A polishing device and method for the outer surface of metal profiles

Abstract

This invention relates to the field of profile polishing equipment technology, and discloses a metal profile outer surface polishing equipment and method. The metal profile outer surface polishing equipment includes a frame, a clamping and rotating mechanism, a polishing mechanism, and a grinding amount control system. The polishing mechanism is mounted on the frame and includes a front polishing execution component and a rear polishing execution component for polishing the front and rear sections of the profile respectively, and a linear drive component for driving the front and rear polishing execution components to move synchronously along the profile axial direction. The grinding amount control system includes a diameter measuring unit, a contact pressure adjusting unit, and a control unit. This invention can compensate for the difference in grinding removal amount between the two sections in real time during the polishing process, without requiring manual adjustment by stopping the machine. This ensures both the consistency of dimensional accuracy throughout the profile axial direction and maintains the high processing efficiency of segmented synchronous polishing.

Description

Technical Field

[0001] This invention relates to the field of profile polishing equipment technology, and more specifically, to a metal profile outer surface polishing equipment and method. Background Technology

[0002] Metal profiles (such as shafts, tubes, and bars) typically require polishing after machining to remove oxide scale and scratches, and to achieve the desired surface roughness and dimensional accuracy. For longer profiles, segmented synchronous polishing is often used to improve polishing efficiency. This involves setting up two polishing actuators along the profile's axial direction, one at the front and one at the rear, to handle the polishing of the front and rear sections of the profile, respectively.

[0003] However, in actual production, due to differences in the wear rate of the grinding media (such as abrasive belts and grinding wheels) used in the front and rear polishing actuators, differences in contact conditions, or gaps in the mechanical structure, the amount of material removed by the grinding in the front and rear stages is often inconsistent. This results in axial deviations or tapers in the profiles, affecting the overall product quality. The traditional solution is to periodically stop the machine to measure and manually adjust the contact conditions of the relevant mechanisms, which is not only inefficient but also cannot achieve online real-time compensation.

[0004] Therefore, there is a need for a metal profile outer surface polishing equipment that can sense the difference in polishing removal amount between the front and rear sections in real time and automatically adjust the contact pressure. Summary of the Invention

[0005] The purpose of this invention is to provide a polishing device and method for the outer surface of metal profiles to solve the aforementioned technical problems.

[0006] The present invention solves the above-mentioned technical problems through the following technical solutions: In a first aspect, the present invention provides a metal profile outer surface polishing device, comprising: frame; The clamping and rotating mechanism, mounted on the frame, is used to drive the profile to rotate around its own axis; The polishing mechanism, mounted on a frame, includes a front polishing execution component and a rear polishing execution component for polishing the front and rear sections of the profile respectively, and a linear drive component for driving the front polishing execution component and the rear polishing execution component to move synchronously along the profile axis. The grinding volume control system includes a diameter measuring unit, a contact pressure adjustment unit, and a control unit; The diameter measuring unit is used to obtain the outer diameter values ​​of the front and rear polishing areas of the profile according to a preset detection cycle during the polishing process. The contact pressure adjustment unit is disposed on the rear polishing execution assembly and is used to adjust the contact pressure between the rear polishing execution assembly and the profile; The control unit is communicatively connected to the diameter measurement unit and the contact pressure adjustment unit, and is configured to: acquire the outer diameter value of the front section and the outer diameter value of the rear section, determine the deviation amount that characterizes the difference in the amount of grinding removal between the front and rear sections, and control the contact pressure adjustment unit to change the contact pressure between the rear polishing execution component and the profile according to the deviation amount, so as to reduce the difference in the amount of grinding between the front polishing execution component and the rear polishing execution component.

[0007] Furthermore, the downstream polishing execution assembly includes a movable seat movably mounted on the frame guide rail and a polishing head slidably mounted on the movable seat, the movable seat being connected to the linear drive assembly.

[0008] Furthermore, the polishing head includes a protective cover, abrasive belts distributed in a triangle on the protective cover, a polishing belt sleeved on the three abrasive belts, and a rotary drive source connected to one of the abrasive belts.

[0009] Furthermore, the contact pressure adjustment unit includes an electric push rod mounted on the movable base and a pressure sensing element disposed between the polishing head and the movable base. The telescopic end of the electric push rod is connected to the outside of the protective cover. The pressure sensing element is communicatively connected to the control unit and is used to acquire the contact pressure value of the polishing head on the profile in real time and feed it back to the control unit.

[0010] Furthermore, the diameter measuring unit consists of two laser measuring sensors respectively located at the two ends of the frame corresponding to the exit side of the polishing area, with their detection positions avoiding the polishing action area.

[0011] Furthermore, the front-end polishing execution assembly includes a movable base movably mounted on the frame guide rail and a polishing head fixedly mounted on the movable base.

[0012] Furthermore, the control unit is configured to: Based on the outer diameter values ​​of the front and rear sections, and combined with the original outer diameter of the profile before polishing, calculate the cumulative grinding removal amount △ of the front section. 前 and the cumulative amount removed by grinding in the later stage △ 后 The cumulative grinding deviation e = △ 后 -△ 前 ; With the preset reference contact pressure F base Based on this, according to formula F target =F base +Kp×e calculates the target contact pressure, where Kp is a preset gain coefficient; The contact pressure adjustment unit controls the contact pressure between the downstream polishing execution component and the profile to the target contact pressure, and the target contact pressure is limited between the preset minimum contact pressure and the maximum contact pressure.

[0013] Furthermore, the control unit is also equipped with a safety limit adjustment function: the change in contact pressure during a single adjustment process does not exceed the preset maximum step value; and the contact pressure adjustment action is only actually performed when the signs of the cumulative grinding amount deviation e in multiple consecutive detection cycles are all the same and the absolute value of each deviation is greater than the preset deviation threshold.

[0014] Furthermore, the preset detection cycle is the reversing window period during which the polishing mechanism pauses briefly after completing a full axial stroke each time.

[0015] On the other hand, the present invention also provides a method for polishing the outer surface of a metal profile, using the above-mentioned metal profile outer surface polishing equipment, comprising the following steps: S100: The profile is clamped onto the clamping and rotating mechanism and rotated around its own axis; S200: Start the front polishing execution component and the rear polishing execution component, and drive them to move synchronously along the profile axis by the linear drive component to polish the front and rear areas of the profile simultaneously. S300. During the polishing process, the outer diameter values ​​of the front and rear polishing areas of the profile are obtained by the diameter measurement unit according to the preset detection cycle. S400: The control unit determines the deviation amount representing the difference in the amount of material removed by the front and rear grinding sections based on the obtained outer diameter value, and controls the contact pressure adjustment unit to change the contact pressure between the rear polishing execution component and the profile based on the deviation amount, so that the amount of material removed by the rear grinding section is close to the amount of material removed by the front grinding section, and the outer diameter of the front and rear sections is consistent.

[0016] The beneficial effects of this invention are as follows: The grinding amount control system of this invention automatically calculates the deviation of the grinding removal amount in the two sections by detecting the real-time outer diameter of the front and rear polishing areas respectively, and dynamically adjusts the contact pressure between the rear polishing execution component and the profile based on this. It can compensate for the difference in the grinding removal amount in the two sections in real time during the polishing process without stopping the machine for manual adjustment. This ensures the consistency of dimensional accuracy in all parts of the profile along the axial direction and maintains the high processing efficiency of segmented synchronous polishing. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of the metal profile outer surface polishing equipment of the present invention; Figure 2 This is a schematic diagram of the back structure of the metal profile outer surface polishing equipment of the present invention; Figure 3 This is a first-view structural schematic diagram of the rear polishing execution component in the metal profile outer surface polishing equipment of the present invention; Figure 4 This is a second-view structural schematic diagram of the rear polishing execution component in the metal profile outer surface polishing equipment of the present invention; Figure 5 This is a structural block diagram of the grinding amount control system in the metal profile outer surface polishing equipment of the present invention; Figure 6 This is a control flowchart of the control unit in the metal profile outer surface polishing equipment of the present invention; Figure 7 This is a flowchart of the metal profile outer surface polishing method of the present invention.

[0018] In the diagram: 1. Frame; 2. Clamping and rotating mechanism; 3. Polishing mechanism; 31. Front polishing execution component; 32. Rear polishing execution component; 321. Moving seat; 322. Polishing head; 3221. Protective cover; 3222. Sanding belt wheel; 3223. Grinding sanding belt; 3224. Rotary drive source; 33. Linear drive component; 4. Contact pressure adjustment unit; 41. Electric push rod; 42. Pressure sensing element; 5. Diameter measuring unit; 6. Profile; 7. Support mechanism. Detailed Implementation

[0019] The subject matter described herein will now be discussed with reference to exemplary embodiments. It should be understood that these embodiments are discussed only to enable those skilled in the art to better understand and implement the subject matter described herein, and changes may be made to the function and arrangement of the elements discussed without departing from the scope of this specification. Various processes or components may be omitted, substituted, or added as needed in the examples. Furthermore, features described in some examples may be combined in other examples.

[0020] Example 1 Please refer to the following: Figures 1 to 6 The metal profile outer surface polishing equipment provided in this embodiment of the invention is used to polish the outer surface of long shaft or tubular metal profiles 6. The equipment includes a frame 1, a clamping and rotating mechanism 2, a polishing mechanism 3, a support mechanism 7, and a polishing amount control system.

[0021] The frame 1 serves as the supporting foundation for the entire equipment. It is typically made of welded or cast steel profiles and is equipped with guide rails that extend along the axial direction of the profiles, allowing the polishing mechanism 3 to move along the axial direction of the profiles.

[0022] The clamping and rotating mechanism 2 includes a rotating drive part and a clamping part, which are respectively disposed at both ends of the frame 1. It is used to clamp both ends of the profile 6 and drive the profile 6 to rotate around its own axis at a certain speed. Since the clamping and rotating mechanism 2 is a conventional technical choice in the field, it will not be described in detail here.

[0023] There are two support mechanisms 7, located at both ends of the frame 1. They are mainly used to provide support for the profile 6 so that it can maintain a stable posture when rotating.

[0024] The polishing mechanism 3 includes a front polishing execution component 31, a rear polishing execution component 32, and a linear drive component 33. The front polishing execution component 31 and the rear polishing execution component 32 are arranged along the axial direction and are used to simultaneously polish the front and rear areas of the profile 6.

[0025] Both the front polishing actuator 31 and the rear polishing actuator 32 include a movable base 321 and a polishing head 322, and both movable bases 321 slide with the guide rail on the frame 1. The difference is that the polishing head 322 in the front polishing actuator 31 is fixedly connected to its corresponding movable base 321, while the polishing head 322 in the rear polishing actuator 32 is slidably connected to its corresponding movable base 321. This design difference is to facilitate the integration of contact pressure adjustment function in the rear polishing actuator 32.

[0026] Reference Figure 3 and Figure 4 The polishing heads 322 in the front polishing execution assembly 31 and the rear polishing execution assembly 32 have the same specific structure, mainly consisting of a protective cover 3221. Inside the protective cover 3221, three abrasive belt wheels 3222 are arranged in a triangular pattern: a drive wheel at the rear end, a tension wheel at the lower end, and a contact wheel at the front end. A sanding belt 3223 is fitted onto the three abrasive belt wheels 3222. A rotational drive source 3224 (such as a servo motor) is connected to one of the abrasive belt wheels 3222 (drive wheel), driving the sanding belt 3223 to rotate at high speed. The side of the contact wheel faces the profile 6 and contacts the outer surface of the profile 6 to achieve polishing. The protective cover 3221 serves as a dustproof and guiding element.

[0027] The linear drive assembly 33 can adopt a screw and nut pair, gear and rack or synchronous belt structure, etc. Its transmission output end is fixedly connected to the moving seat of the front polishing execution assembly 31 and the rear polishing execution assembly 32 respectively, driving the two to move synchronously back and forth along the guide rail of the frame 1 to achieve full coverage polishing of the entire profile length.

[0028] The grinding amount control system is a key component for achieving consistency in grinding amount between the front and rear stages. It includes a diameter measuring unit 5, a contact pressure regulating unit 4, and a control unit (not shown in the figure, which can be installed in the electrical control cabinet).

[0029] Specifically, the diameter measuring unit 5 consists of two non-contact laser measuring sensors, installed at both ends of the frame 1, located at the exit sides of the front and rear polishing areas respectively. The emitted laser lines or spots are aimed at the polished sections, avoiding the polishing action area to prevent interference from flying chips or vibrations. The preset detection cycle is one measurement taken during the brief reversal window after each complete axial stroke of the polishing mechanism. During this time, the profile continues to rotate, and there is no relative axial movement between the polishing actuator and the profile, ensuring stable measurement conditions and accurately obtaining the outer diameter values ​​of the front and rear polishing areas at that moment. The measured signals are transmitted to the control unit.

[0030] See Figure 3 The contact pressure adjustment unit 4 is mounted on the rear polishing execution assembly 32, and mainly includes an electric push rod 41 and a pressure sensing element 42. The fixed end of the electric push rod 41 is fixedly mounted on the moving base 321, and its telescopic end is connected to the outside of the protective cover 3221 through a connecting seat, so that the telescopic movement of the electric push rod 41 can drive the entire polishing head 322 to slide relative to the moving base 321 in the radial direction of the profile, thereby changing the contact pressure between the abrasive belt 3223 and the profile 6. The pressure sensing element 42 can be a piezoelectric or strain gauge force sensor, which is set on the force transmission path between the polishing head 322 and the moving base 321. In this embodiment, the pressure sensing element 42 is a piezoelectric sensor and is installed at the connection between the telescopic end of the electric push rod and the protective cover 3221. The pressure sensing element 42 senses the contact pressure value of the polishing head 322 on the profile in real time and feeds it back to the control unit, thereby forming a closed-loop control of the contact pressure.

[0031] See Figure 5 and Figure 6 The control unit (such as a PLC or industrial computer) is communicatively connected to electrical components such as the diameter measuring unit 5, the contact pressure regulating unit 4, and the linear drive assembly 33. Its core control logic is as follows: Before polishing begins, the operator inputs or the system automatically measures the original outer diameter D0 of the profile 6 before polishing, and sets the reference contact pressure F. base (This can be learned from experience or through self-learning). During the polishing process, the profile rotates under the drive of the clamping and rotating mechanism 2. The front polishing execution component 31 and the rear polishing execution component 32 reciprocate along the axial direction under the drive of the linear drive component 33, respectively polishing the front and rear sections of the profile.

[0032] After each complete axial stroke, the linear drive assembly 33 briefly stops at the reversal point, and the diameter measuring unit 5 obtains the outer diameter D of the front polishing area. f and the outer diameter D of the polished area in the rear section rThe control unit calculates the cumulative amount of material removed by grinding in the front section, Δ. 前 =D0-D f The cumulative amount removed by grinding in the later stage △ 后 =D0-D r Since the front and rear sections use the same original outer diameter, this calculation can accurately reflect the material removal depth of each section.

[0033] The cumulative grinding deviation e = △ 后 -△ 前 If e is positive, it means that the amount of material removed by the grinding in the later stage is greater than that in the earlier stage, and the later stage is too fine, so the contact pressure in the later stage needs to be reduced; if e is negative, it means that the amount of material removed by the grinding in the later stage is insufficient, and the later stage is too coarse, so the contact pressure in the later stage needs to be increased.

[0034] The control unit is based on formula F target =F base The target contact pressure is calculated as +Kp×e. Kp is a preset gain coefficient, which needs to be pre-tuned based on process conditions such as material hardness and abrasive belt grit size. Then, the control unit compares this value with the pressure value measured by the current pressure sensor 42, and outputs a signal to the electric push rod 41 via a PID or incremental control algorithm to adjust the position of the polishing head 322 in real time until the actual contact pressure reaches F. target Meanwhile, to ensure equipment safety and grinding quality, the target contact pressure is limited to a preset range: [F min ,F max The minimum contact pressure ensures that the sanding belt does not slip or run idle, while the maximum contact pressure prevents the motor from overloading or damaging the profile surface.

[0035] In addition, the control unit also implements an adjustment safety limiting strategy: the change in contact pressure ΔF during a single adjustment process does not exceed the preset maximum step value ΔF. max To prevent impact; and only when the cumulative grinding amount deviation e calculated in multiple consecutive detection cycles (e.g., 3 consecutive times) has the same sign, and the absolute value of the deviation in each cycle is greater than the preset deviation threshold e. min Only when a deviation is confirmed as real and not merely a random fluctuation will the aforementioned pressure adjustment action be executed. This effectively avoids frequent misadjustments caused by measurement noise or local defects, thus improving system stability.

[0036] Example 2 Reference Figure 7 In addition, the present invention also provides a polishing method using the above-mentioned metal profile outer surface polishing equipment, comprising the following steps: S100: The profile 6 is clamped onto the clamping and rotating mechanism 2 and rotated around its own axis.

[0037] S200: Start the rotation drive source of the front polishing execution component 31 and the rear polishing execution component 32 to make the grinding belt run. At the same time, the linear drive component 33 drives the two to move synchronously along the profile axis to polish the front and rear areas of the profile 6 simultaneously.

[0038] S300: During the polishing process, whenever the polishing mechanism completes a full axial stroke and pauses briefly during the reversing window, the outer diameter values ​​of the front and rear polishing areas of the profile are obtained by the diameter measuring unit 5 and sent to the control unit.

[0039] S400: The control unit calculates the cumulative grinding removal amount and its deviation of the front and rear sections based on the obtained outer diameter value, and calculates the target contact pressure based on the deviation, the reference contact pressure and the gain coefficient. It controls the contact pressure adjustment unit 4 to change the contact pressure between the rear polishing execution component 32 and the profile 6, so that the grinding removal amount of the rear section is close to that of the front section, and the outer diameter of the front and rear sections is consistent.

[0040] Through the above closed-loop adjustment, the grinding amount drift caused by changes in abrasive belt wear and lubrication status can be actively compensated during continuous production, thereby significantly improving the axial dimensional accuracy of long profiles.

[0041] The embodiments of the present invention have been described above, but the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of the present invention, all of which are within the protection scope of the present invention.

Claims

1. A metal profile outer surface polishing device, characterized in that, include: frame; The clamping and rotating mechanism, mounted on the frame, is used to drive the profile to rotate around its own axis; The polishing mechanism, mounted on a frame, includes a front polishing execution component and a rear polishing execution component for polishing the front and rear sections of the profile respectively, and a linear drive component for driving the front polishing execution component and the rear polishing execution component to move synchronously along the profile axis. The grinding volume control system includes a diameter measuring unit, a contact pressure adjustment unit, and a control unit; The diameter measuring unit is used to obtain the outer diameter values ​​of the front and rear polishing areas of the profile according to a preset detection cycle during the polishing process. The contact pressure adjustment unit is disposed on the rear polishing execution assembly and is used to adjust the contact pressure between the rear polishing execution assembly and the profile; The control unit is communicatively connected to the diameter measurement unit and the contact pressure adjustment unit, and is configured to: acquire the outer diameter value of the front section and the outer diameter value of the rear section, determine the deviation amount that characterizes the difference in the amount of grinding removal between the front and rear sections, and control the contact pressure adjustment unit to change the contact pressure between the rear polishing execution component and the profile according to the deviation amount, so as to reduce the difference in the amount of grinding between the front polishing execution component and the rear polishing execution component.

2. The metal profile outer surface polishing equipment according to claim 1, characterized in that, The downstream polishing execution component includes a movable base movably mounted on a frame guide rail and a polishing head slidably mounted on the movable base. The movable base is connected to a linear drive component for transmission.

3. The metal profile outer surface polishing equipment according to claim 2, characterized in that, The polishing head includes a protective cover, abrasive belts arranged in a triangle on the protective cover, a polishing belt fitted on the three abrasive belts, and a rotary drive source connected to one of the abrasive belts.

4. The metal profile outer surface polishing equipment according to claim 2, characterized in that, The contact pressure adjustment unit includes an electric push rod mounted on a movable base and a pressure sensing element disposed between the polishing head and the movable base. The telescopic end of the electric push rod is connected to the outside of the protective cover. The pressure sensing element is communicatively connected to the control unit and is used to acquire the contact pressure value of the polishing head on the profile in real time and feed it back to the control unit.

5. The metal profile outer surface polishing equipment according to claim 1, characterized in that, The diameter measuring unit consists of two laser measuring sensors located at the ends of the frame, corresponding to the exit side of the polishing area, with their detection positions avoiding the polishing zone.

6. The metal profile outer surface polishing equipment according to claim 1, characterized in that, The front-end polishing execution component includes a movable base movably mounted on a frame guide rail and a polishing head fixedly mounted on the movable base.

7. The metal profile outer surface polishing equipment according to claim 1, characterized in that, The control unit is configured to: Based on the outer diameter values ​​of the front and rear sections, and combined with the original outer diameter of the profile before polishing, calculate the cumulative grinding removal amount △ of the front section. 前 and the cumulative amount removed by grinding in the later stage △ 后 The cumulative grinding deviation e = △ 后 -△ 前 ; With the preset reference contact pressure F base Based on this, according to formula F target =F base +Kp×e calculates the target contact pressure, where Kp is a preset gain coefficient; The contact pressure adjustment unit controls the contact pressure between the downstream polishing execution component and the profile to the target contact pressure, and the target contact pressure is limited between the preset minimum contact pressure and the maximum contact pressure.

8. The metal profile outer surface polishing equipment according to claim 1, characterized in that, The control unit is also equipped with a safety limit adjustment function: the change in contact pressure during a single adjustment process does not exceed the preset maximum step value; and the contact pressure adjustment action is only actually performed when the signs of the cumulative grinding amount deviation e in multiple consecutive detection cycles are all the same and the absolute values ​​of each deviation are all greater than the preset deviation threshold.

9. The metal profile outer surface polishing equipment according to claim 1, characterized in that, The preset detection cycle is the reversing window period during which the polishing mechanism pauses briefly after completing a full axial stroke each time.

10. A method for polishing the outer surface of a metal profile, using the metal profile outer surface polishing equipment as described in any one of claims 1-9, characterized in that, Includes the following steps: S100: The profile is clamped onto the clamping and rotating mechanism and rotated around its own axis; S200: Start the front polishing execution component and the rear polishing execution component, and drive them to move synchronously along the profile axis by the linear drive component to polish the front and rear areas of the profile simultaneously; S300: During the polishing process, the outer diameter values ​​of the front and rear polishing areas of the profile are obtained by the diameter measurement unit according to the preset detection cycle. S400: The control unit determines the deviation amount representing the difference in the amount of material removed by the front and rear grinding sections based on the obtained outer diameter value, and controls the contact pressure adjustment unit to change the contact pressure between the rear polishing execution component and the profile based on the deviation amount, so that the amount of material removed by the rear grinding section is close to the amount of material removed by the front grinding section, and the outer diameter of the front and rear sections is consistent.

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