Dynamic pre-control type digital management and control system for aviation high-rigidity long-axis deep hole machining

Abstract

The invention relates to a dynamic pre-control type digital management and control system for aviation high-rigidity long-axis deep hole machining. Relates to the crossing field of aviation precision manufacturing and intelligent control. At present, an existing management and control system focuses on state monitoring and afterward adjustment in machining and lacks the capacity of pre-judging the deformation trend in advance, and parameter optimization depends on a large amount of historical data training and is difficult to meet the production requirements of small-batch and multi-specification aeronautical parts. Relates to the crossing field of aviation precision manufacturing and intelligent management and control, the system integrates the functions of deformation pre-judgment before machining, dynamic regulation and control in machining and quality tracing after machining, and through multi-field coupling digital modeling and a small sample learning algorithm, precise sensing, advanced intervention and closed-loop management and control of the whole machining process of the high-rigidity long-axis deep hole are achieved, and the machining precision is improved. The problems of deformation lag monitoring, poor parameter adaptability and large quality fluctuation in traditional machining are solved, and the precision stability and batch consistency of deep hole machining of aviation key parts are remarkably improved.

Description

Technical Field

[0001] This invention belongs to the interdisciplinary field of aerospace precision manufacturing and intelligent control, and mainly relates to a dynamic pre-control type digital control system for machining high-rigidity long shaft deep holes in aerospace. Background Technology

[0002] Key components such as the main shaft of an aero-engine and the long shaft of the transmission system are mostly made of high-strength alloy materials, possessing high rigidity characteristics. The machining accuracy of their deep hole structures directly affects the operational safety of the equipment. During the machining of these parts, factors such as the large length-to-diameter ratio, concentrated cutting forces, and enclosed machining area can easily lead to bending deformation and dimensional deviations. Furthermore, the concealed nature of deep hole machining makes it difficult to detect deformation in real time, often requiring adjustments only after problems occur, thus increasing the risk of parts being scrapped.

[0003] Existing control systems primarily focus on monitoring the machining process and making post-process adjustments, lacking the ability to predict deformation trends in advance. Furthermore, parameter optimization relies heavily on training with large amounts of historical data, making it difficult to adapt to the production needs of small-batch, multi-specification aerospace parts. Simultaneously, the control of clamping force and cutting parameters is independent, failing to achieve synergistic compensation and effectively suppressing complex deformations. Therefore, there is an urgent need for an intelligent control system with pre-control capabilities and adaptability to small-sample scenarios to meet high-quality machining requirements. Summary of the Invention

[0004] To address the aforementioned problems, the purpose of this invention is to provide a dynamic pre-control digital management and control system for machining high-rigidity long-shaft deep holes in aerospace applications. This system overcomes the limitations of existing management and control systems, which primarily focus on in-process status monitoring and post-process adjustments, by integrating pre-analysis, real-time sensing, and dynamic regulation throughout the entire process. A dynamic pre-control digital management and control system for machining high-rigidity long-shaft deep holes in aerospace includes a pre-analysis module, a multi-source real-time sensing module, a dynamic pre-control decision module, an execution adjustment module, and a full-chain traceability module. Each module achieves real-time data interaction and collaborative operation through an industrial 5G network. The pre-processing analysis module provides benchmark parameters and deformation prediction basis for the processing; The multi-source real-time sensing module captures and processes dynamic data from the entire scene. The dynamic pre-control decision-making module is based on data output parameter optimization and deviation compensation instructions. The execution adjustment module completes the precise adjustment of equipment parameters and clamping status; The full-chain traceability module enables structured storage and traceability of processing data.

[0005] Furthermore, the pre-processing analysis module constructs a multi-field coupled digital model containing cutting force field, temperature field and stress field based on the three-dimensional model of the part, material mechanical parameters and preset process route. After training with historical processing data, it can predict the deformation trend of the workpiece at different processing stages and output the initial parameter scheme.

[0006] Furthermore, the multi-source real-time sensing module deploys a combined sensing unit; The integrated sensing unit includes a distributed strain sensor attached to the workpiece axis, a dynamic cutting force sensor integrated into the tool holder, and a flow and pressure composite sensor installed in the cutting fluid circuit, which can simultaneously collect data on deformation, cutting load, and cooling and lubrication status.

[0007] Furthermore, the dynamic pre-control decision-making module incorporates a small-sample learning model and a bias correction algorithm; The small sample learning model dynamically optimizes cutting speed and feed rate parameters based on the prediction results of the pre-analysis module and real-time sensing data. The deviation correction algorithm generates compensation instructions for clamping support force and cutting fluid parameters by comparing the deviation between the measured deformation and the estimated value.

[0008] Furthermore, the execution adjustment module includes a CNC parameter adaptation unit, a floating clamping control unit, and a cutting fluid control unit, which can respectively respond to decision commands to realize adaptive adjustment of machining parameters, dynamic compensation of clamping force, and precise supply of cooling and lubrication.

[0009] Furthermore, the full-chain traceability module associates and stores pre-processing analysis reports, in-process sensing data and adjustment records, and post-processing accuracy detection results, generating processing archives containing QR codes to support full-process data traceability and process optimization analysis.

[0010] Beneficial effects: This invention transforms deformation control from post-processing adjustment to pre-processing intervention by using multi-field coupled modeling before processing and deviation correction during processing, significantly reducing the risk of dimensional deviations in deep hole machining.

[0011] This invention optimizes parameters based on a few-sample learning model, without relying on massive historical data, and is more in line with the characteristics of multi-specification, small-batch production of aerospace parts.

[0012] This invention effectively improves the consistency of machining accuracy and quality stability of batch parts by coordinating the control of cutting parameters and clamping force, combined with full-process data traceability and process optimization. Detailed Implementation

[0013] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0014] In this invention, unless otherwise expressly specified and limited, the first feature "on" or "below" the second feature may be in direct contact with the first and second features, or indirect contact through an intermediate medium. In the description of this specification, references to terms such as "an embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0015] Example 1:

[0016] A dynamic pre-control digital management and control system for machining high-rigidity long-shaft deep holes in aerospace includes a pre-analysis module, a multi-source real-time sensing module, a dynamic pre-control decision module, an execution adjustment module, and a full-chain traceability module. Each module achieves real-time data interaction and collaborative operation through an industrial 5G network. The pre-processing analysis module provides benchmark parameters and deformation prediction basis for the processing; The multi-source real-time sensing module captures and processes dynamic data from the entire scene. The dynamic pre-control decision-making module is based on data output parameter optimization and deviation compensation instructions. The execution adjustment module completes the precise adjustment of equipment parameters and clamping status; The full-chain traceability module enables structured storage and traceability of processing data.

[0017] Example 2: According to the dynamic pre-control type digital management and control system for machining deep holes of high rigidity long shafts in aerospace as described in Example 1, the pre-analysis module before machining constructs a multi-field coupled digital model containing cutting force field, temperature field and stress field based on the three-dimensional model of the part, material mechanical parameters and preset process route. After training with historical machining data, it can predict the deformation trend of the workpiece at different machining stages and output the initial parameter scheme.

[0018] The pre-analysis module before processing serves as the prediction center of the system. It first imports the CAD model of the part and parameters such as the elastic modulus and thermal expansion coefficient of the material. Combined with preset process routes such as drilling and reaming, it constructs a multi-field coupled digital model to simulate the comprehensive influence of cutting force and temperature on workpiece deformation.

[0019] Then, historical machining data of similar parts are input to train and calibrate the model. Before machining, the deformation distribution pattern at different hole depths can be predicted, and suitable initial cutting parameters and clamping support schemes can be output to provide a benchmark for the machining process.

[0020] Example 3: According to the dynamic pre-control type digital management and control system for high-rigidity long-axis deep hole machining in aviation as described in Embodiment 1 or 2, the multi-source real-time sensing module is deployed with a combined sensing unit. The integrated sensing unit includes a distributed strain sensor attached to the workpiece axis, a dynamic cutting force sensor integrated into the tool holder, and a flow and pressure composite sensor installed in the cutting fluid circuit, which can simultaneously collect data on deformation, cutting load, and cooling and lubrication status.

[0021] The multi-source real-time sensing module is responsible for the accurate sensing function of the processing status. It adopts a distributed sensing layout, with strain sensors arranged at intervals along the workpiece axis to capture the radial deformation at different positions in real time. A dynamic cutting force sensor is integrated into the tool holder to monitor changes in three-dimensional cutting load to reflect the machining load. A combined flow and pressure sensor is installed in the cutting fluid inlet line to ensure stable operation of the cooling and lubrication system. All sensed data is preprocessed by edge computing and then transmitted with low latency to the system data platform via an industrial 5G network.

[0022] Example 4: According to Embodiment 1, 2 or 3, the dynamic pre-control type digital control system for machining high-rigidity long shaft deep holes in aerospace has a built-in small sample learning model and deviation correction algorithm in the dynamic pre-control decision module. The small sample learning model dynamically optimizes cutting speed and feed rate parameters based on the prediction results of the pre-analysis module and real-time sensing data. The deviation correction algorithm generates compensation instructions for clamping support force and cutting fluid parameters by comparing the deviation between the measured deformation and the estimated value.

[0023] The dynamic pre-control decision-making module adopts a dual-model collaborative decision-making mechanism. On the one hand, it processes real-time sensing data and pre-analysis results based on a small-sample learning model, which can quickly output dynamic optimization parameters of cutting speed and feed rate without a large number of samples, making it suitable for small-batch production scenarios of aerospace parts; On the other hand, the difference between the measured deformation and the estimated value is calculated by the deviation correction algorithm. When the deviation exceeds the threshold, the compensation command for clamping support force and the cutting fluid pressure adjustment scheme are automatically generated to realize early intervention in deformation.

[0024] Example 5: According to the dynamic pre-control type digital control system for machining high-rigidity long shaft deep holes in aerospace as described in Embodiment 1, 2, 3 or 4, the execution adjustment module includes a numerical control parameter adaptation unit, a floating clamping control unit and a cutting fluid control unit, which can respectively respond to decision commands to realize adaptive adjustment of machining parameters, dynamic compensation of clamping force and precise supply of cooling and lubrication.

[0025] The execution adjustment module ensures the precise implementation of decision-making instructions, and is executed collaboratively by three units; The CNC parameter adaptation unit communicates directly with the machine tool's CNC system to complete the real-time update of cutting parameters; The floating clamping control unit adjusts the pressure of the support block based on compensation commands, and suppresses workpiece deformation through flexible support to avoid pre-deformation caused by excessive clamping. The cutting fluid control unit responds to pressure adjustment commands to ensure sufficient cooling and lubrication in the cutting area, reducing the impact of thermal deformation.

[0026] Example 6: According to the dynamic pre-control digital management and control system for machining high-rigidity long shaft deep holes in aerospace as described in Embodiments 1, 2, 3, 4, or 5, the full-chain traceability module associates and stores pre-analysis reports before machining, sensing data and adjustment records during machining, and precision detection results after machining, and generates machining archives containing QR codes, supporting full-process data traceability and process optimization analysis.

[0027] The end-to-end traceability module establishes a traceable record of processing quality, assigning a unique QR code to each part and linking it to pre-processing analysis reports, real-time sensing data and parameter adjustment records during processing, and post-processing test results such as hole diameter and coaxiality. Users can scan the code to query the complete processing chain, and the system automatically summarizes the data to generate process optimization suggestions, providing a reference for subsequent processing.

[0028] The above description is merely an embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principle of the present invention should be included within the scope of the claims of the present invention.

Claims

1. A dynamic pre-control type digital control system for machining deep holes on long, rigid aerospace shafts, characterized in that, It includes a pre-processing analysis module, a multi-source real-time sensing module, a dynamic pre-control decision-making module, an execution adjustment module, and a full-chain traceability module. Each module achieves real-time data interaction and collaborative operation through an industrial 5G network. The pre-processing analysis module provides benchmark parameters and deformation prediction basis for the processing; The multi-source real-time sensing module captures and processes dynamic data from the entire scene. The dynamic pre-control decision-making module is based on data output parameter optimization and deviation compensation instructions; The execution adjustment module completes the precise adjustment of equipment parameters and clamping status; The full-chain traceability module enables structured storage and traceability of processing data.

2. The dynamic pre-control digital management and control system for machining deep holes of high-rigidity long shafts in aerospace applications according to claim 1, characterized in that, The pre-processing analysis module is based on the three-dimensional model of the part, material mechanical parameters and preset process route. It constructs a multi-field coupled digital model including cutting force field, temperature field and stress field. After training with historical processing data, it can predict the deformation trend of the workpiece at different processing stages and output the initial parameter scheme.

3. The dynamic pre-control digital management and control system for machining deep holes on long shafts of aerospace high rigidity as described in claim 1, characterized in that, The multi-source real-time sensing module deploys a combined sensing unit; The integrated sensing unit includes a distributed strain sensor attached to the workpiece axis, a dynamic cutting force sensor integrated into the tool holder, and a flow and pressure composite sensor installed in the cutting fluid circuit, which can simultaneously collect data on deformation, cutting load, and cooling and lubrication status.

4. The dynamic pre-control digital management and control system for machining deep holes on long shafts of aerospace high rigidity as described in claim 1, characterized in that, The dynamic pre-control decision-making module incorporates a small-sample learning model and a bias correction algorithm. The small sample learning model dynamically optimizes cutting speed and feed rate parameters based on the prediction results of the pre-analysis module and real-time sensing data. The deviation correction algorithm generates compensation instructions for clamping support force and cutting fluid parameters by comparing the deviation between the measured deformation and the estimated value.

5. The dynamic pre-control digital management system for machining deep holes on long shafts of aerospace high rigidity as described in claim 1, characterized in that, The execution adjustment module includes a CNC parameter adaptation unit, a floating clamping control unit, and a cutting fluid control unit, which can respectively respond to decision commands to realize adaptive adjustment of machining parameters, dynamic compensation of clamping force, and precise supply of cooling and lubrication.

6. The dynamic pre-control digital management system for machining deep holes on long shafts of aerospace high rigidity as described in claim 1, characterized in that, The full-chain traceability module associates and stores pre-processing analysis reports, in-process sensing data and adjustment records, and post-processing accuracy detection results, generating processing archives containing QR codes, supporting full-process data traceability and process optimization analysis.