration, and maintain the accuracy after leveling throughout the process.

[0031] The clamping force pressure sensor monitors the locking status of the support base throughout the process, and the grating ruler displacement sensor monitors the position of the support base throughout the process. Once the position shift or the clamping force decreases, a stop warning is immediately triggered to avoid processing deviations. After the drilling operation is completed, the main body 8 of the drilling machine returns to the initial position. The central controller disconnects the power supply to the electromagnetic driver 24 and the magnetic coil 38. The magnetic field disappears, the magnetorheological fluid 23 instantly returns to a liquid state, and the position lock of the rigid skeleton support rod 18 is released. The central controller controls all electric push rods 35 to drive the corresponding rigid skeleton support rod 18 back to the initial position. The operator uses the hoisting equipment to remove the processed track beam, completing a single processing leveling cycle and preparing for the next workpiece processing.

[0032] In a preferred embodiment, the sliding base 12 includes a docking base plate 25, slide rails 26, and clamping limiters 27. The slide rails 26 are fixedly connected to both sides of the bottom end of the docking base plate 25, and the clamping limiters 27 are fixedly connected between the two sets of slide rails 26. Each clamping limiter 27 is equipped with a clamping force pressure sensor to detect the clamping force of the clamping limiter 27 on the locking bar 11 in real time, so as to ensure reliable locking of the base and avoid position deviation during processing. There are three sets of clamping limiters 27.

[0033] In a preferred embodiment, the alignment and drilling mechanism 2 includes a lifting bracket 6, with a mounting bracket 7 fixedly connected to the top of the lifting bracket 6. A drilling machine body 8 is slidably connected to one side of the mounting bracket 7. A three-dimensional laser contour sensor is fixedly mounted on the spindle box of the drilling machine body 8, with its scanning direction facing the downward workpiece processing station. This sensor is used to scan and acquire the three-dimensional spatial coordinates, contour data, hole position reference, and flatness data of the surface to be processed on the track beam, thereby achieving automatic workpiece alignment and posture recognition. A dual-axis tilt sensor is also fixedly mounted on the spindle box of the drilling machine body 8 to detect the verticality of the drilling machine spindle axis in real time, serving as a reference for workpiece leveling. Position encoders are installed on the XYZ axis feed mechanisms of the drilling machine body 8 to acquire the spatial position coordinates of the spindle in real time, working in conjunction with the three-dimensional laser contour sensor to complete the system calibration of the workpiece coordinates and machine tool coordinates. The system includes a variable support base 3, a first movable support base 4, and a second movable support base 5. Each of the top surfaces of the movable support base 5 is equipped with a dual-axis tilt sensor for real-time detection of the reference level of each support station, providing reference data for leveling calculations. The bottom of the variable support base 3, the first movable support base 4, and the second movable support base 5 is provided with a sliding base plate 9. The upper surface of the sliding base plate 9 is fixedly installed with a grating ruler displacement sensor along the direction parallel to the limiting groove 10. The reading head of the grating ruler is fixed to the bottom end of the sliding base 12 of the first movable support base 4 and the second movable support base 5, respectively, for real-time detection of the sliding displacement and relative distance of the two movable support bases, so as to achieve precise pre-positioning of track beams of different lengths. The sliding base plate 9 is provided with a limiting groove 10 at one end of the clamping limiter 27. Both ends of the limiting groove 10 are fixedly installed with stroke limit sensors to prevent the movable support base from sliding beyond its travel and to avoid equipment collision. The limiting groove 10 is provided with a locking strip 11 inside.

[0034] The working process of this application is as follows: First, according to the length specifications of the track beam to be processed, adjust the relative positions of the first movable support base 4 and the second movable support base 5 on the sliding base plate 9 so that the variable support base 3 corresponds to supporting the main body section of the track beam, and the first movable support base 4 and the second movable support base 5 respectively correspond to supporting the suspended sections at both ends of the track beam, thus completing the pre-positioning of the support positions; then, hoist the track beam to be processed and place it above the pre-positioned variable support base 3, the first movable support base 4, and the second movable support base 5. Under the action of gravity, the track beam presses down on the rigid frame in the variable fixing component 14 at each support position. The support rod 18, being compressed, drives the compression magnetic actuator 33 downwards into the placement cavity 21 of the magnetorheological fluid placement box 20, compressing the magnetorheological fluid 23 in the placement cavity 21. This causes the magnetorheological fluid 23 to flow into the composite isolation membrane 22, filling the fitting gap between the bottom surface of the track beam and each rigid frame support rod 18, thus completing the initial conformal fitting support of the track beam. The spatial coordinates and reference posture data of the track beam to be processed surface are obtained through the alignment and drilling mechanism 2. The perpendicularity deviation between the track beam to be processed surface and the drill bit axis of the drilling machine body 8 is calculated. Based on the deviation data, the corresponding rigid frame support rods in each support station are adjusted in different areas. The lifting height of the skeleton support rod 18 is adjusted by multi-zone coordinated height adjustment to correct the attitude deviation of the track beam, so that the surface of the track beam to be processed is perpendicular to the axis of the drill bit of the main body 8 of the drilling machine, and the whole-domain intelligent leveling is completed; Step 4: After the leveling is completed, the electromagnetic driver 24 of the magnetorheological liquid placement box 20 and the extrusion magnetic driver 33 corresponding to each rigid skeleton support rod 18 are started simultaneously to apply a magnetic field of preset intensity to the magnetorheological liquid 23 in the placement cavity 21, so that the magnetorheological liquid 23 instantly changes from liquid to solid, and completes the position locking of the rigid skeleton support rod 18 and the conformal rigid wrapping limit of the bottom surface of the track beam, forming a whole-domain rigid support system; Step 5: Start the drilling machine body 8 of the alignment and drilling mechanism 2, and perform drilling operations on the track beam according to the preset processing program. During the entire drilling process, the magnetic field is continuously loaded to maintain the solidified and locked state of the magnetorheological fluid 23 and suppress the track beam attitude deviation caused by drilling vibration. Step 6: After the drilling operation is completed, disconnect the power supply of the electromagnetic driver 24 and the extrusion magnetic drive 33. The magnetic field disappears, the magnetorheological fluid 23 returns to the liquid state, the rigid frame support rod 18 is reset and unlocked, and the processed track beam is hoisted and removed to complete a single processing cycle. The above is the working principle of the integrated automatic alignment centering device and its intelligent leveling method for drilling track beams.

Claims

1. An integrated automatic centering device for drilling track beams, comprising an adjustable machine tool (1) and a first movable support base (4), characterized in that: The adjustable machine tool (1) includes a aligning and drilling mechanism (2), and a variable support base (3) is placed below the aligning and drilling mechanism (2). A first movable support base (4) and a second movable support base (5) are slidably connected to both ends of the variable support base (3). The first movable support base (4) includes a sliding base (12), a placement bracket (13) and a variable fixing component (14). The placement bracket (13) is fixedly connected above the sliding base (12), and the variable fixing component (14) is fixedly connected to the top of the placement bracket (13).

2. The integrated automatic centering device for drilling track beams according to claim 1, characterized in that: The variable fixing assembly (14) includes a barrier box (17), a rigid skeleton support rod (18), a sealing partition plate (19), and a magnetorheological fluid placement box (20). The rigid skeleton support rod (18) is arranged equidistantly inside the barrier box (17). The bottom of the rigid skeleton support rod (18) is fixedly connected to the sealing partition plate (19). The bottom of the sealing partition plate (19) is sealed to the magnetorheological fluid placement box (20).

3. The integrated automatic centering device for drilling track beams according to claim 2, characterized in that: The magnetorheological fluid placement box (20) has a reserved placement cavity (21) inside. A temperature sensor is fixedly installed on the inner wall of the placement cavity (21) of the magnetorheological fluid placement box (20). The sealing partition plate (19) is located in the placement cavity (21) of the magnetorheological fluid placement box (20) and a composite isolation membrane (22) is placed therein. The composite isolation membrane (22) is tubular and sealed at one end. The composite isolation membrane (22) is located at the center of the four sets of rigid skeleton support rods (18).

4. The integrated automatic centering device for drilling track beams according to claim 2, characterized in that: The magnetorheological fluid (23) is placed in the placement cavity (21) of the magnetorheological fluid placement box (20). The magnetorheological fluid (23) in the magnetorheological fluid placement box (20) fills the placement cavity (21) and is sealed by a partition plate. There is no air in the placement cavity (21). An electromagnetic actuator (24) is fixedly connected to the base of the magnetorheological fluid placement box (20). A magnetic flux sensor is fixedly installed on each of the rigid skeleton support rods (18) next to the electromagnetic actuator (24) of the magnetorheological fluid placement box (20).

5. The integrated automatic centering device for drilling track beams according to claim 2, characterized in that: The rigid frame support rod (18) includes a tube (28), an extrusion head (29), a lifting adjustment column (30), a limiting column (31), a limiting ring (32), and an extrusion magnetic actuator (33). The top end of the tube (28) is fixedly connected to the extrusion head (29), and a thin-film contact pressure sensor is embedded on the upper end face of the extrusion head (29). The bottom end of the tube (28) is connected to the lifting adjustment column (30), and the four sides of the tube (28) are fixedly connected to the limiting columns (31). The column body of the limiting column (31) is connected through the tube. A limit ring (32) is provided. A pull rod type linear displacement sensor is fixedly installed between the limit ring (32) of the rigid skeleton support rod (18) and the tube body (28). A compression magnetic actuator (33) is fixedly connected to the bottom end of the lifting adjustment column (30). The rigid skeleton support rod (18) also includes a compression chamber tube (34), an electric push rod (35) and a connecting column (36). The bottom of the compression chamber tube (34) is fixedly connected to the electric push rod (35), and the pushing end of the electric push rod (35) is fixedly connected to the connecting column (36).

6. The integrated automatic centering device for drilling track beams according to claim 5, characterized in that: The extrusion magnetic actuator (33) includes a docking ring (37), a magnetic coil (38), and an extrusion box (39). The magnetic coil (38) is placed at the bottom of the docking ring (37), and the extrusion box (39) is placed at the bottom of the magnetic coil (38). The extrusion box (39) and the docking ring (37) are sealed together.

7. The integrated automatic centering device for drilling track beams according to claim 1, characterized in that: The variable support base (3) includes a lifting placement seat (15) and a support rod assembly group (16). The support rod assembly group (16) is placed inside the lifting placement seat (15). The support rod assembly group (16) and the variable fixing assembly (14) have the same structure.

8. The integrated automatic centering device for drilling track beams according to claim 1, characterized in that: The sliding base (12) includes a docking base plate (25), a slide rail (26) and a clamping limiter (27). The slide rail (26) is fixedly connected to both sides of the bottom end of the docking base plate (25). The clamping limiter (27) is fixedly connected between the two sets of slide rails (26). Each clamping limiter (27) is equipped with a clamping force pressure sensor. There are three sets of clamping limiters (27).

9. The integrated automatic centering device for drilling track beams according to claim 1, characterized in that: The alignment and drilling mechanism (2) includes a lifting bracket (6), the top of which is fixedly connected to a mounting bracket (7), and the drilling machine body (8) is slidably connected to one side of the mounting bracket (7). A three-dimensional laser contour sensor and a spindle dual-axis tilt sensor are fixedly installed on the spindle box side of the drilling machine body (8). The XYZ axis feed mechanism of the drilling machine body (8) is equipped with a position encoder. The bottom of the variable support base (3), the first movable support base (4) and the second movable support base (5) is provided with a sliding base plate (9). The upper surface of the sliding base plate (9) is fixedly installed with a grating ruler displacement sensor in the direction parallel to the limiting groove (10). The sliding base plate (9) is provided with a limiting groove (10) at one end of the clamping limiter (27). Both ends of the limiting groove (10) are fixedly installed with a travel limit sensor. The inside of the limiting groove (10) is provided with a locking strip (11).

10. An integrated intelligent leveling method for drilling holes in track beams, characterized in that: The intelligent leveling method The process includes the following steps: Step 1: According to the length specifications of the track beam to be processed, adjust the relative positions of the first movable support base (4) and the second movable support base (5) on the sliding base plate (9), so that the variable support base (3) corresponds to the main body section supporting the track beam, and the first movable support base (4) and the second movable support base (5) respectively correspond to the suspended sections at both ends of the track beam, thus completing the pre-positioning of the support station; Step 2: Hoist the track beam to be processed and place it above the pre-positioned variable support base (3), the first movable support base (4) and the second movable support base (5), and the track beam presses down on each support station under the action of gravity and changes accordingly. The rigid skeleton support rod (18) inside the component (14) is squeezed. The squeezed rigid skeleton support rod (18) drives the extrusion magnetic actuator (33) to descend into the placement cavity (21) of the magnetorheological fluid placement box (20), squeezing the magnetorheological fluid (23) in the placement cavity (21), causing the magnetorheological fluid (23) to flow into the composite isolation membrane (22), filling the fitting gap between the bottom surface of the track beam and each rigid skeleton support rod (18), and completing the initial conformal fitting support of the track beam; Step 3: Obtain the spatial coordinates and reference posture data of the track beam to be processed surface through the alignment drilling mechanism (2), and calculate the perpendicularity between the track beam to be processed surface and the drill bit axis of the drilling machine body (8). Straightness deviation, based on deviation data, the lifting height of the corresponding rigid skeleton support rod (18) in each support station is adjusted in different areas. Through multi-zone coordinated height adjustment, the attitude deviation of the track beam is corrected so that the track beam to be processed surface is perpendicular to the drill bit axis of the drilling machine body (8), and the whole-domain intelligent leveling is completed; Step 4: After the leveling is completed, the electromagnetic driver (24) of the magnetorheological liquid placement box (20) and the extrusion magnetic drive (33) corresponding to each rigid skeleton support rod (18) are started simultaneously to apply a magnetic field of preset intensity to the magnetorheological liquid (23) in the placement cavity (21), so that the magnetorheological liquid (23) instantly changes from liquid to solid, and the rigid skeleton support rod (18) is completed. 8) The position locking and the rigid wrapping limit of the bottom surface of the track beam form a rigid support system in the whole domain; Step 5: Start the drilling machine body (8) of the alignment drilling mechanism (2) and drill the track beam according to the preset processing program. The magnetic field is continuously loaded throughout the drilling process to maintain the solidified locking state of the magnetorheological fluid (23) and suppress the track beam attitude deviation caused by drilling vibration; Step 6: After the drilling operation is completed, disconnect the power supply of the electromagnetic driver (24) and the extrusion magnetic drive (33). The magnetic field disappears, the magnetorheological fluid (23) returns to the liquid state, the rigid skeleton support rod (18) is reset and unlocked, and the processed track beam is hoisted and removed to complete a single processing cycle.

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