Intelligent visual monitoring system and process method for whole process of complex micro-component machining

Abstract

This invention relates to an intelligent visual monitoring system and process method for the entire process of machining complex micro-components. It addresses the problems of existing monitoring methods for the milling of surface features in thin-walled micro-spherical shell-like complex micro-components, which struggle to effectively identify material removal behavior and workpiece-tool contact during milling due to factors such as a single observation angle, limited observation area, and a disconnect between observation and analysis. This invention includes an image acquisition unit and an information processing unit. The image acquisition unit uses an industrial camera to collect image data of the entire machining process, including tool-workpiece contact, material removal behavior, and tool wear, in both horizontal and vertical planes, and transmits this data to the information processing unit. The image information processing unit adjusts parameters such as mode, image format, image quality, and color conversion mode to display the entire micro-milling process in real time. This invention is used for machining complex micro-components.

Description

Technical Field

[0001] This invention relates to the field of complex micro-component processing technology, specifically to an intelligent visual monitoring system and process method for the entire process of complex micro-component processing. Background Technology

[0002] With the rapid development of ultra-precision machining and micro / nano manufacturing technologies, the demand for high-precision, integrated thin-walled microsphere shell components is increasing in fields such as biomedicine, aerospace, and precision optics. These components are tiny (millimeters to sub-millimeters in size) and complex in shape, with dozens to hundreds of multi-scale feature structures on their surfaces requiring micrometer-level surface accuracy, nanometer-level surface roughness, and high uniformity and consistency of distribution. This necessitates the use of ultra-precision micromilling processes and high-precision vision systems to monitor the entire microstructure forming process and adjust process parameters in real time to meet the extreme manufacturing requirements for precision and surface quality.

[0003] Microsphere shell components are made of amorphous, soft, and brittle polymers with a shell thickness of only tens of micrometers. During micromilling, they are prone to elastoplastic plowing, adhesive adhesion, deliquescence, and thermal softening due to process parameters, significantly deteriorating the machined surface. Monitoring the microscopic material removal process and the transient evolution of the workpiece-tool contact area during micromilling using a high-precision visual imaging system, and adjusting process parameters and improving cooling and lubrication conditions accordingly, is crucial for ensuring the quality of microstructure machining. Currently, mainstream visual monitoring technologies mainly rely on high-magnification, high-resolution static microscopic imaging systems, which typically acquire images from a single fixed direction. The observation range is limited to a tiny machining area, and the monitoring process mainly involves static image acquisition at discrete time points, making it difficult to fully capture the entire transient evolution of material removal. Furthermore, existing monitoring systems mostly remain at the level of visual image observation, lacking real-time quantitative characterization and intelligent processing capabilities for image information, and cannot effectively identify and analyze material removal behavior and workpiece-tool contact conditions during milling. Therefore, the aforementioned mainstream visual monitoring systems and process methods cannot meet the requirements for high-precision dynamic observation and characterization of the machining area during material milling. Therefore, in order to meet the high-precision machining requirements of the surface features and microstructures of micro spherical shell components, there is an urgent need to develop an intelligent visual monitoring system and process method for the entire micro-component machining process to meet the application needs of the engineering field. Summary of the Invention

[0004] The purpose of this invention is to solve the problems in the existing technology of monitoring the machining process of complex micro-components such as thin-walled micro-spherical shells. These problems are that existing machining process monitoring methods are difficult to effectively identify the material removal behavior and workpiece-tool contact during milling due to factors such as single observation angle, limited observation area, and disconnect between observation and analysis, which makes it impossible to dynamically control the machining quality. Therefore, this invention provides an intelligent visual monitoring system and process method for the entire machining process of complex micro-components.

[0005] This invention relates to a multi-axis linkage ultra-precision machining equipment for complex micro-components, comprising an image acquisition module and an information processing unit. Based on the image acquisition module, two high-resolution industrial area array digital cameras, one first and one second, respectively acquire image data of the entire machining process, including tool-workpiece contact, material removal behavior, and tool wear, in the horizontal and vertical planes. This data is then transmitted to the control software of the machining equipment via a USB 3.0 data interface. The image information processing unit controls the equipment's on / off state and the start / stop of image acquisition, and can adjust parameters such as acquisition mode, image format, image quality, and color conversion mode. It provides real-time and intuitive visualization of the entire micro-milling process, effectively solving the problem of real-time monitoring and control of material removal behavior and tool contact status during micro-milling under multi-factor interference, thus providing technical support for intelligent visual monitoring of the entire machining process of complex micro-components.

[0006] The technical solution adopted by this invention to solve the above problems is: an intelligent visual monitoring system for the entire process of machining complex micro-components, including an image acquisition unit and an information processing unit; the image acquisition unit uses an industrial camera to acquire image data of the entire machining process status, such as tool-workpiece contact, material removal behavior, and tool wear, in both horizontal and vertical planes, and transmits them to the information processing unit; the image information processing unit controls the on / off switch and start / stop of image acquisition, and adjusts parameters such as acquisition mode, image format, image quality, and color conversion mode, to display the entire process of microstructure micro-milling in real time.

[0007] Furthermore, the image acquisition unit includes a first camera and a second camera. The micro-component is connected to the fixture of the multi-axis linkage ultra-precision machining equipment by vacuum adsorption, and the cutting tool is connected to the end of the milling axis of the multi-axis linkage ultra-precision machining equipment by a pneumatic chuck. The first camera and the second camera respectively acquire image data of the tool-workpiece contact area in the horizontal plane and the vertical plane.

[0008] The first camera is connected to a vertical four-degree-of-freedom micro-displacement platform, which is connected to the Y-axis of the machining equipment. The first camera can move with the Y-axis and remain stationary relative to the micro-component. The second camera is connected to a horizontal four-degree-of-freedom micro-displacement platform, which is fixed to the machining equipment B. The second camera can rotate with the B-axis, move with the Z-axis, and remain stationary relative to the cutting tool.

[0009] Furthermore, the information processing unit includes an image acquisition card, a memory, and a PLC controller; the first camera and the second camera are respectively connected to the image acquisition card, the image acquisition card is respectively connected to the memory and the PLC controller, the PLC controller is connected to the computer, and the computer is connected to the display module.

[0010] Furthermore, the first camera and the second camera are 26-megapixel high-resolution industrial area array digital cameras with a field of view of 6.4mm × 4.8mm.

[0011] Furthermore, both the vertical four-degree-of-freedom micro-displacement platform and the horizontal four-degree-of-freedom micro-displacement platform are capable of linear displacement adjustment along the X / Y / Z axes and rotational angle adjustment along the vertical direction of the mounting surface. The linear displacement adjustable stroke is ±12.5mm, and the fine adjustment accuracy is 2μm. The rotational angle coarse adjustment stroke is 360°, the fine adjustment stroke is ±5°, and the fine adjustment accuracy is 1°.

[0012] Furthermore, the computer includes an information processing module, which receives raw image data from the image acquisition unit, adjusts parameters such as acquisition mode, image format, image quality, and color conversion mode of the raw image data, displays the image processing results on the display module, and controls the device to power on and off and the acquisition to start and stop during image acquisition.

[0013] Another technical solution adopted by the present invention to solve the above problems is: an intelligent visual monitoring method for the entire process of processing complex micro-components, which adopts a visual monitoring system and includes the following steps:

[0014] Step 1 S100: Milling image acquisition. Adjust the negative pressure source of the multi-axis linkage ultra-precision machining equipment for complex micro-components to ensure that the complex micro-component 2 is stably adsorbed at the end of the fixture 1; turn on the pneumatic switch of the milling axis, and the tool 5 is clamped and locked at the end of the milling axis through the chuck; the image acquisition module includes two high-resolution industrial cameras, the first camera 3 and the second camera 4; the first camera 3 and the second camera 4 are arranged perpendicular to each other to achieve all-round monitoring of the micro-component processing area;

[0015] Step 2 S200: Image data processing. Based on the image information of the micro-milling area acquired by the image acquisition module, the information processing unit controls and processes the parameters of the acquisition process and the image. The display module is equipped with a device selection bar, an image display bar, an instruction control bar, and a status display bar. The device selection bar is used to select the cameras connected to the first and second vision monitoring windows. The corresponding camera models can be browsed and selected by clicking the drop-down box. The image display bar is used to display the images of the processing area acquired from the first and second cameras. The instruction control bar is used to adjust the parameters of the cameras connected to the vision monitoring system and the monitoring process. Each of the two CD cameras corresponds to a set of operation controls. The status display bar intuitively displays the camera connection status and allows for closing, maximizing / minimizing the information processing bar window.

[0016] The parameter setting controls in the status bar of the command control display module can adjust configuration parameters such as image acquisition format, acquisition control, analog control, image quality, color conversion, and HDR, thereby controlling the presentation of the monitored image in the image display bar and monitoring the material removal behavior during the micro-milling process.

[0017] The present invention has the following beneficial technical effects:

[0018] This invention addresses the problems of existing milling monitoring methods, such as limited observation angle, restricted observation area, and disconnect between observation and analysis, which make it difficult to effectively identify material removal behavior and workpiece-tool contact during milling, thus hindering dynamic control of machining quality. It proposes an intelligent monitoring method for milling process status based on an image acquisition module and an information processing unit. By using dual cameras for all-round monitoring and adjusting image parameters, real-time monitoring and characterization of the microstructure machining process can be achieved.

[0019] This invention employs dual 26-megapixel high-resolution cameras with a field of view of 6.4mm × 4.8mm to optimize vertical arrangement, and is combined with a high-precision four-degree-of-freedom micro-displacement platform (adjustable linear displacement travel of ±12.5mm, fine adjustment accuracy of 2μm, coarse adjustment travel of 360°, fine adjustment travel of ±5°, and fine adjustment accuracy of 1° for rotation angle), enabling all-round observation of the process status of the micro-milling area from both vertical and horizontal angles.

[0020] The micro-milling image information processing unit of this invention can realize the collaborative acquisition and intelligent control of images from two high-resolution industrial cameras, and can adjust parameters such as acquisition mode and image commands to meet the intelligent monitoring needs of the entire process of complex micro-component processing.

[0021] This invention is universally applicable, not only to the intelligent monitoring of the entire process of machining microstructures on the surface of complex micro-components, but also to the specific practice of monitoring the process status of macro-micro-nano scale parts and multi-process forming of cross-scale feature structures. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the structure of the present invention;

[0023] Figure 2 This is a schematic diagram of a vertical four-degree-of-freedom micro-displacement platform;

[0024] Figure 3 This is a schematic diagram of a horizontal four-degree-of-freedom micro-displacement platform;

[0025] Figure 4 This is a schematic diagram of the display module of the image information processing unit of the present invention;

[0026] Figure 5This is a schematic diagram of the structure of an embodiment of the intelligent visual monitoring system and process method of the present invention;

[0027] Figure 6 This is a schematic diagram of the workflow of the present invention;

[0028] Figure 7 This is the control principle diagram of the present invention;

[0029] In the figure: 1. Fixture; 2. Micro-component; 3. First camera; 4. Second camera; 5. Tool; 6. Horizontal four-degree-of-freedom micro-displacement platform; 7. Vertical four-degree-of-freedom micro-displacement platform. Detailed Implementation

[0030] 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. The specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0031] Specific implementation method one: Combining Figures 1 to 7 This embodiment describes an intelligent visual monitoring system for the entire process of machining complex micro-components, comprising an image acquisition unit and an information processing unit. The image acquisition unit uses an industrial camera to acquire image data of the entire machining process, including tool-workpiece contact, material removal behavior, and tool wear, in both horizontal and vertical planes, and transmits this data to the information processing unit. The image information processing unit controls the on / off state of the equipment and the start / stop of image acquisition, and adjusts parameters such as acquisition mode, image format, image quality, and color conversion mode to display the entire process of microstructure micro-milling in real time.

[0032] In a preferred embodiment, the image acquisition unit includes a first camera 3 and a second camera 4. The micro-component 2 is connected to the fixture 1 of the multi-axis linkage ultra-precision machining equipment by vacuum adsorption. The cutting tool 5 is connected to the end of the milling axis of the multi-axis linkage ultra-precision machining equipment by a pneumatic chuck. The first camera 3 and the second camera 4 respectively acquire image data of the tool-workpiece contact area in the horizontal and vertical planes. The first camera 3 is connected to a vertical four-degree-of-freedom micro-displacement platform 7, which is connected to the Y-axis of the machining equipment. The first camera 3 can move with the Y-axis and is stationary relative to the micro-component 2. The second camera 4 is connected to a horizontal four-degree-of-freedom micro-displacement platform 6, which is fixed to the machining equipment B. The second camera 4 can rotate with the B-axis, move with the Z-axis, and is stationary relative to the cutting tool 5.

[0033] In a preferred embodiment, the information processing unit includes an image acquisition card, a memory, and a PLC controller; the first camera 3 and the second camera 4 are respectively connected to the image acquisition card, the image acquisition card is respectively connected to the memory and the PLC controller, the PLC controller is connected to a computer, and the computer is connected to a display module.

[0034] In a preferred embodiment, the first camera 3 and the second camera 4 are 26-megapixel high-resolution industrial area array digital cameras with a field of view of 6.4mm × 4.8mm.

[0035] In a preferred embodiment, both the vertical four-degree-of-freedom micro-displacement platform 7 and the horizontal four-degree-of-freedom micro-displacement platform 6 are capable of linear displacement adjustment along the X / Y / Z axes and rotational angle adjustment along the direction perpendicular to the mounting surface. The linear displacement is adjustable with a stroke of ±12.5mm and a fine-tuning accuracy of 2μm; the rotational angle is coarsely adjusted with a stroke of ±5° and a fine-tuning accuracy of 1°.

[0036] In a preferred embodiment, the computer includes an information processing module that receives raw image data from the image acquisition unit, adjusts parameters such as acquisition mode, image format, image quality, and color conversion mode of the raw image data, displays the image processing results on the display module, and controls the device to power on and off and the acquisition to start and stop during image acquisition.

[0037] Specific Implementation Method Two: Combining Figures 1 to 7 This embodiment describes an intelligent visual monitoring method for the entire process of manufacturing complex micro-components, which employs a visual monitoring system and includes the following steps:

[0038] Step 1 S100: Milling image acquisition. Adjust the negative pressure source of the multi-axis linkage ultra-precision machining equipment for complex micro-components to ensure that the complex micro-component 2 is stably adsorbed at the end of the fixture 1; turn on the pneumatic switch of the milling axis, and the tool 5 is clamped and locked at the end of the milling axis through the chuck; the image acquisition module includes two high-resolution industrial cameras, the first camera 3 and the second camera 4; the first camera 3 and the second camera 4 are arranged perpendicular to each other to achieve all-round monitoring of the micro-component processing area;

[0039] Step 2 S200: Image data processing. Based on the image information of the micro-milling area acquired by the image acquisition module, the information processing unit controls and processes the parameters of the acquisition process and the image. The display module is equipped with a device selection bar, an image display bar, an instruction control bar, and a status display bar. The device selection bar is used to select the cameras connected to the first and second vision monitoring windows. The corresponding camera models can be browsed and selected by clicking the drop-down box. The image display bar is used to display the images of the processing area acquired from the first and second cameras. The instruction control bar is used to adjust the parameters of the cameras connected to the vision monitoring system and the monitoring process. Each of the two CD cameras corresponds to a set of operation controls. The status display bar intuitively displays the camera connection status and allows for closing, maximizing / minimizing the information processing bar window.

[0040] The parameter setting controls in the status bar of the command control display module can adjust configuration parameters such as image acquisition format, acquisition control, analog control, image quality, color conversion, and HDR, thereby controlling the presentation of the monitored image in the image display bar and monitoring the material removal behavior during the micro-milling process.

[0041] In a preferred embodiment, the negative pressure source of the multi-axis linkage ultra-precision machining equipment used in step S100 has an adjustable range of -77.89 kPa.

[0042] In a preferred embodiment, the tool 5 used in step S100 is clamped and locked to the end of the milling shaft using an HSK high-precision chuck; the tool 5 used is a single-flute diamond ball end mill with a radius R of 0.303 mm.

[0043] In a preferred embodiment, in step two S200, the vertical four-degree-of-freedom micro-displacement platform 7 and the horizontal four-degree-of-freedom micro-displacement platform 6 are adjusted so that the line of sight of the first camera 3 is parallel to the Y-axis movement direction and points to the micro-component 2, and the micro-component 2 is located at the working distance of the first camera 3; the line of sight of the second camera 4 is parallel to the X-axis movement direction and points to the tool 5, and the tool 5 is located at the working distance of the second camera 4.

[0044] The other components and connections are the same as in Specific Implementation Method 1.

[0045] Specific implementation method three: Combining Figures 1 to 7 This embodiment describes the image acquisition module of the intelligent visual monitoring system and process method for the entire process of complex and minute component manufacturing. Figure 1As shown, the image acquisition module of the full-process visual monitoring system for micro-component machining mainly consists of a complex micro-component 2, a cutting tool 5, a first high-resolution industrial camera (hereinafter referred to as the first camera 3), and a second high-resolution industrial camera (hereinafter referred to as the second camera 4). The complex micro-component 2 is connected to the fixture 1 by vacuum adsorption, and the cutting tool 5 is connected to the end of the milling spindle by a high-precision pneumatic chuck. The first camera 3 and the second camera 4 respectively acquire image data of the tool-workpiece contact area in the horizontal and vertical planes.

[0046] The information processing unit and display module of the intelligent visual monitoring system for the entire process of complex and minute component manufacturing are as follows: Figure 4 As shown, the information processing unit of the visual monitoring system is used to intuitively display the entire process of micro-milling of tiny components, and can set and adjust parameters such as image acquisition mode, image format, and image quality. It mainly includes templates such as equipment selection bar, image display bar, command control bar, and status display bar.

[0047] The workflow diagram of the intelligent visual monitoring system and process method for the entire process of complex micro-component processing is as follows: Figure 6 As shown, an intelligent visual monitoring system and process method for the entire process of machining complex micro-components is an image information processing unit and process method for observing the material removal behavior and tool-workpiece contact process status during the entire process of micro-milling the surface feature structure of micro-components. The micro-component 2 is adsorbed onto the end of the fixture by negative pressure, and the tool 5 is connected to the end of the milling axis via a pneumatic chuck. A first camera 3 is used to monitor the material milling process status in the XZ horizontal plane, and a second camera 4 is used to monitor the material milling process status in the YZ vertical plane. The image information acquired by the dual high-resolution cameras is transmitted to the control software of the multi-axis linkage ultra-precision machining equipment for complex micro-components via a USB 3.0 data interface. The intelligent visual monitoring system integrates an image display bar to intuitively show the real-time contact status of the tool and workpiece; the monitoring system can also adjust the image acquisition mode, image format, and quality through the command control bar, thereby realizing intelligent visual monitoring of the entire machining process of complex micro-components.

[0048] Working principle and operation method:

[0049] The intelligent visual monitoring system and process method for the entire process of machining complex micro-components are aimed at monitoring the behavior of tool-workpiece contact, material removal, and tool wear during the micro-milling of surface features of complex micro-components. It can be divided into an image acquisition module. Figure 1 and information processing unit Figure 7 Two parts. For example... Figure 5 As shown, high-resolution industrial cameras are used to collect image information of the milling area's process status, which is then processed by the information processing unit and presented intuitively, realizing intelligent visual monitoring of the entire process of feature structure forming.

[0050] Detailed instructions and operating procedures:

[0051] I. Milling Image Acquisition: Adjusting the negative pressure source of the multi-axis linkage ultra-precision machining equipment for complex micro-components (adjustable range: -77.89 kPa) ensures that the complex micro-component 2 is stably adsorbed at the end of the fixture 1. Turning on the pneumatic switch of the milling axis, the tool is clamped and locked at the end of the milling axis via an HSK high-precision chuck. The tool used is a single-flute diamond ball end mill with a radius R of 0.303 mm. The image acquisition module includes two high-resolution industrial cameras (first and second), a high-resolution zoom lens, data transmission cables, and other accessories. The lens and camera are connected via a standard USB-C port; the camera and cable are connected via a standard Micro USB-B interface with a fastening screw; image data is transmitted to the machining equipment's industrial control computer via USB 3.0. The first camera 3 and its auxiliary lens are connected to a vertical four-degree-of-freedom micro-displacement platform 7 and connected to the machining equipment's Y-axis slide via a transition plate (it can move with the Y-axis but remains stationary relative to the micro-component). The second camera 4 and its auxiliary lens are connected to the horizontal four-degree-of-freedom micro-displacement platform 6 and fixed to the hydraulic rotary B-axis transition plate of the machining equipment via a transition plate (it can rotate with the B-axis, move with the Z-axis, and remain stationary relative to the tool). The first and second cameras are arranged perpendicularly to each other, enabling omnidirectional monitoring of the machining area of ​​the micro-components. The first and second cameras are 26-megapixel high-resolution cameras with a field of view of 6.4mm × 4.8mm. The four-degree-of-freedom micro-displacement platform can be adjusted linearly along the X / Y / Z axes and rotated vertically along the mounting surface (linear displacement adjustable stroke ±12.5mm, fine adjustment accuracy 2μm; rotational angle coarse adjustment stroke 360°, fine adjustment stroke ±5°, fine adjustment accuracy 1°).

[0052] The vertical and horizontal micro-displacement platforms are adjusted so that: 1) the line of sight of the first camera 3 is parallel to the Y-axis movement direction and points to the micro-component 2, and the micro-component is located at the working distance of the first camera 3; 2) the line of sight of the second camera 4 is parallel to the X-axis movement direction and points to the tool, and the tool 5 is located at the working distance of the second camera 4; 3) the tool-workpiece contact area is clearly imaged in the information processing unit, and the lens magnification is adjusted so that the tool-workpiece contact area fills more than 3 / 4 of the information processing unit-image display area, thereby realizing real-time acquisition of the processing area image.

[0053] (II) Image Data Processing: Based on the image information of the micro-milling area acquired by the image acquisition module, the information processing unit controls and processes the acquisition process and image parameters. For example... Figure 4As shown, the information processing unit display module includes modules such as a device selection bar, an image display bar, a command control bar, and a status display bar. The device selection bar is used to select the cameras connected to the first and second vision monitoring windows; users can browse and select the corresponding camera model by clicking the drop-down menu. The image display bar displays images of the processing area acquired from the first and second CCD cameras. The command control bar is used to adjust the parameters and monitoring process of the cameras connected to the vision monitoring system; each of the two CCD cameras corresponds to a set of operation controls. The status display bar visually displays the camera connection status and allows users to close, maximize, or minimize the information processing unit window. The parameter setting controls in the command control bar allow users to adjust configuration parameters such as image acquisition format, acquisition control, analog control, image quality, color conversion, and HDR, thereby controlling the presentation of the monitored image in the image display bar for a more intuitive and comprehensive understanding of material removal behavior during the micro-milling process. After confirming that the hardware connection of the dual CCD camera image acquisition module is normal, open the information processing unit of the visual monitoring system. In the device selection bar of the first and second CCD camera monitoring windows, select the corresponding camera model respectively. Click the "Open Device" button as needed to display the image acquired by the corresponding camera in the corresponding image display bar. Click the "Start Acquisition" button to completely record the material micro-removal process. The acquisition mode, image quality, and other parameters can be adjusted using the parameter setting buttons. The "Stop Acquisition" and "Close Device" buttons can be used to stop the recording process and close the CCD camera, respectively. Note: The same camera cannot be selected in both device selection bars simultaneously. After setting parameters, the camera must be closed and reopened. The information processing unit integrates camera selection and image display, parameter setting, and process control, enabling rapid processing and intuitive display of image information. In conjunction with the image acquisition module, it acquires regional images in real time, enabling intelligent visual monitoring of the entire process of micro-milling of complex micro-components.

[0054] In this embodiment, the information processing unit includes an image acquisition card, a memory, and a PLC controller. The first camera 3 and the second camera 4 are respectively connected to the image acquisition card, which is connected to both the memory and the PLC controller. The PLC controller is connected to a computer, and the computer is connected to a display module. The computer includes an information processing module that receives raw image data from the image acquisition unit and adjusts parameters such as acquisition mode, image format, image quality, and color conversion mode. It displays the image processing results on the display module and controls the device's on / off state and the start / stop of image acquisition. The algorithm used by the information processing module to adjust parameters such as acquisition mode, image format, image quality, and color conversion mode for the raw image data is existing technology. Preferably, the technology disclosed in patent application CN2021110618458, entitled "A High-Precision Tool Setting Method and Device for Machining the Full Surface Micro-Pit Structure of Thin-Walled Spherical Shell Micro-Components," or patent application CN2022103665196, entitled "An Ultra-Precision Turning Machine Tool and Tool Setting and Machining Monitoring Method for Micro-Conical Rotating Components," is preferred.

[0055] The other components and connections are the same as in Specific Implementation Method 1.

[0056] Specific implementation method four: Combination Figures 1 to 7 This embodiment describes an intelligent monitoring system and method for the entire machining process of complex micro-components. This system addresses the problems of existing milling monitoring methods, such as limited observation perspective, restricted observation area, and disconnect between observation and analysis, which make it difficult to effectively identify material removal behavior and workpiece-tool contact during milling, thus hindering dynamic control of machining quality. The operation flow is illustrated below. Figure 6 As shown, specific implementation examples are as follows:

[0057] Step 4.1: Turn on the multi-axis linkage ultra-precision machining equipment for complex micro-components and confirm the hardware connection. Turn on the negative pressure and adsorb and clamp the micro-component 2 onto the fixture 1. Turn on the milling axis conversion switch and clamp the single-edged diamond tool 5 onto the milling axis to complete the compilation and loading of the machining program.

[0058] Step 4.2: Check the hardware connection of the visual monitoring system. Open the monitoring system information processing unit on the industrial computer desktop. Select MER2-302-56U3M (FDU22070166) in the monitoring window of the first camera 3 and MER2-302-56U3M (FDU22070167) in the monitoring window of the second camera 4.

[0059] Step 4.3: In the dual-camera monitoring window, open the device and start acquisition in sequence. The dual CCD cameras will then acquire the process status of the milling area in real time, such as... Figure 5As shown. Clicking the start button in the micro-milling equipment control software program initiates the microstructure removal process, while the vision monitoring system monitors the tool-workpiece contact area morphology in real time and displays it visually. Users can save relevant images and adjust process parameters as needed to improve the machining quality of complex micro-components.

[0060] The other components and connections are the same as in Specific Implementation Method 1.

[0061] The above are merely preferred embodiments of the present invention and are not intended to limit the present 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 principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An intelligent visual monitoring system for the entire process of processing complex micro-components, characterized in that: It includes an image acquisition unit and an information processing unit; the image acquisition unit uses an industrial camera to acquire image data of the entire machining process, such as tool and workpiece contact, material removal behavior, and tool wear, in both horizontal and vertical planes, and transmits them to the information processing unit. The information processing unit controls the camera device to turn on and off and to start and stop image acquisition during image acquisition, and adjusts parameters such as acquisition mode, image format, image quality and color conversion mode, and displays the entire process of microstructure micromilling in real time.

2. The intelligent visual monitoring system for the entire process of complex micro-component processing according to claim 1, characterized in that: The image acquisition unit includes a first camera (3) and a second camera (4). The micro-component (2) is connected to the fixture (1) of the multi-axis linkage ultra-precision machining equipment by vacuum adsorption. The cutting tool (5) is connected to the end of the milling shaft of the multi-axis linkage ultra-precision machining equipment by a pneumatic chuck. The first camera (3) and the second camera (4) respectively acquire image data of the tool-workpiece contact area in the horizontal plane and the vertical plane. The first camera (3) is connected to a vertical four-degree-of-freedom micro-displacement platform (7), which is connected to the Y-axis of the processing equipment. The first camera (3) can move with the Y-axis and remain stationary relative to the micro-component (2). The second camera (4) is connected to a horizontal four-degree-of-freedom micro-displacement platform (6), which is fixed to the processing equipment B. The second camera (4) can rotate with the B-axis, move with the Z-axis, and remain stationary relative to the tool (5).

3. The intelligent visual monitoring system for the entire process of complex micro-component processing according to claim 1, characterized in that: The information processing unit includes an image acquisition card, a memory, and a PLC controller; the first camera (3) and the second camera (4) are respectively connected to the image acquisition card, the image acquisition card is respectively connected to the memory and the PLC controller, the PLC controller is connected to the computer, and the computer is connected to the display module.

4. The intelligent visual monitoring system for the entire process of complex micro-component processing according to claim 2, characterized in that: The first camera (3) and the second camera (4) are 26-megapixel high-resolution industrial area array digital cameras with a field of view of 6.4mm×4.8mm.

5. The intelligent visual monitoring system for the entire process of complex micro-component processing according to claim 2, characterized in that: Both the vertical four-degree-of-freedom micro-displacement platform (7) and the horizontal four-degree-of-freedom micro-displacement platform (6) can be adjusted for linear displacement along the X / Y / Z axis and for rotational angle adjustment along the vertical direction of the mounting surface. The linear displacement adjustable stroke is ±12.5mm and the fine adjustment accuracy is 2μm. The rotational angle coarse adjustment stroke is 360° and the fine adjustment stroke is ±5°, with a fine adjustment accuracy of 1°.

6. The intelligent visual monitoring system for the entire process of complex micro-component processing according to claim 3, characterized in that: The computer includes an information processing module, which receives raw image data from the image acquisition unit and adjusts parameters such as acquisition mode, image format, image quality, and color conversion mode of the raw image data. The information processing module displays the image processing results on the display module and controls the device to turn on and off and to start and stop the acquisition during image acquisition.

7. A method for intelligent visual monitoring of the entire process of processing complex micro-components, characterized in that: The visual monitoring system described in any one of claims 1-6 includes the following steps: Step 1 S100: Milling image acquisition, adjust the pressure of the negative pressure source of the multi-axis linkage ultra-precision machining equipment for complex micro-components so that the complex micro-component (2) is stably adsorbed at the end of the fixture (1); Turn on the pneumatic switch of the milling axis, and the tool (5) is clamped and locked at the end of the milling axis through the chuck; the image acquisition module includes two high-resolution industrial cameras, the first camera (3) and the second camera (4); the first camera (3) and the second camera (4) are arranged perpendicular to each other to realize all-round monitoring of the processing area of ​​the micro-components; Step 2 S200: Image data processing. Based on the image information of the micro-milling area obtained by the image acquisition module, the information processing unit controls and processes the parameters of the acquisition process and the image. The display module is equipped with a device selection bar, an image display bar, an instruction control bar, and a status display bar. The device selection bar is used to select the cameras connected to the first and second vision monitoring windows. You can browse and select the corresponding camera model by clicking the drop-down box. The image display bar is used to display the processing area images obtained from the first camera (3) and the second camera (4). The instruction control bar is used to adjust the parameters of the cameras connected to the vision monitoring system and the monitoring process. The two CD cameras correspond to a set of operation controls. The status display bar intuitively displays the camera connection status and can close, maximize / minimize the information processing bar window. The parameter setting controls in the status bar of the command control display module can adjust configuration parameters such as image acquisition format, acquisition control, analog control, image quality, color conversion, and HDR, thereby controlling the presentation of the monitored image in the image display bar and monitoring the material removal behavior during the micro-milling process.

8. The intelligent visual monitoring method for the entire process of complex micro-component processing according to claim 7, characterized in that: The negative pressure source of the multi-axis linkage ultra-precision machining equipment used in step S100 has an adjustable range of -77.89 kPa.

9. The intelligent visual monitoring method for the entire process of complex micro-component processing according to claim 7, characterized in that: The tool (5) used in step S100 is clamped and locked at the end of the milling shaft by an HSK high-precision chuck; the tool (5) used is a single-edged diamond ball end mill with a radius R of 0.303mm.

10. The intelligent visual monitoring method for the entire process of complex micro-component processing according to claim 7, characterized in that: In step two S200, the vertical four-degree-of-freedom micro-displacement platform (7) and the horizontal four-degree-of-freedom micro-displacement platform (6) are adjusted so that the line of sight of the first camera (3) is parallel to the Y-axis movement direction and points to the micro-component (2), and the micro-component (2) is located at the working distance of the first camera (3); the line of sight of the second camera (4) is parallel to the X-axis movement direction and points to the tool (5), and the tool (5) is located at the working distance of the second camera (4).

Images