Aluminum plate multi-wire saw process parameter monitoring control system and method

Abstract

The application discloses an aluminum plate multi-wire cutting process parameter monitoring control system and method, relates to the technical field of process parameter monitoring, and realizes real-time acquisition of real-time cutting parameters in the aluminum plate cutting process, pretreatment and generation of multi-dimensional process parameters; the continuous medium characteristics of the cut aluminum plate are extracted, a two-dimensional grid of the aluminum plate is generated, dynamic adjustment of the two-dimensional grid is carried out based on the multi-dimensional process parameters, two-dimensional grid state data is generated, an independent virtual mass block is constructed for each cutting wire, response state parameters of each cutting wire are generated based on the virtual mass block, multi-dimensional control adjustment amounts of corresponding motors of each cutting wire are generated based on the response state parameters, actuator control instructions are generated based on the multi-dimensional control adjustment amounts, and the actuator control instructions are sent to the corresponding motors; the aluminum plate virtual grid and the cutting wire virtual mass block model are constructed, real-time simulation and independent control of the stress state of the multiple cutting wires are realized, and the stability and machining quality of the cutting process are significantly improved.

Description

Technical Field

[0001] This invention relates to the field of process parameter monitoring technology, specifically to a monitoring and control system and method for multi-wire cutting process parameters of aluminum plates. Background Technology

[0002] Currently, the monitoring and control system of multi-wire cutting process generally adopts an independent control strategy based on the tension feedback of a single cutting wire. This strategy equips each cutting wire with an independent tension sensor and a take-up and release motor. The control system performs proportional, integral and derivative adjustment based on the deviation between the tension of a single wire and the preset target value, simplifying the complex wire mesh cutting process into parallel control of multiple independent loops. However, existing technologies have certain shortcomings. First, the independent control strategy ignores the physical coupling relationship between cutting lines through the aluminum plate being processed. When a cutting line encounters a sudden change in material hardness causing a change in tension, only the control loop corresponding to that line responds. Adjacent cutting lines cannot sense the disturbance and adjust in advance, leading to the easy spread of local tension fluctuations and triggering a chain of wire breakage accidents. At the same time, traditional proportional-integral-derivative (PID) controllers require repeated adjustments of the proportional, integral, and derivative coefficients for different processing materials and process conditions. The parameter tuning process relies on the experience of professional technicians, and the control effect is quite sensitive to parameter changes. Furthermore, the existing system's monitoring of the cutting process is limited to the real-time display of single-point tension values. Operators find it difficult to quickly determine the overall stress distribution and potential risk areas of the wire network from the scattered tension data. The control system lacks the ability to adapt to changes in the properties of the aluminum plate material and cannot record the characteristic information of the processed area for use in subsequent cutting. Therefore, it is of great significance to develop a monitoring and control system for the process parameters of multi-wire cutting of aluminum plates. Summary of the Invention

[0003] The purpose of this invention is to provide a monitoring and control system and method for multi-wire cutting process parameters of aluminum plates, so as to solve the problems in the background art.

[0004] To achieve the above objectives, the present invention provides the following technical solution: a monitoring and control system for multi-wire cutting process parameters of aluminum plates, comprising: Data acquisition module: Real-time acquisition of cutting parameters during the aluminum plate cutting process, and preprocessing to generate multi-dimensional process parameters; Foundation construction module: Extract the continuous medium characteristics of the cut aluminum plate, generate a two-dimensional mesh of the aluminum plate based on the continuous medium characteristics, initialize the two-dimensional mesh, and dynamically adjust the two-dimensional mesh based on multi-dimensional process parameters to generate two-dimensional mesh state data. Cutting simulation module: Constructs an independent virtual mass block for each cutting line. The virtual mass block outputs the response state parameters of each cutting line based on the two-dimensional mesh state and multi-dimensional process parameters at the corresponding cutting line location. Control decision module: Generates multi-dimensional control adjustment quantities for the motor corresponding to each cutting line based on response state parameters; Command execution module: encapsulates multi-dimensional control adjustment quantities into actuator control commands and sends the actuator control commands to the corresponding motor.

[0005] In a preferred embodiment, the data acquisition module includes: The tension acquisition unit reads the tension value of each cutting line in real time through a tension sensor; The position acquisition unit reads the spatial position coordinates of the cutting line in real time through the spindle encoder; The motor status acquisition unit reads the speed and current values ​​of the motor corresponding to each cutting line in real time through the motor driver feedback interface; The parameter preprocessing unit is used to perform time synchronization and filtering on tension values, spatial position, rotational speed values, and current values ​​to generate multi-dimensional process parameters.

[0006] In a preferred embodiment, the foundation construction module includes: The characteristic analysis unit is used to obtain the material property parameters of the cut aluminum plate, determine the continuous medium characteristic parameters of the aluminum plate through offline experimental calibration based on the material property parameters, and output the continuous medium characteristic parameters. The mesh generation unit determines the topology of the two-dimensional mesh based on the characteristic parameters of the continuous medium, and generates a two-dimensional mesh of aluminum plate covering the cutting area. The two-dimensional mesh is composed of multiple mesh points, and each mesh point corresponds to a spatial position on the aluminum plate. The mesh parameter configuration unit is used to set the coverage area, mesh point density, and influence radius of each mesh point in the two-dimensional mesh. The initial state assignment unit is used to initialize the height value of all grid points in the two-dimensional mesh to zero and initialize the stiffness value of all grid points to a uniform initial stiffness value. The foundation update unit dynamically adjusts the height and stiffness values ​​of each grid point in the two-dimensional grid based on multi-dimensional process parameters, and outputs two-dimensional grid state data.

[0007] In a preferred embodiment, the step of dynamically adjusting the height and stiffness values ​​of each grid point in the two-dimensional grid based on multi-dimensional process parameters and outputting the two-dimensional grid state data is as follows: The displacement conversion subunit is used to convert the real-time tension value of each cutting line into virtual displacement through a preset linear mapping relationship; The coordinate positioning sub-unit is used to determine the grid point directly below each cutting line based on the real-time spatial position of each cutting line. The height adjustment sub-unit is used to incrementally adjust the height value of the grid point directly below based on the virtual displacement, and attenuate the height value of the neighboring grid point based on the influence radius. The stiffness accumulation sub-element is used to cumulatively increase the stiffness value of a grid point based on the incremental height value adjustment for each grid point.

[0008] In a preferred embodiment, the cutting simulation module includes: The grid point mass configuration unit is used to configure an independent virtual mass block for each grid point in the two-dimensional grid, and to set the inertia coefficient of each virtual mass block based on the continuous medium characteristics of the aluminum plate, and output the grid point mass parameters. The external force mapping unit is used to map the real-time virtual displacement of each cutting line to the force of the virtual mass block at the corresponding grid point of the cutting line, which is used as the force parameter. The motion calculation unit drives the virtual mass block to move based on the reference height value of the grid point corresponding to the force parameter, and updates the position and velocity of the virtual mass block in real time as response state parameters.

[0009] In a preferred embodiment, the control decision module includes: The wire mesh position matching unit determines the mesh point corresponding to each cutting line based on the real-time spatial position of each cutting line, extracts the motion velocity value and current position offset of the virtual mass block of the mesh point, and outputs the real-time virtual velocity signal and real-time virtual offset signal corresponding to each cutting line. The trend discrimination unit determines the trend of force change at the corresponding position of the cutting line based on the positive and negative directions of the virtual velocity signal. If the virtual velocity signal is positive, it is determined to be a decreasing force trend; if the virtual velocity signal is negative, it is determined to be an increasing force trend. The trend determination result is then output. The state assessment unit evaluates the current degree of force deviation based on the absolute value of the virtual offset signal; The larger the absolute value of the virtual offset signal, the greater the degree of force deviation; the smaller the absolute value, the smaller the degree of force deviation. The deviation assessment result is output. The amplitude calculation unit combines the absolute values ​​of the virtual velocity signal and the virtual offset signal, and calculates the initial adjustment amplitude value of the corresponding cutting line according to the preset mapping rules. The instruction generation unit generates multi-dimensional control adjustment quantities for the corresponding cutting line based on the preliminary adjustment amplitude value, trend judgment result, and deviation degree evaluation result. The multi-dimensional control adjustment quantities include the winding and unwinding motor speed adjustment quantity and the feed speed adjustment quantity.

[0010] In a preferred embodiment, the instruction execution module includes: The instruction encapsulation unit converts the multi-dimensional control adjustment quantities into data formats and encapsulates them into instructions according to the communication protocol of the corresponding motor driver, generating executable actuator control instructions. The instruction distribution unit sends the actuator control instructions to the corresponding motors in parallel, based on the motor identifier corresponding to each cutting line. The execution status monitoring unit is used to monitor the speed and current values ​​after the command is executed in real time through the motor driver feedback interface.

[0011] This invention also provides a method for monitoring and controlling process parameters of multi-wire cutting of aluminum plates, comprising: Real-time cutting parameters are collected during the aluminum plate cutting process and preprocessed to generate multi-dimensional process parameters; Extract the continuous medium characteristics of the cut aluminum plate, generate a two-dimensional mesh of the aluminum plate based on the continuous medium characteristics, initialize the two-dimensional mesh, and dynamically adjust the two-dimensional mesh based on multi-dimensional process parameters to generate two-dimensional mesh state data. An independent virtual mass block is constructed for each cutting line. The virtual mass block outputs the response state parameters of each cutting line based on the two-dimensional mesh state and multi-dimensional process parameters at the corresponding cutting line location. The multi-dimensional control adjustment amount of the motor corresponding to each cutting line is generated based on the response state parameters. The multi-dimensional control adjustment is encapsulated into actuator control instructions, and the actuator control instructions are sent to the corresponding motor.

[0012] The technical effects and advantages provided by the present invention in the above technical solution are as follows: 1. This invention constructs a two-dimensional grid simulating the continuous medium characteristics of an aluminum plate and configures an independent virtual mass block for each grid point. Physically independent cutting lines are coupled together through a shared virtual foundation. When a cutting line encounters a sudden change in material hardness that causes a change in tension, its corresponding virtual displacement will update the height and stiffness of the grid point in real time. It will also affect the state of neighboring grid points through elastic continuity. This allows adjacent cutting lines to sense disturbances in advance and respond before their own tension changes through the movement of the virtual mass block. Based on the distributed coupling mechanism of the shared medium, this invention differs from the mode of independent decision-making for each cutting line. It realizes the coordinated adjustment between the wire meshes, which helps to suppress the chain reaction caused by local disturbances and effectively improves the stability and processing consistency of the multi-wire cutting process. 2. This invention maps the problem of monitoring and controlling cutting process parameters into a dynamic simulation of a virtual physical world. The velocity and positional offset of the virtual mass block are used as response state parameters to intuitively characterize the trend and degree of deviation of the force changes on the cutting line. The control decision module generates multi-dimensional control adjustment quantities based on these physically meaningful parameters, reducing the complexity of parameter tuning in traditional control methods and enabling the system to adapt to changes in material properties. Simultaneously, the height and stiffness of the two-dimensional grid are dynamically and cumulatively adjusted during the cutting process, recording the characteristic information of the processed area and achieving gradual adaptation to changes in material properties. The height change of the two-dimensional grid reflects the stress and deformation history of the aluminum plate, and the motion trajectory of the virtual mass block presents the dynamic response process of the cutting line in real time. This gives the monitoring and adjustment of process parameters intuitive visualization features, effectively improving the operability and maintainability of the multi-wire cutting system. Attached Figure Description

[0013] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0014] Figure 1 This is a system flowchart of the present invention.

[0015] Figure 2 This is a flowchart of the method of the present invention.

[0016] Figure 3 This is a logic block diagram of the present invention. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0018] Example 1, please refer to Figure 1 and Figure 3 As shown in this embodiment, a monitoring and control system for multi-wire cutting process parameters of aluminum plates includes: Data acquisition module: Real-time acquisition of cutting parameters during the aluminum plate cutting process, and preprocessing to generate multi-dimensional process parameters; Foundation construction module: Extract the continuous medium characteristics of the cut aluminum plate, generate a two-dimensional mesh of the aluminum plate based on the continuous medium characteristics, initialize the two-dimensional mesh, and dynamically adjust the two-dimensional mesh based on multi-dimensional process parameters to generate two-dimensional mesh state data. Cutting simulation module: Constructs an independent virtual mass block for each cutting line. The virtual mass block outputs the response state parameters of each cutting line based on the two-dimensional mesh state and multi-dimensional process parameters at the corresponding cutting line location. Control decision module: Generates multi-dimensional control adjustment quantities for the motor corresponding to each cutting line based on response state parameters; Instruction execution module: encapsulates multi-dimensional control adjustment quantities into actuator control instructions, and sends the actuator control instructions to the corresponding motor; Furthermore, the current monitoring and control systems for multi-wire cutting processes generally adopt an independent control strategy based on the tension feedback of a single cutting wire. This strategy equips each cutting wire with an independent tension sensor and a take-up and untake-up motor. The control system performs proportional, integral, and derivative adjustments based on the deviation between the tension of a single wire and the preset target value, simplifying the complex wire mesh cutting process into parallel control of multiple independent loops. However, existing technologies have certain shortcomings. First, the independent control strategy ignores the physical coupling relationship between cutting lines through the aluminum plate being processed. When a cutting line encounters a sudden change in material hardness causing a change in tension, only the control loop corresponding to that line responds. Adjacent cutting lines cannot sense the disturbance and adjust in advance, leading to the easy spread of local tension fluctuations and triggering a chain of wire breakage accidents. At the same time, traditional proportional-integral-derivative (PID) controllers require repeated adjustments of the proportional, integral, and derivative coefficients for different processing materials and process conditions. The parameter tuning process relies on the experience of professional technicians, and the control effect is quite sensitive to parameter changes. Furthermore, the existing system's monitoring of the cutting process is limited to the real-time display of single-point tension values. Operators find it difficult to quickly determine the overall stress distribution and potential risk areas of the wire network from the scattered tension data. The control system lacks the ability to adapt to changes in the properties of the aluminum plate material and cannot record the characteristic information of the processed area for use in subsequent cutting. This invention constructs a two-dimensional mesh simulating the continuous medium characteristics of an aluminum plate and configures an independent virtual mass block for each mesh point. Physically independent cutting lines are coupled together through a shared virtual foundation. When a cutting line encounters a sudden change in material hardness leading to a change in tension, its corresponding virtual displacement updates the height and stiffness of the mesh point in real time. Through elastic continuity, it affects the state of neighboring mesh points, allowing adjacent cutting lines to sense disturbances and respond in advance through the movement of the virtual mass block before their own tension changes. Based on the distributed coupling mechanism of the shared medium, unlike the mode of independent decision-making for each cutting line, it realizes the coordinated adjustment between the meshes, which helps to suppress the chain reaction caused by local disturbances and effectively improves the stability and processing consistency of the multi-wire cutting process. By mapping the monitoring and control of cutting process parameters to a dynamic simulation of a virtual physical world, the movement speed and positional offset of a virtual mass block are used as response state parameters to intuitively characterize the trend and degree of deviation of the force changes on the cutting line. The control decision module generates multi-dimensional control adjustment quantities based on these physically meaningful parameters, reducing the complexity of parameter tuning in traditional control methods and enabling the system to adapt to changes in material properties. At the same time, the height and stiffness of the two-dimensional grid are dynamically and cumulatively adjusted with the cutting process, which can record the characteristic information of the processed area and achieve gradual adaptation to changes in material properties. The height change of the two-dimensional grid reflects the stress deformation history of the aluminum plate, and the movement trajectory of the virtual mass block presents the dynamic response process of the cutting line in real time. This gives the monitoring and adjustment of process parameters intuitive visualization features, effectively improving the operability and maintainability of the multi-wire cutting system.

[0019] In one embodiment, the data acquisition module includes: The tension acquisition unit reads the tension value of each cutting line in real time through a tension sensor; The position acquisition unit reads the spatial position coordinates of the cutting line in real time through the spindle encoder; The motor status acquisition unit reads the speed and current values ​​of the motor corresponding to each cutting line in real time through the motor driver feedback interface; The parameter preprocessing unit is used to perform time synchronization and filtering on tension values, spatial position, rotation speed values ​​and current values ​​to generate multi-dimensional process parameters. Furthermore, the tension acquisition unit detects the tension changes of the cutting wire in real time through tension sensors installed near each cutting wire guide wheel. The tension sensors, employing strain gauge or piezoelectric principles, output analog voltage or current signals proportional to the tension. These signals are converted from analog to digital via a high-speed analog input module at a preset sampling frequency, such as 1000 times / s, and then transmitted to the parameter preprocessing unit via a fieldbus. The position acquisition unit is connected to the cutting machine spindle encoder, which is either an incremental photoelectric encoder or an absolute encoder. As the spindle rotates, it outputs pulse signals or absolute position codes. The position acquisition unit reads the encoder's pulse count value or directly reads the absolute position coordinates in real time via a high-speed counting module or communication interface at the same sampling frequency as the tension acquisition unit, converting them into the real-time spatial position coordinates of the cutting wire. These spatial position coordinates reflect the current position of the cutting wire on the aluminum plate cutting path. The motor status acquisition unit establishes a communication connection with the take-up and untake-up motor driver corresponding to each cutting wire through the feedback interface of the motor driver. It adopts industrial Ethernet protocols such as EtherCAT or fieldbus protocols such as CANopen to read the real-time speed and real-time current values ​​of the motor from each motor driver at a preset communication period of 1ms. These data reflect the actual operating status and load of the motor. The parameter preprocessing unit aligns all data to the same time base based on a software synchronization method with a unified timestamp, ensuring that various types of data collected at the same time can be accurately matched. Then, digital filtering algorithms such as moving average filtering or first-order low-pass filtering are used on the synchronized data to remove high-frequency noise and random interference. Finally, the filtered tension value, spatial position coordinates, speed value and current value are encapsulated according to a preset data structure to generate multi-dimensional process parameters containing time tags and various parameter values.

[0020] In one embodiment, the foundation building module includes: The characteristic analysis unit is used to obtain the material property parameters of the cut aluminum plate, determine the continuous medium characteristic parameters of the aluminum plate through offline experimental calibration based on the material property parameters, and output the continuous medium characteristic parameters. The mesh generation unit determines the topology of the two-dimensional mesh based on the characteristic parameters of the continuous medium, and generates a two-dimensional mesh of aluminum plate covering the cutting area. The two-dimensional mesh is composed of multiple mesh points, and each mesh point corresponds to a spatial position on the aluminum plate. The mesh parameter configuration unit is used to set the coverage area, mesh point density, and influence radius of each mesh point in the two-dimensional mesh. The initial state assignment unit is used to initialize the height value of all grid points in the two-dimensional mesh to zero and initialize the stiffness value of all grid points to a uniform initial stiffness value. The foundation renewal unit dynamically adjusts the height and stiffness values ​​of each grid point in the two-dimensional grid based on multi-dimensional process parameters, and outputs two-dimensional grid state data. Furthermore, the characteristic analysis unit first obtains the material property parameters of the cut aluminum plate. These parameters include the elastic modulus and Poisson's ratio of the aluminum plate. Indentation or tensile tests are performed on the aluminum plate samples using offline experimental calibration methods, and the load-deformation relationship curve is recorded. Based on the theory of elasticity, the continuous medium characteristic parameters of the aluminum plate are calculated, and the continuous medium characteristic parameters, including the elastic modulus and stress diffusion coefficient, are output. The steps are as follows: First, the basic material property parameters of the aluminum plate are read from the material quality certificate document. These basic material property parameters include the grade, supply condition, and nominal thickness of the aluminum plate. Then, several samples are cut from the aluminum plate to prepare standard specimens. The specimen dimensions are based on the tensile test of metallic materials. The national standard stipulates that samples are taken along the rolling direction and perpendicular to the rolling direction of the aluminum plate to evaluate the anisotropic characteristics of the material. The prepared specimens are calibrated offline. The specimens are mounted on an electronic universal testing machine, and strain gauges are attached to the middle of the specimens or connected to extensometers to accurately measure the deformation. Tensile loads are applied to the specimens at a constant loading rate until the end of the elastic deformation stage. The load and deformation data during the loading process are recorded, stress-strain curves are plotted, and the slope of the elastic stage is calculated to obtain the elastic modulus of the aluminum plate. At the same time, the ratio of the transverse shrinkage to the longitudinal elongation of the specimen in the elastic stage is measured to obtain the Poisson's ratio of the aluminum plate.To simulate the actual localized compression of the aluminum plate during cutting, an additional aluminum plate sample was subjected to indentation tests. A spherical indenter was used to press into the aluminum plate surface with different loads, and the relationship curve between the indentation load and the indentation depth was recorded. Based on Hertzian contact theory, the indentation curves were fitted and analyzed to obtain the equivalent stiffness coefficient and stress diffusion coefficient of the aluminum plate under localized compression. The elastic modulus and Poisson's ratio obtained from the tensile test were comprehensively calibrated with the stress diffusion coefficient obtained from the indentation test. When there were differences in the parameters obtained by the two test methods, the indentation test results were used as the primary weighted correction, because the indentation test more closely approximates the actual localized stress conditions of the aluminum plate during cutting. Finally, the calibrated elastic modulus, Poisson's ratio, and stress diffusion coefficient were integrated into the continuous medium characteristic parameters of the aluminum plate. The mesh generation unit received the continuous medium characteristic parameters, determined the topology of the two-dimensional mesh based on the elastic modulus, and used a uniform mesh generation method. The algorithm generates a two-dimensional mesh of the aluminum plate covering the entire cutting area. The two-dimensional mesh consists of multiple mesh points, each corresponding to a spatial position on the aluminum plate. The boundary of the mesh is aligned with the edge of the cutting area. The mesh parameter configuration unit defines the coverage area, mesh point density, and influence radius of each mesh point. The influence radius is calculated based on the stress diffusion coefficient in the continuous medium characteristic parameters and is used to determine the influence range of a single mesh point on surrounding mesh points when under stress. The initial state assignment unit initializes the height value of all mesh points in the two-dimensional mesh to zero and initializes the stiffness value of all mesh points to a uniform initial stiffness value. The initial stiffness value is determined by mechanical equivalent calculation based on the elastic modulus of the aluminum plate and the mesh point density. The foundation update unit updates the height and stiffness values ​​of the two-dimensional mesh in real time based on the multi-dimensional process parameters collected in real time during the aluminum plate cutting process.

[0021] In one embodiment, the step of dynamically adjusting the height and stiffness values ​​of each grid point in the two-dimensional grid based on multi-dimensional process parameters and outputting the two-dimensional grid state data is as follows: The displacement conversion subunit is used to convert the real-time tension value of each cutting line into virtual displacement through a preset linear mapping relationship; The coordinate positioning sub-unit is used to determine the grid point directly below each cutting line based on the real-time spatial position of each cutting line. The height adjustment sub-unit is used to incrementally adjust the height value of the grid point directly below based on the virtual displacement, and attenuate the height value of the neighboring grid point based on the influence radius. The stiffness accumulation sub-element is used to cumulatively increase the stiffness value of a grid point based on the incremental height value adjustment for each grid point. Furthermore, the displacement conversion subunit receives the tension value of each cutting line in real time and converts it into a virtual displacement according to a preset linear mapping relationship. The scaling factor of this linear mapping relationship is determined through offline calibration experiments on the cutting lines. During calibration, a known tension is applied to the cutting lines and their elastic elongation is measured to establish the correspondence between tension and displacement, ensuring that the virtual displacement can truly reflect the degree of elastic deformation of the cutting lines under tension. The displacement conversion subunit converts the tension value of each cutting line into the corresponding virtual displacement in real time and outputs it to the height adjustment subunit. The coordinate positioning subunit receives the spatial position coordinates of each cutting line in real time and, based on the two-dimensional mesh... The grid point coordinate distribution is calculated using a nearest neighbor search algorithm to determine the current grid point of each cutting line, identifying its row and column numbers within the 2D grid, and recording its index information. The coordinate positioning subunit outputs the grid point index corresponding to each cutting line to the height adjustment subunit. The height adjustment subunit first receives the virtual displacement and grid point index corresponding to each cutting line, and then incrementally adjusts the height value of the grid point directly below it based on the magnitude of the virtual displacement. Specifically, the incremental adjustment method involves directly adding the virtual displacement value to the current height value of the grid point. Simultaneously, the height adjustment subunit determines the influence radius preset by the subunit according to the grid parameter configuration subunit. Centered on the grid point directly below, the height values ​​of all neighboring grid points within this influence area are adjusted using a distance attenuation function. Specifically, the attenuation coefficient is calculated based on the Euclidean distance between the neighboring grid point and the grid point directly below; the closer the distance, the larger the attenuation coefficient. When the distance reaches the influence radius, the attenuation coefficient becomes zero. The virtual displacement is multiplied by the attenuation coefficient and added to the current height value of the neighboring grid point, thus updating the height values ​​of all affected grid points. The height increment can be positive or negative, representing increases and decreases in tension, respectively. The stiffness accumulation sub-element monitors the adjusted height increment of each grid point in real time. When a grid point is adjusted... When the height adjustment subunit adjusts the height value, the stiffness accumulation subunit records the increment of the height value for that adjustment and increases the stiffness value of the grid point according to the preset accumulation rule. The specific implementation of the accumulation rule is to multiply the height value increment by a hardening coefficient and add it to the current stiffness value of the grid point. The hardening coefficient is determined by experimental calibration based on the work hardening characteristics of the aluminum plate material. At the same time, the stiffness accumulation subunit sets an upper limit for the stiffness value. When the stiffness value accumulates to the upper limit, it will no longer continue to increase, so as to simulate the state of material hardening reaching saturation. The stiffness accumulation subunit finally outputs two-dimensional grid state data containing the updated height value and stiffness value of each grid point.

[0022] In one embodiment, the cutting simulation module includes: The grid point mass configuration unit is used to configure an independent virtual mass block for each grid point in the two-dimensional grid, and to set the inertia coefficient of each virtual mass block based on the continuous medium characteristics of the aluminum plate, and output the grid point mass parameters. The external force mapping unit is used to map the real-time virtual displacement of each cutting line to the force of the virtual mass block at the corresponding grid point of the cutting line, which is used as the force parameter. The motion calculation unit drives the virtual mass block to move based on the reference height value of the grid point corresponding to the force parameter, and updates the position and velocity of the virtual mass block in real time as the response state parameter. Furthermore, the grid point mass configuration unit first obtains the area of ​​the aluminum plate micro-element represented by each grid point based on the two-dimensional grid information provided by the foundation construction module. This micro-element area is calculated by dividing the grid coverage area by the total number of grid points, based on the grid point density and grid coverage range. Then, based on the density value in the continuous medium characteristic parameters of the aluminum plate, the micro-element area is multiplied by the aluminum plate thickness and density to calculate the equivalent mass corresponding to each grid point. This equivalent mass is used as the inertia coefficient of the virtual mass block. Simultaneously, based on the elastic modulus in the continuous medium characteristic parameters, the equivalent spring stiffness coefficient between the virtual mass block and the reference height is calculated using the elasticity mechanics formula. The inertia coefficient and spring stiffness coefficient are then configured to the virtual mass block of each grid point, outputting the grid point mass parameters containing the inertia coefficient and spring stiffness coefficient of the virtual mass block of each grid point. The external force mapping unit receives the virtual displacement corresponding to each cutting line and the grid point index determined by the coordinate positioning unit in real time, and regards the virtual displacement as the target equilibrium position offset of the virtual mass block of that grid point. Based on the spring stiffness coefficient of the virtual mass block of that grid point in the grid point mass parameters, the equivalent spring stiffness coefficient is calculated. The stiffness coefficient is calculated by multiplying the difference between the virtual displacement and the current position of the virtual mass block by the spring stiffness coefficient to obtain the elastic restoring force. Simultaneously, the damping force is obtained by multiplying the current velocity of the virtual mass block by the preset damping coefficient. The resultant force of the elastic restoring force and the damping force is output as the force parameter to the motion calculation unit. The motion calculation unit receives the force parameter and the reference height value of the corresponding grid point. The reference height value is the current height value of the grid point in the foundation construction module. The motion calculation unit establishes the motion differential equation of the virtual mass block according to Newton's second law. The acceleration is obtained by dividing the force parameter by the inertia coefficient of the virtual mass block. The motion of the virtual mass block is solved in real time using the fourth-order Runge-Kutta numerical integration method with a preset integration step size. In each integration step, the velocity of the virtual mass block is updated first according to the current acceleration, and then the position of the virtual mass block is updated according to the updated velocity. The position represents the instantaneous offset of the virtual mass block relative to the reference height value, and the velocity represents the speed of the virtual mass block's movement. The motion calculation unit outputs the real-time position and velocity of the virtual mass block at each grid point as response state parameters.

[0023] In one embodiment, the control decision module includes: The wire mesh position matching unit determines the mesh point corresponding to each cutting line based on the real-time spatial position of each cutting line, extracts the motion velocity value and current position offset of the virtual mass block of the mesh point, and outputs the real-time virtual velocity signal and real-time virtual offset signal corresponding to each cutting line. The trend discrimination unit determines the trend of force change at the corresponding position of the cutting line based on the positive and negative directions of the virtual velocity signal. If the virtual velocity signal is positive, it is determined to be a decreasing force trend; if the virtual velocity signal is negative, it is determined to be an increasing force trend. The trend determination result is then output. The state assessment unit evaluates the current degree of force deviation based on the absolute value of the virtual offset signal; The larger the absolute value of the virtual offset signal, the greater the degree of force deviation; the smaller the absolute value, the smaller the degree of force deviation. The deviation assessment result is output. The amplitude calculation unit combines the absolute values ​​of the virtual velocity signal and the virtual offset signal, and calculates the initial adjustment amplitude value of the corresponding cutting line according to the preset mapping rules. The instruction generation unit generates multi-dimensional control adjustment quantities for the corresponding cutting line based on the preliminary adjustment amplitude value, trend judgment result, and deviation degree evaluation result. The multi-dimensional control adjustment quantities include the adjustment quantity of the winding and unwinding motor speed and the adjustment quantity of the feed speed. Furthermore, the wire mesh position matching unit first obtains the real-time spatial coordinates of each cutting line from the data acquisition module. Then, based on the grid point distribution information of the two-dimensional grid in the foundation construction module, it quickly determines the grid point index corresponding to each cutting line. Next, it extracts the motion velocity value and current position offset of the virtual mass block of that grid point from the response state parameters output by the cutting simulation module. The extracted velocity value and offset are used as the real-time virtual velocity signal and real-time virtual offset signal of that cutting line, respectively. These two signals are associated and stored according to the cutting line number and then output to the trend discrimination unit and the state evaluation unit. The trend discrimination unit receives the real-time data of each cutting line. The virtual velocity signal is determined by sign discrimination logic. If the value of the virtual velocity signal is greater than zero, it is determined that the force at the corresponding cutting line position is decreasing; if the value is less than zero, it is determined that the force is increasing; and if the value is equal to zero, it is determined that the force is in equilibrium. The trend discrimination unit outputs the force change trend discrimination result of each cutting line in the form of a trend indicator. The state evaluation unit receives the real-time virtual offset signal of each cutting line and obtains the quantified value of the force deviation at the corresponding cutting line position by calculating the absolute value of the virtual offset signal. The larger the absolute value of the virtual offset signal, the more stable the force. The greater the deviation of the forward force from the reference equilibrium position, the more the state assessment unit, according to preset deviation grading rules, compares the absolute value with multiple thresholds, converting continuous absolute values ​​into discrete deviation levels or directly outputting the absolute value itself as the deviation assessment result. The amplitude calculation unit receives the absolute value of the virtual velocity signal, the absolute value of the virtual offset signal, and the trend judgment result for each cutting line, and calculates the preliminary adjustment amplitude value according to preset mapping rules. This mapping rule uses a weighted summation method, multiplying the absolute values ​​of velocity and offset by their respective weighting coefficients and then adding them together. The weighting coefficients are pre-calibrated according to process requirements. The instruction generation unit receives the preliminary adjustment amplitude value for each cutting line. The results of force change trend judgment and force deviation assessment are used to determine the adjustment direction first. A decreasing force trend corresponds to a decrease in the speed of the take-up and release motors to loosen the cutting wire, while an increasing force trend corresponds to an increase in the speed of the take-up and release motors to tighten the cutting wire. Then, the initial adjustment range is corrected according to the degree of force deviation. When the deviation is large, the adjustment range is appropriately increased to ensure rapid convergence, and when the deviation is small, the adjustment range is appropriately decreased to avoid over-adjustment. Finally, according to the preset motor control protocol, the corrected adjustment range is converted into specific adjustment amounts for the take-up and release motor speeds and feed speeds, and these two adjustment amounts are combined into a multi-dimensional control adjustment amount.

[0024] In one embodiment, the instruction execution module includes: The instruction encapsulation unit converts the multi-dimensional control adjustment quantities into data formats and encapsulates them into instructions according to the communication protocol of the corresponding motor driver, generating executable actuator control instructions. The instruction distribution unit sends the actuator control instructions to the corresponding motors in parallel, based on the motor identifier corresponding to each cutting line. The execution status monitoring unit is used to monitor the speed and current values ​​after the command is executed in real time through the motor driver feedback interface; Furthermore, the instruction encapsulation unit first receives the multi-dimensional control adjustment quantity corresponding to each cutting line. According to the communication protocol requirements, it converts the data format of the multi-dimensional control adjustment quantity. For analog control, it converts the speed adjustment quantity into the corresponding analog voltage or current value. For digital communication, it encapsulates the adjustment quantity according to the data frame structure specified in the protocol, adding fields such as motor address, function code, data length, and checksum, generating an executable actuator control instruction conforming to the protocol specifications. This instruction is then associated with the corresponding motor identifier and output to the instruction distribution unit. The instruction distribution unit receives all actuator control instructions corresponding to all cutting lines and the motor identifier. The instruction distribution unit maintains a motor control instruction sending queue and triggers a batch sending task according to a preset control cycle, such as 1ms. Within each control cycle, it sends the actuator control instructions in parallel to the corresponding motor driver through the corresponding physical interface based on the motor identifier. For analog control, it outputs voltage signals simultaneously through a multi-channel digital-to-analog converter module. For digital communication, it sends the instruction data via a fieldbus in a broadcast or polling manner. The packet is sent to the corresponding slave station to ensure that the control commands of all motors are synchronized in time. The execution status monitoring unit is connected to the motor driver feedback interface. After the command distribution unit sends the actuator control command, the execution status monitoring unit reads the actual speed value and actual current value of the motor corresponding to each cutting line in real time through the driver feedback interface. The reading method corresponds to the command sending method. In analog control, the analog feedback signal output by the driver is collected through the analog-to-digital conversion module. In digital communication, the status word or process data object of the driver is read through the fieldbus. The execution status monitoring unit converts the collected actual speed value and actual current value into a format conversion and scaling transformation, converting them into engineering unit values ​​consistent with the multi-dimensional process parameters. Then, these real-time feedback data are associated and stored according to the cutting line number and output to the parameter preprocessing unit of the data acquisition module for comparison and verification with the command adjustment amount to form a closed-loop monitoring. At the same time, when the deviation between the actual speed value and the command target value exceeds the preset threshold or the current value exceeds the safety range, the execution status monitoring unit triggers an alarm signal and records the abnormal status information.

[0025] Example 2, please refer to Figure 2 As shown in this embodiment, a method for monitoring and controlling process parameters of multi-wire cutting of aluminum plates includes: Real-time cutting parameters are collected during the aluminum plate cutting process and preprocessed to generate multi-dimensional process parameters; Extract the continuous medium characteristics of the cut aluminum plate, generate a two-dimensional mesh of the aluminum plate based on the continuous medium characteristics, initialize the two-dimensional mesh, and dynamically adjust the two-dimensional mesh based on multi-dimensional process parameters to generate two-dimensional mesh state data. An independent virtual mass block is constructed for each cutting line. The virtual mass block outputs the response state parameters of each cutting line based on the two-dimensional mesh state and multi-dimensional process parameters at the corresponding cutting line location. The multi-dimensional control adjustment amount of the motor corresponding to each cutting line is generated based on the response state parameters. The multi-dimensional control adjustment is encapsulated into actuator control instructions, and the actuator control instructions are sent to the corresponding motor.

[0026] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included 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 monitoring and control system for process parameters of multi-wire cutting of aluminum plates, characterized in that, Data acquisition module: Real-time acquisition of cutting parameters during the aluminum plate cutting process, and preprocessing to generate multi-dimensional process parameters; Foundation construction module: Extract the continuous medium characteristics of the cut aluminum plate, generate a two-dimensional mesh of the aluminum plate based on the continuous medium characteristics, initialize the two-dimensional mesh, and dynamically adjust the two-dimensional mesh based on multi-dimensional process parameters to generate two-dimensional mesh state data. The steps for outputting two-dimensional mesh state data are as follows: a displacement transformation sub-unit is used to convert the real-time tension value of each cutting line into virtual displacement through a preset linear mapping relationship; The coordinate positioning sub-unit is used to determine the grid point directly below each cutting line based on the real-time spatial position of each cutting line. The height adjustment sub-unit is used to incrementally adjust the height value of the grid point directly below based on the virtual displacement, and attenuate the height value of the neighboring grid point based on the influence radius. The stiffness accumulation sub-element is used to cumulatively increase the stiffness value of a grid point based on the incremental height value adjustment for each grid point. Cutting simulation module: Constructs an independent virtual mass block for each cutting line. The virtual mass block outputs the response state parameters of each cutting line based on the two-dimensional mesh state and multi-dimensional process parameters at the corresponding cutting line location. The cutting simulation module includes: a grid point mass configuration unit, which is used to configure an independent virtual mass block for each grid point in the two-dimensional grid, and set the inertia coefficient of each virtual mass block based on the continuous medium characteristics of the aluminum plate, and output the grid point mass parameters; The external force mapping unit is used to map the real-time virtual displacement of each cutting line to the force of the virtual mass block at the corresponding grid point of the cutting line, which is used as the force parameter. The motion calculation unit drives the virtual mass block to move based on the reference height value of the grid point corresponding to the force parameter, and updates the position and velocity of the virtual mass block in real time as the response state parameter. Control decision module: Generates multi-dimensional control adjustment quantities for the motor corresponding to each cutting line based on response state parameters; Command execution module: encapsulates multi-dimensional control adjustment quantities into actuator control commands and sends the actuator control commands to the corresponding motor.

2. The aluminum plate multi-wire cutting process parameter monitoring and control system according to claim 1, characterized in that, The data acquisition module includes: The tension acquisition unit reads the tension value of each cutting line in real time through a tension sensor; The position acquisition unit reads the spatial position coordinates of the cutting line in real time through the spindle encoder; The motor status acquisition unit reads the speed and current values ​​of the motor corresponding to each cutting line in real time through the motor driver feedback interface; The parameter preprocessing unit is used to perform time synchronization and filtering on tension values, spatial position, rotational speed values, and current values ​​to generate multi-dimensional process parameters.

3. The aluminum plate multi-wire cutting process parameter monitoring and control system according to claim 1, characterized in that, The foundation construction module includes: The characteristic analysis unit is used to obtain the material property parameters of the cut aluminum plate, determine the continuous medium characteristic parameters of the aluminum plate through offline experimental calibration based on the material property parameters, and output the continuous medium characteristic parameters. The mesh generation unit determines the topology of the two-dimensional mesh based on the characteristic parameters of the continuous medium, and generates a two-dimensional mesh of aluminum plate covering the cutting area. The two-dimensional mesh is composed of multiple mesh points, and each mesh point corresponds to a spatial position on the aluminum plate. The mesh parameter configuration unit is used to set the coverage area, mesh point density, and influence radius of each mesh point in the two-dimensional mesh. The initial state assignment unit is used to initialize the height value of all grid points in the two-dimensional mesh to zero and initialize the stiffness value of all grid points to a uniform initial stiffness value. The foundation update unit dynamically adjusts the height and stiffness values ​​of each grid point in the two-dimensional grid based on multi-dimensional process parameters, and outputs two-dimensional grid state data.

4. The aluminum plate multi-wire cutting process parameter monitoring and control system according to claim 1, characterized in that, The control decision module includes: The wire mesh position matching unit determines the mesh point corresponding to each cutting line based on the real-time spatial position of each cutting line, extracts the motion velocity value and current position offset of the virtual mass block of the mesh point, and outputs the real-time virtual velocity signal and real-time virtual offset signal corresponding to each cutting line. The trend discrimination unit determines the trend of force change at the corresponding position of the cutting line based on the positive and negative directions of the virtual velocity signal. If the virtual velocity signal is positive, it is determined to be a decreasing force trend; if the virtual velocity signal is negative, it is determined to be an increasing force trend. The trend determination result is then output. The state assessment unit evaluates the current degree of force deviation based on the absolute value of the virtual offset signal; The larger the absolute value of the virtual offset signal, the greater the degree of force deviation; the smaller the absolute value, the smaller the degree of force deviation. The deviation assessment result is output. The amplitude calculation unit combines the absolute values ​​of the virtual velocity signal and the virtual offset signal, and calculates the initial adjustment amplitude value of the corresponding cutting line according to the preset mapping rules. The instruction generation unit generates multi-dimensional control adjustment quantities for the corresponding cutting line based on the preliminary adjustment amplitude value, trend judgment result, and deviation degree evaluation result. The multi-dimensional control adjustment quantities include the winding and unwinding motor speed adjustment quantity and the feed speed adjustment quantity.

5. The aluminum plate multi-wire cutting process parameter monitoring and control system according to claim 1, characterized in that, The instruction execution module includes: The instruction encapsulation unit converts the multi-dimensional control adjustment quantities into data formats and encapsulates them into instructions according to the communication protocol of the corresponding motor driver, generating executable actuator control instructions. The instruction distribution unit sends the actuator control instructions to the corresponding motors in parallel, based on the motor identifier corresponding to each cutting line. The execution status monitoring unit is used to monitor the speed and current values ​​after the command is executed in real time through the motor driver feedback interface.

6. A method for monitoring and controlling process parameters of multi-wire cutting of aluminum plates, used to implement the monitoring and control system for monitoring and controlling process parameters of multi-wire cutting of aluminum plates as described in any one of claims 1-5, characterized in that, Real-time cutting parameters are collected during the aluminum plate cutting process and preprocessed to generate multi-dimensional process parameters; Extract the continuous medium characteristics of the cut aluminum plate, generate a two-dimensional mesh of the aluminum plate based on the continuous medium characteristics, initialize the two-dimensional mesh, and dynamically adjust the two-dimensional mesh based on multi-dimensional process parameters to generate two-dimensional mesh state data. An independent virtual mass block is constructed for each cutting line. The virtual mass block outputs the response state parameters of each cutting line based on the two-dimensional mesh state and multi-dimensional process parameters at the corresponding cutting line location. The multi-dimensional control adjustment amount of the motor corresponding to each cutting line is generated based on the response state parameters. The multi-dimensional control adjustment is encapsulated into actuator control instructions, and the actuator control instructions are sent to the corresponding motor.

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