A continuous automatic secondary tool setting method, device, equipment and medium based on a numerical control gear machine tool

Abstract

The application relates to the technical field of machine tool machining control, in particular to a continuous automatic secondary tool setting method, device, equipment and medium based on a numerical control gear machine tool, which comprises the following steps: after the coupling of a tool shaft and a workpiece shaft, the tool shaft and the workpiece shaft are continuously rotated in one direction; the full-tooth coordinates of the workpiece are collected by using a continuous measurement function, and the installed tooth number is verified by calculating the coordinate jump data; if the tooth numbers match, the actual angle of each tooth of the full tooth is calculated, the quenching deformation amount is estimated, and the initial phase deviation is determined; the first piece is cut by using a hand wheel guide function, and the accurate compensation angle is determined; finally, the compensation angle is superimposed into the workpiece shaft coordinates in the coupled state by using a phase tracking function, and the automatic tool setting with high precision is completed. By continuously measuring the full tooth in one direction after the coupling, the application solves the reverse gap precision problem, the quenching deformation uneven problem and the efficiency problem of repeated start and stop of the main shaft in the prior art, and realizes the secondary tool setting with higher precision, lower rejection rate and higher automation level.

Description

Technical Field

[0001] This application relates to the field of machine tool processing control technology, and in particular to a continuous automatic secondary tool setting method, device, equipment and medium based on a CNC gear machine tool. Background Technology

[0002] CNC gear machine tools, such as CNC gear hobbing machines and gear grinding machines, are core equipment in modern precision gear manufacturing. With the development of industrial technology, especially the demand for high-load, high-speed, and high-smoothness transmission systems (such as new energy vehicle gearboxes, precision reducers, and planetary screws), the surface hardness and machining accuracy requirements for gears are constantly increasing. Therefore, gear machining processes commonly involve rough machining (such as gear hobbing), followed by heat treatment (such as quenching and carburizing), and then returning the gears to the machine tool for secondary finishing (such as precision hobbing and precision grinding).

[0003] Secondary tool setting is an indispensable and crucial step in the gear manufacturing process described above. Its core task is to precisely determine the phase relationship between the center of the tooth grooves and the cutting edge center of the finishing tool (such as a hob or grinding wheel) when a gear workpiece, after rough machining and heat treatment, is removed from the rough machining equipment and re-clamped onto the finishing equipment. After finding this phase deviation, a series of measurements and program compensation methods must be used to ensure precise alignment of the two before finishing begins, guaranteeing that the finishing tool can accurately cut into the tooth grooves left by rough machining, achieving uniform removal of excess material. The accuracy, efficiency, and reliability of secondary tool setting directly determine the meshing performance, load-bearing capacity, and service life of the final gear, making it one of the bottleneck processes for ensuring the quality of the final product.

[0004] However, traditional secondary tool setting methods and existing patented technologies have revealed many serious shortcomings when facing increasingly stringent requirements for precision, efficiency, and automation: 1. Limitations of traditional manual tool setting: The most primitive tool setting methods, such as the coloring method and visual inspection method, rely entirely on the operator's experience and subjective judgment. They are time-consuming, labor-intensive, have extremely low accuracy and poor consistency, and cannot meet the needs of modern automated mass production.

[0005] 2. Deficiencies of existing three-point measurement methods (such as patent application number 201310244103.8): This patent discloses a three-point measurement method based on an intelligent amplifier, sensor, and mechanical device. Its main deficiency is: (a) Poor measurement location: This method requires acquiring coordinates near the tooth tip and root. However, burrs are easily generated at the tooth tip and root after rough machining, and these areas are the most significant areas of thermal deformation (such as expansion and twisting) after heat treatment (quenching). Acquiring coordinates at these geometrically unstable locations introduces huge measurement errors and seriously affects tool setting accuracy.

[0006] (b) Complex operation and high cost: This method heavily relies on imported intelligent amplifiers. Operators need to tediously set parameters such as high and low points and trigger thresholds on the amplifier according to different gear specifications and probes, which requires a very high level of skill from the operators and involves a long training period. At the same time, the intelligent amplifiers and matching high-precision imported probes are expensive and have long supply cycles, increasing the manufacturing cost and maintenance difficulty of the machine tool.

[0007] 3. Deficiencies of existing reverse rotation measurement methods (such as patent application number 202311197485.3): Although this patent optimizes the sampling point position, it requires the workpiece axis to rotate in the reverse direction during the sampling process (e.g., from point 102 to point 103). For most non-direct drive workpiece spindles (e.g., using worm gears or gear trains), there will inevitably be backlash in the mechanical transmission chain. When the spindle reverses, this backlash will immediately be reflected in the coordinate readings, causing serious and unpredictable impacts on the accuracy of the acquired coordinates, thereby directly reducing the accuracy and reliability of secondary tool setting.

[0008] 4. Common defects in existing technologies: (a) Limitations (fundamental flaw) of "adjacent two teeth" measurement: Existing technologies essentially only collect the tooth surface coordinates of any two adjacent teeth on the workpiece. This method assumes that the workpiece is an ideal rigid body or that the deformation is uniform. However, in actual production, during the heat treatment (quenching) process of gears, uneven cooling, stress release, and other factors will almost inevitably result in uneven circumferential deformation (i.e., the deformation of each tooth may be different). In addition, workpiece clamping eccentricity will also lead to circumferential errors. The "adjacent two teeth" measurement method cannot detect or take into account such uneven quenching deformation or clamping eccentricity of the entire tooth. It can only calculate a compensation value based on the data of two local teeth. When this local compensation value is used to machine the entire tooth, it will inevitably lead to: excessive cutting on some teeth and insufficient cutting on others, or even no cutting at all, resulting in the so-called "black skin" phenomenon. This "black skin" is a serious quality defect in gear finishing, which will lead to the direct scrapping of the gear. Therefore, the method of measuring only two adjacent teeth results in a high scrap rate when dealing with high-precision gears and workpieces with high quenching deformation.

[0009] (b) Risk of Unverifiable Workpiece Parameters: Measuring only two teeth makes it impossible to accurately determine whether the actual number of teeth (Z) of the gear currently installed on the machine tool matches the gear data entered by the operator in the software program. In automated production, if workpiece mixing occurs (e.g., a gear with Z=40 is mistakenly loaded as a gear with Z=41), and the tool setting program cannot recognize it, the measurement comparison benchmark will be completely incorrect. Subsequent finishing will be performed according to the incorrect parameters, causing catastrophic damage to the workpiece and tool, resulting in an extremely high scrap rate.

[0010] (c) Inefficiency and wear of "pre-coupling" measurements: Existing technologies generally perform tool setting measurements before coupling the electronic gearbox (EGB). This means that the machine tool needs to execute a process of "measurement (spindle stop) → compensation calculation → spindle start → EGB coupling → machining". In mass production, this results in the electronic gearbox needing to be repeatedly switched on and off, and the workpiece and tool axes also needing to be repeatedly started and stopped. This working mode not only seriously affects the machining cycle time and significantly reduces production efficiency, but also causes frequent impacts and wear on the spindle and transmission system (especially the EGB coupling mechanism), significantly reducing the service life of the spindle and critical components.

[0011] (d) Pervasive reliance on amplifiers: As mentioned above, most existing technologies rely on amplifiers for signal conditioning, which introduces problems in terms of cost, complexity and operational skill requirements.

[0012] In conclusion, the industry urgently needs a new secondary tool setting technology solution that must be able to: 1. Overcome the impact of backlash on accuracy; 2. Completely solve the problem of "black skin" scrap caused by the inability to take into account the uneven quenching deformation of the entire tooth due to the measurement of "adjacent two teeth"; 3. Provide a reliable mechanism to verify the parameters of the actual workpiece and prevent incorrect machining; 4. Solve the problems of low efficiency and spindle wear caused by "pre-coupling" measurement; 5. Reduce reliance on complex external hardware (such as amplifiers), simplify operation, and reduce costs. Summary of the Invention

[0013] This application provides a continuous automatic secondary tool setting method, device, equipment, and medium based on CNC gear machine tools. By optimizing the measurement process to be coupled and adopting a continuous measurement method for the entire gear, combined with advanced CNC system functions and self-developed professional process software packages, high-precision and high-efficiency automated tool setting is achieved, effectively solving the problems of backlash accuracy, uneven quenching deformation, and the influence of machining cycle time.

[0014] In a first aspect, this application provides a continuous automatic secondary tool setting method based on a CNC gear machine tool, the method comprising: S1: After orienting the tool axis and workpiece axis of the CNC gear machine tool, open the electronic gearbox to couple the tool axis and workpiece axis, and instruct the tool axis and workpiece axis to rotate continuously in one direction at a matched secondary tool setting speed; S2: Using a self-made sensor probe to detect tooth surface signals, and in conjunction with the continuous measurement function of the CNC system, the coordinate jump signals of the entire tooth of the workpiece clamped on the workpiece shaft are collected under the coupled rotation state; S3: By calculating the number of coordinate jumps in one measurement cycle, the actual number of teeth on the workpiece is determined and compared with the preset number of teeth input by the CNC system for verification; S4: If the actual number of teeth matches the preset number of teeth, the position coordinates of the left and right tooth surfaces of each tooth groove are extracted using the data of the coordinate jump signal to calculate the actual center coordinates of each tooth groove. Then, the actual angle of each tooth is calculated and compared with the theoretical angle to estimate the quenching deformation and clamping eccentricity of each tooth, and to determine the initial phase deviation value. S5: Utilizing the phase tracking function of the CNC system, in the coupled state, the phase compensation value used to compensate for the quenching deformation and the clamping eccentricity is automatically superimposed on the movement coordinates of the workpiece axis, thereby achieving phase matching between the tool axis and the workpiece axis and completing automatic secondary tool setting.

[0015] In some embodiments of this application, in step S3, if the actual number of teeth does not match the preset number of teeth, the CNC system issues an alarm and stops the subsequent secondary finishing process.

[0016] In some embodiments of this application, prior to step S4, the following steps are also included: The first piece is cut using the handwheel guidance function of the CNC system. The relative feed between the tool axis and the workpiece axis is controlled by the handwheel guiding function, so that the tool and the workpiece are slightly engaged, and the scraping of the entire tooth surface of the workpiece is observed. Based on the scraping condition of the entire tooth surface of the workpiece, the phase compensation value is determined and input into the self-developed professional process software package of the CNC system.

[0017] In some embodiments of this application, step S4, which involves estimating the quenching deformation per tooth and determining the initial phase deviation value, includes: Calculate the set of deviation values ​​between the actual angle of each tooth and the theoretical angle. Take the average or median of the set of deviation values ​​as the initial phase deviation value to ensure that each tooth can be processed uniformly after the second finishing process and avoid the phenomenon of black skin on some tooth surfaces.

[0018] In some embodiments of this application, the unidirectional continuous rotation in step S1 is intended to prevent the workpiece shaft from entering a backlash due to reverse rotation, thereby eliminating its impact on the accuracy of coordinate acquisition.

[0019] In some embodiments of this application, in step S2, The self-made sensor probe is equipped with an indicator light. The method further includes, before step S1, adjusting the position of the self-made sensor probe according to the module and number of teeth of the workpiece, and ensuring that the self-made sensor probe is located in the middle area of ​​the tooth surface of the gear pitch circle by observing the status of the indicator light at the tail of the self-made sensor probe.

[0020] In some embodiments of this application, the CNC system has advanced programming, continuous measurement, handwheel guidance, and phase tracking functions; Steps S1 to S5 are all completed by the CNC system executing an automatic continuous secondary tool setting program and a self-developed professional process software package in a coordinated manner.

[0021] Secondly, this application provides a secondary tool setting device based on a CNC machine tool, the device comprising: The coupling rotation module is used to couple the tool axis and the workpiece axis and make them rotate continuously in one direction at a matched secondary tool setting speed; The measurement and verification module is used to acquire the coordinate jump signal of the full teeth of the workpiece clamped on the workpiece shaft in the coupled rotation state using the continuous measurement function, and to determine the actual number of teeth of the workpiece by calculating the number of coordinate jumps, and to verify it by comparing it with the preset number of teeth. The deviation estimation module is used to calculate the actual angle per tooth when the actual number of teeth matches the preset number of teeth, and compare it with the theoretical angle to estimate the quenching deformation and clamping eccentricity of each tooth, and determine the initial phase deviation value. The phase compensation module is used to automatically superimpose the phase compensation value onto the workpiece axis movement coordinates in the coupled state using the phase tracking function, thereby achieving automatic secondary tool setting.

[0022] Thirdly, this application provides a computer device, comprising: One or more processors; Memory; One or more programs, wherein the one or more programs are stored in the memory and configured to be executed by the one or more processors, the one or more programs being configured to perform the methods of this application.

[0023] Fourthly, this application provides a computer-readable storage medium storing program code that can be invoked by a processor to execute the method of this application.

[0024] By adopting the above technical solution, this application includes at least one of the following beneficial effects: 1. Fundamental Improvement in Precision and Quality: This application employs continuous measurement across the entire tooth, replacing the "adjacent two-tooth" measurement method. This allows the application to acquire deformation data for the entire circumference of the workpiece and calculate the quenching deformation and clamping eccentricity of each tooth accordingly. Through a uniform compensation algorithm, this application can find an "optimal solution" that takes into account the deformation of all teeth, ensuring that each tooth is uniformly scraped after secondary finishing. This fundamentally solves the "black skin" phenomenon and high scrap rate problems caused by the inability of existing technologies to account for uneven deformation across the entire tooth, resulting in a significant improvement in product quality and consistency.

[0025] 2. Solving the problem of decreased accuracy caused by backlash: This application adopts unidirectional continuous rotation measurement. During the measurement process, the workpiece axis always rotates in one direction, which completely eliminates the mechanical backlash introduced by reverse rotation and ensures the original accuracy and reliability of coordinate acquisition.

[0026] 3. Significantly improved production efficiency and extended workpiece axis life: This application enables direct measurement after coupling. Compared to existing technologies that require measurement "before coupling," this application eliminates the need for repeated switching of the electronic gearbox and repeated starting and stopping of the workpiece axis. Tool setting and compensation actions are completed "seamlessly" during workpiece axis rotation and coupling, greatly shortening auxiliary time for single-piece machining and significantly improving machining cycle time and production efficiency. Simultaneously, it avoids frequent start-stop shocks to the workpiece axis and electronic gearbox, significantly extending the service life of core machine tool components.

[0027] 4. Extremely high reliability and automation level (preventing mismachining): This application incorporates an "automatic verification of actual tooth count" step. By measuring the number of coordinate jumps of the entire tooth, the program can automatically determine whether the actual workpiece is correctly installed. This "error prevention" mechanism is completely absent in existing technologies. It can effectively avoid catastrophic mismachining caused by workpiece mixing or data input errors, greatly improving the reliability of automated production.

[0028] 5. Reduced costs and greatly simplified operation: This application uses a self-made sensor probe with an integrated light, completely eliminating the reliance on expensive and complex intelligent amplifiers. When adjusting the probe position, operators only need to observe the indicator light status at the probe's tail (e.g., light on / off), without needing to understand complex analog signals or set threshold parameters, significantly reducing the skill requirements for operators. Furthermore, this application uses a handwheel-guided function to optimize the first-piece adjustment, allowing operators to intuitively find the optimal compensation value, greatly improving the first-time success rate of the first-piece adjustment and shortening the debugging time.

[0029] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0030] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0031] Figure 1 This is a flowchart illustrating a continuous automatic secondary tool setting method based on a CNC gear machine tool provided in an embodiment of this application. Figure 2 This is a schematic diagram of a continuous automatic secondary tool setting method based on a CNC gear machine tool provided in an embodiment of this application; Figure 3 This is a schematic diagram of the structure of a continuous automatic secondary tool setting device based on a CNC gear machine tool provided in an embodiment of this application; Figure 4 This is a structural block diagram of a device for executing the continuous automatic secondary tool setting method based on a CNC gear machine tool according to an embodiment of this application. Detailed Implementation

[0032] 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, 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.

[0033] The following detailed description of some embodiments of this application is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0034] It should be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the scope of the application. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0035] It should be understood that, in order to clearly describe the technical solutions of the embodiments of this application, the terms "first" and "second" are used in the embodiments of this application to distinguish identical or similar items with essentially the same function and effect. For example, the first groove and the second groove are only used to distinguish different grooves and do not limit their order. Those skilled in the art will understand that the terms "first" and "second" do not limit the quantity or execution order, and the terms "first" and "second" are not necessarily different.

[0036] It should also be further understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0037] This application reconstructs the secondary tool setting process, moves the measurement action from "before coupling" to "after coupling", expands the measurement object from "two adjacent teeth" to "the entire tooth", and uses specific advanced functions of the CNC system (continuous measurement, phase tracking, handwheel guidance) to replace traditional inefficient operations and expensive hardware (amplifiers), thereby comprehensively surpassing existing technologies in four dimensions: accuracy, efficiency, reliability and cost.

[0038] like Figures 1 to 4 As shown in the embodiments of this application, a continuous automatic secondary tool setting method based on a CNC gear machine tool can be implemented using a CNC system, where the CNC system is the core controller. This application requires that the selected CNC system (e.g., FANUC, SIEMENS, Huazhong, or the domestic Googol GNS-016 system) must possess or be configurable with the following key advanced functions and hardware interfaces: Continuous measurement / high-speed jump function: This is the physical basis for achieving high-precision sampling. This function corresponds to a specific hardware I / O interface. When the sensor signal (from the self-made sensor probe) connected to this interface experiences a level transition (e.g., rising edge), the CNC system's hardware layer immediately "latches" the absolute position coordinates of the currently controlled axis (i.e., the workpiece axis) into a dedicated system register. Because this is a hardware behavior, it is completely unaffected by the scanning cycle of the CNC system software (such as PLC or NC program), avoiding software delays. Therefore, even when the workpiece axis is rotating at high speed, extremely accurate trigger position coordinates can be captured. This is the technical guarantee for performing S2 full-tooth measurement.

[0039] Electronic gearbox: This is a standard feature of geared machine tools, used to establish a rigid, programmable transmission ratio between the tool axis and the workpiece axis, enabling them to rotate synchronously.

[0040] Handwheel guidance function: This function allows the operator to temporarily control the machine tool's feed (F) or the movement of a specific axis via the electronic handwheel during automatic program (Auto mode) operation. The operator directly controls the tool's feed speed and position by turning the electronic handwheel. This enables the operator to perform trial cuts (adjustment cuts) using the electronic handwheel in a "human-machine collaboration" manner. This is a key function for performing the first piece adjustment cut.

[0041] Phase tracking function: This is an advanced feature of the electronic gearbox and is the core of the "coupling compensation" achieved in this application. In a standard electronic gearbox, the theoretical position of the workpiece axis is a function of the tool axis position. The phase tracking function allows the program to inject a compensation offset into the formula without decoupling the electronic gearbox. This causes the actual position of the workpiece axis to become: + This application utilizes this function to measure and calculate... The compensation value is dynamically and smoothly superimposed onto the workpiece axis before machining to complete automatic tool setting.

[0042] The self-made sensor probe is a key hardware simplification in this application, replacing the expensive amplifier.

[0043] A homemade sensor probe is an integrated component. It contains a sensing element (e.g., an inductor coil for detecting metal teeth), a conversion element and a signal conditioning circuit (for converting the weak analog signal detected by the sensing element into a clear, interference-resistant digital switching signal, such as 0V / 24V), and a status indicator circuit (usually an LED).

[0044] Working principle: Its internal conditioning circuit is precisely set. When the distance between the end face of the self-made sensor probe and the metal tooth surface of the gear being measured is exactly within a very narrow "optimal detection window" (for example, corresponding to the region with the most stable geometry near the gear's pitch circle), the conditioning circuit outputs a high level (24V), and the status indicator light illuminates. When the distance is too close or too far (for example, at the tooth groove), the circuit outputs a low level (0V), and the indicator light goes out.

[0045] Traditional amplifiers require operators to set complex analog thresholds. However, the self-made sensor probe of this application has its "threshold" physically fixed. When adjusting the probe position for the first part, operators do not need any instruments or parameter settings. They simply need to slowly rotate the workpiece shaft under the guidance of an electronic handwheel while adjusting the radial / axial position of the self-made sensor probe. Their sole objective is to observe the indicator light at the tail until they find a position where the indicator light illuminates precisely in the center of the metal tooth surface (pitch circle area) and extinguishes at the tooth groove. This "light-observation operation" is extremely intuitive and simple, greatly reducing the skill requirements for operators.

[0046] Different self-made sensor probes with different diameters are required for gears with different modules. For example, for gears with a smaller module Mn (e.g., 0.4mm~1.25mm), the tooth grooves are narrower, requiring a self-made sensor probe with a smaller diameter (e.g., Φ4). For gears with a larger module (e.g., 1.25mm~3mm), a self-made sensor probe with a larger diameter (e.g., Φ6.5) can be used to obtain a stronger signal and anti-interference capability.

[0047] The self-developed professional process software package is the software carrier for implementing the process described in this application. It is a special software developed on the open platform of the CNC system (such as PCU or HMI).

[0048] Human-machine interface: A graphical interface is provided where the operator inputs all the process parameters of the workpiece (preset number of teeth Z, module Mn, helix angle β, tool parameters, etc.). A key "automatic secondary tool setting" function option (e.g., a checkbox) is provided on the interface.

[0049] Background program: This is the core NC program and PLC logic (i.e., the "automatic continuous secondary tool setting program"). When the "automatic secondary tool setting" function on the human-machine interface is activated, the background main program will automatically call the "automatic continuous secondary tool setting subroutine" at the beginning of the machining program.

[0050] Parameter transmission and storage: The human-machine interface is responsible for transmitting parameters such as the preset tooth count Zpreset input by the operator to the background program for tooth count verification and deformation estimation. Simultaneously, the human-machine interface also includes a "compensation motion value" input / display box to store the phase compensation value determined during the first piece cutting process. And pass it to the phase tracking function.

[0051] like Figure 1 As shown, it includes the following steps: Step S1: Coupling and Startup The operator clamps the quenched gear workpiece (Z=40) onto the workpiece shaft fixture of the machine tool.

[0052] The operator inputs the preset number of teeth on the human-machine interface of the self-developed professional process software package. ... (other parameters), and check the "Automatic Secondary Tool Setting" function option.

[0053] (If it is the first piece) The operator performs the preparation steps: use the electronic handwheel to adjust the position of the self-made sensor probe, observe the indicator light, until it is stably triggered at the pitch circle position.

[0054] The operator presses the "cycle start" button on the machine tool.

[0055] The background program begins execution: first, orientation is performed, then the electronic gearbox is turned on to couple the tool axis and the workpiece axis.

[0056] The program instructs the tool axis to rotate at a preset "secondary tool setting speed," while the workpiece axis rotates synchronously and continuously in one direction according to the transmission ratio of the electronic gearbox.

[0057] Since the workpiece shaft always rotates in one direction (e.g., clockwise), the backlash in its transmission chain is always eliminated on the same side, ensuring that no backlash error is introduced during the measurement process.

[0058] Step S2: Continuous full tooth measurement When the tool axis and workpiece axis are in coupled rotation, the program activates the continuous measurement / high-speed jump function of the CNC system.

[0059] A homemade sensor probe sweeps across the tooth surface of a workpiece while rotating. For example... Figure 2 As shown, for a gear with Z=40, for each rotation of the workpiece shaft, the self-made sensor probe will sequentially sweep across the left and right tooth surfaces of the 1st tooth, the 2nd tooth, and so on, up to the left and right tooth surfaces of the 40th tooth.

[0060] Whenever the self-made sensor probe sweeps across a tooth surface (for example, from the tooth groove to the tooth surface, the signal jumps from 0V to 24V), the continuous measurement / high-speed jump function interface will hardware latch the absolute coordinate of a workpiece axis.

[0061] The program waits for the workpiece axis to rotate more than 360 degrees (e.g., 370 degrees) to ensure that all teeth (all 40 teeth) are measured.

[0062] The program stops measuring. At this point, the CNC system's registers have stored 2 × 40 = 80 high-precision absolute coordinates of the workpiece axes.

[0063] Step S3: Automatic tooth count verification The background program reads a system variable that records the number of coordinates actually captured during S2.

[0064] The program reads the input from the human-computer interaction interface. .

[0065] The core condition for program execution is: IF (CaptureCount != (Zpreset) 2))? Suppose the operator mistakenly installs a gear with Z=39; the program will only capture 2 in S2. 39 = 78 coordinates, that is, the number of coordinates is 78.

[0066] Judgment 78!= (40 2) If true. The system immediately executes the alarm procedure: displays "Alarm: The actual number of teeth on the workpiece

[39] does not match the program input

[40] !" on the human-machine interface, and stops all subsequent finishing processes.

[0067] This step 100% prevents catastrophic misprocessing and scrapping caused by workpiece mixing or data input errors.

[0068] If the number of coordinates is 80, then 80 = (40) 2) If true, the verification is successful, and the program continues.

[0069] Step S4: Deformation estimation The program confirmed the verification was successful and began processing the 80 coordinate data points collected in S2.

[0070] The goal of the program is to calculate the deformation distribution of the entire tooth.

[0071] The program loops from i to 40 (Z): =Coordinates[2i-1] =coordinates[2i] =( + ) / 2 (Calculate the actual center coordinates of the i-th tooth groove) Theoretical angle per tooth calculation: .

[0072] Calculate the actual angle per tooth: : (connected from beginning to end) Calculate the quenching deformation per tooth At this point, the program obtains an array `Deformation_Error[] = {\Delta\theta_1, \Delta\theta_2, ..., \Delta\theta_{40}}` containing 40 elements. This array completely depicts the circumferential deformation distribution of the workpiece caused by quenching and clamping eccentricity.

[0073] The program calculates an initial phase deviation value. This value must take into account the center positions of all 40 tooth grooves (e.g., calculating...). (The average or median of the array) is used to find a compensation value that minimizes the overall deviation.

[0074] Existing methods can only obtain one element from the array above, for example... (Because it only measured teeth 10 and 11). It completely lost the deformation information for the other 39 teeth. If =+0.02 ,and =-0.05 It will be based on +0.02 Compensation was applied, resulting in a -0.07 at the 30th tooth. The large machining error caused by the material results in "black skin". The S4 step of this application fundamentally solves this defect through full tooth estimation and equal compensation.

[0075] The steps preceding step S4 also include: The first piece is cut using the handwheel guidance function of the CNC system. For the first part, the program automatically determines (e.g., by an M00 or a specific flag) whether to pause or activate the handwheel guidance function.

[0076] The human-computer interface displays the calculated initial phase deviation value. (e.g., 0.500) () is used as the recommended starting value.

[0077] The operator takes over and precisely controls the tool (tool axis) to slowly perform radial trial cuts (scraping) on ​​the rotating workpiece (workpiece axis) by turning the electronic handwheel.

[0078] The operator carefully examined the scraping marks on all 40 tooth surfaces.

[0079] because The value has already been "evenly distributed" to its optimal level, and the result of the first scraping is already very close to the ideal state. The operator may only need to input the compensation value into the compensation value input box on the human-machine interface, setting it to 0.500. Make fine adjustments (e.g., change it to 0.505). This ensures that the scraping marks are perfectly uniform across the entire tooth.

[0080] This finalized value of 0.505 This is the phase compensation value. The operator stores it in the "Compensation Motion Value" box on the human-machine interface.

[0081] The operator presses "Cycle Start" to continue.

[0082] Step S5: Phase tracking automatic tool setting For subsequent batch processing of all identical parts, the program will automatically skip the S5 (electronic handwheel adjustment) step.

[0083] After executing S4, the program automatically reads the stored data from the storage area of ​​the human-computer interaction interface. Value (i.e., 0.505) ).

[0084] The program does not require stopping the workpiece axis or disconnecting the electronic handwheel.

[0085] Instead, the program immediately executes the core compensation command: activating the phase tracking function of the CNC system.

[0086] The CNC system takes effect immediately. The actual position of the workpiece axis, based on its original theoretical tracking position, is smoothly and in real-time adjusted, and while in a coupled and rotating state, this adjustment is enhanced. =0.505 The compensation offset.

[0087] This step is completed almost instantaneously. It saves all the time required in existing technology to "stop the spindle → disconnect the electronic gearbox → rotate the workpiece axis → couple the electronic gearbox → restart the spindle." This greatly improves the machining cycle time and avoids impact and wear on the workpiece axis, tool axis, and electronic gearbox.

[0088] The second tool setting is now complete with high precision. The program seamlessly transitions and immediately and automatically proceeds to the subsequent finishing processes (such as precision rolling or precision grinding).

[0089] Figure 3 A schematic diagram of a secondary tool setting device based on a CNC machine tool provided in this application embodiment is shown below. Figure 3 As shown, the secondary tool setting device 100 based on a CNC machine tool includes: The coupling rotation module 110 is used to couple the tool axis and the workpiece axis and make them rotate continuously in one direction at a matched secondary tool setting speed. The measurement and verification module 120 is used to acquire the coordinate jump signal of the full teeth of the workpiece clamped on the workpiece shaft in the coupled rotation state using the continuous measurement function, and to determine the actual number of teeth of the workpiece by calculating the number of coordinate jumps, and to verify it by comparing it with the preset number of teeth. The deviation estimation module 130 is used to calculate the actual angle per tooth when the actual number of teeth matches the preset number of teeth, and compare it with the theoretical angle to estimate the quenching deformation and clamping eccentricity of each tooth, and determine the initial phase deviation value. The phase compensation module 140 is used to automatically superimpose the phase compensation value onto the movement coordinates of the workpiece axis in the coupled state using the phase tracking function, thereby realizing automatic secondary tool setting.

[0090] Figure 4 This is a schematic diagram of a continuous automatic secondary tool setting device based on a CNC gear machine tool, provided as an embodiment of this application. Figure 4 As shown, the device 200 includes: The device includes a processor 201 with one or more processing cores, a memory 202 with one or more computer-readable storage media, a communication component 203, and other components. The processor 201, memory 202, and communication component 203 are connected via a bus 204.

[0091] In the specific implementation process, at least one processor 201 executes computer-executable instructions stored in memory 202. This enables at least one processor 201 to execute the above-described secondary tool setting method based on CNC machine tools. The specific implementation process of processor 201 can be found in the above-described method embodiments, where the implementation principle and technical effects are similar. This embodiment will not be described in detail here.

[0092] The processor can be a Central Processing Unit (CPU), or other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), etc. A general-purpose processor can be a microprocessor or any conventional processor. The steps of the method disclosed in this application can be directly implemented by a hardware processor, or implemented by a combination of hardware and software modules within the processor.

[0093] The memory may include random access memory (RAM) and may also include non-volatile memory (NVM), such as at least one disk storage device.

[0094] The bus can be an Industry Standard Architecture (ISA) bus, a Peripheral Component Interconnect (PCI) bus, or an Extended Industry Standard Architecture (EISA) bus, etc. Buses can be categorized as address buses, data buses, control buses, etc. For ease of illustration, the buses shown in the accompanying drawings are not limited to a single bus or a single type of bus.

[0095] In some embodiments, a computer program product is also provided, including a computer program or instructions that, when executed by a processor, implement the steps in any of the above-described continuous automatic secondary tool setting methods based on CNC gear machine tools.

[0096] For details on the implementation of each of the above operations, please refer to the previous examples, which will not be repeated here.

[0097] Those skilled in the art will understand that all or part of the steps in the various methods of the above embodiments can be performed by instructions, or by instructions controlling related hardware. These instructions can be stored in a computer-readable storage medium and loaded and executed by a processor.

[0098] Therefore, embodiments of this application provide a computer-readable storage medium storing a plurality of program codes, which can be loaded by a processor to execute the steps in any of the continuous automatic secondary tool setting methods based on CNC gear machine tools provided in embodiments of this application.

[0099] The storage medium may include: read-only memory (ROM), random access memory (RAM), disk or optical disk, etc.

[0100] According to one aspect of this application, a computer program product or computer program is provided, which includes computer instructions stored in a computer-readable storage medium.

[0101] Since the instructions stored in the storage medium can execute the steps in any of the continuous automatic secondary tool setting methods based on CNC gear machine tools provided in the embodiments of this application, the beneficial effects that any of the continuous automatic secondary tool setting methods based on CNC gear machine tools provided in the embodiments of this application can achieve can be realized. For details, please refer to the previous embodiments, which will not be repeated here.

[0102] The above are merely specific embodiments of this application, but the scope of protection of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this application, and these modifications or substitutions should all be covered within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A continuous automatic secondary tool setting method based on a CNC gear machine tool, characterized in that, The method includes: S1: After orienting the tool axis and workpiece axis of the CNC gear machine tool, open the electronic gearbox to couple the tool axis and workpiece axis, and instruct the tool axis and workpiece axis to rotate continuously in one direction at a matched secondary tool setting speed; S2: Using a self-made sensor probe to detect tooth surface signals, and in conjunction with the continuous measurement function of the CNC system, the coordinate jump signals of the entire tooth of the workpiece clamped on the workpiece shaft are collected under the coupled rotation state; S3: By calculating the number of coordinate jumps in one measurement cycle, determine the actual number of teeth on the workpiece, and compare and verify it with the preset number of teeth input by the CNC system; S4: If the actual number of teeth matches the preset number of teeth, the position coordinates of the left and right tooth surfaces of each tooth groove are extracted using the data of the coordinate jump signal to calculate the actual center coordinates of each tooth groove, and then the actual angle of each tooth is calculated and compared with the theoretical angle to estimate the quenching deformation and clamping eccentricity of each tooth, and to determine the initial phase deviation value. S5: Utilizing the phase tracking function of the CNC system, in the coupled state, the phase compensation value used to compensate for the quenching deformation and the clamping eccentricity is automatically superimposed on the movement coordinates of the workpiece axis, thereby achieving phase matching between the tool axis and the workpiece axis and completing automatic secondary tool setting.

2. The method according to claim 1, characterized in that, In step S3, if the actual number of teeth does not match the preset number of teeth, the CNC system will issue an alarm and stop the subsequent secondary finishing process.

3. The method according to claim 1, characterized in that, Before step S4, the following is also included: The first piece is cut using the handwheel guidance function of the CNC system. The relative feed between the tool axis and the workpiece axis is controlled by the handwheel guiding function, so that the tool and the workpiece are slightly engaged, and the scraping of the entire tooth surface of the workpiece is observed. Based on the scraping condition of the entire tooth surface of the workpiece, the phase compensation value is determined and input into the self-developed professional process software package of the CNC system.

4. The method according to claim 1, characterized in that, In step S4, estimating the quenching deformation of each tooth and determining the initial phase deviation value includes: Calculate the set of deviation values ​​between the actual angle of each tooth and the theoretical angle. Take the average or median of the set of deviation values ​​as the initial phase deviation value to ensure that each tooth can be processed uniformly after the second finishing process and avoid the phenomenon of black skin on some tooth surfaces.

5. The method according to claim 1, characterized in that, In step S1, the unidirectional continuous rotation is intended to prevent the workpiece shaft from entering a backlash due to reverse rotation, thereby eliminating its impact on the accuracy of coordinate acquisition.

6. The method according to claim 1, characterized in that, In step S2 The self-made sensor probe is equipped with an indicator light. The method further includes, before step S1, adjusting the position of the self-made sensor probe according to the module and number of teeth of the workpiece, and ensuring that the self-made sensor probe is located in the middle area of ​​the tooth surface of the gear pitch circle by observing the status of the indicator light at the tail of the self-made sensor probe.

7. The method according to claim 1, characterized in that, The CNC system has advanced programming, continuous measurement, handwheel guidance and phase tracking functions; Steps S1 to S5 are all completed by the CNC system executing an automatic continuous secondary tool setting program and a self-developed professional process software package in a coordinated manner.

8. A continuous automatic secondary tool setting device based on a CNC gear machine tool, characterized in that, The device includes: The coupling rotation module is used to couple the tool axis and the workpiece axis and make them rotate continuously in one direction at a matched secondary tool setting speed; The measurement and verification module is used to acquire the coordinate jump signal of the entire tooth of the workpiece clamped on the workpiece shaft in the coupled rotation state using the continuous measurement function, and to determine the actual number of teeth of the workpiece by calculating the number of coordinate jumps, and to verify it by comparing it with the preset number of teeth. The deviation estimation module is used to calculate the actual angle per tooth when the actual number of teeth matches the preset number of teeth, and compare it with the theoretical angle to estimate the quenching deformation and clamping eccentricity of each tooth, and determine the initial phase deviation value. The phase compensation module is used to automatically superimpose the phase compensation value onto the workpiece axis movement coordinates in the coupled state using the phase tracking function, thereby achieving automatic secondary tool setting.

9. A device, characterized in that, include: One or more processors; Memory; One or more programs, wherein the one or more programs are stored in the memory and configured to be executed by the one or more processors, the one or more programs being configured to perform the method as described in any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores program code that can be invoked by a processor to perform the method as described in any one of claims 1 to 7.

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