A multi-wire saw positioning control system for aluminum plate manufacturing

Abstract

The application discloses a multi-wire cutting positioning control system for aluminum plate manufacturing and relates to the technical field of cutting regulation.The application establishes a workpiece aluminum plate model based on point cloud data, plans a multi-wire cutting path on the workpiece aluminum plate model according to an aluminum plate cutting scheme, maps each high-speed camera scanning range on the workpiece aluminum plate model, then according to the relative positions of the multi-wire cutting path and each high-speed camera scanning range, selects the multi-wire cutting path close to the center position of the scanning range and binds the corresponding high-speed camera, sends the multi-wire cutting path to a multi-wire cutting machine for execution, performs multi-dimensional segmentation on the workpiece aluminum plate model with the multi-wire cutting path, then divides out an abnormal analysis area, performs abnormal analysis on each abnormal analysis area according to the aluminum plate cutting scheme, and generates a cutting adjustment scheme according to the abnormal analysis result.

Description

Technical Field

[0001] This invention relates to the field of cutting control technology, specifically to a multi-wire cutting positioning control system for aluminum plate manufacturing. Background Technology

[0002] In precision manufacturing fields such as photovoltaics and semiconductors, aluminum plates serve as core substrate materials, and their processing precision directly determines the performance of the final product. Multi-wire cutting technology is a key process for achieving efficient and precise slicing of aluminum plates. However, traditional multi-wire cutting processes heavily rely on preset fixed programs and offline modeling, lacking closed-loop control capabilities for dynamic matching of workpiece morphology, equipment status, and cutting path during processing. Due to the potential for micro-deformation or positional shifts in the aluminum plate during loading, fixing, and cutting, and the presence of uncertainties such as wear and vibration on the high-speed cutting wire, deviations occur between the actual cutting path and the theoretical plan, resulting in problems such as out-of-tolerance cutting dimensions, rough cross-sections, and even wire breakage, severely impacting production yield and material utilization.

[0003] Existing technologies typically employ independent vision systems for pre-cut positioning or post-cut inspection. However, information is fragmented between these systems, hindering the deep integration and dynamic linkage of real-time acquired workpiece 3D topography with cutting execution decisions. When local anomalies occur during cutting, the system struggles to quickly identify the root cause (path deviation, wire wear, or aluminum plate deformation), and is unable to make adaptive adjustments to cutting parameters or paths within milliseconds, resulting in persistently high defect rates. Therefore, there is an urgent need for an adaptive cutting system that integrates real-time 3D perception, intelligent decision-making, and multi-dimensional online anomaly analysis to achieve a fully intelligent closed-loop process from perception to decision-making to control, thereby solving core challenges such as poor consistency and large yield fluctuations in high-precision aluminum plate cutting. Summary of the Invention

[0004] The purpose of this invention is to provide a multi-wire cutting positioning control system for aluminum plate manufacturing, so as to solve the problems in the prior art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A multi-wire cutting positioning control system for aluminum plate manufacturing includes a workpiece topology module, an adaptive cutting decision module, and a multi-dimensional anomaly analysis module. The workpiece topology module is used to scan the workpiece aluminum plate on the multi-wire cutting machine from different angles using multiple high-speed cameras, generate point cloud data at each angle, and build a workpiece aluminum plate model based on the point cloud data. The adaptive cutting decision module is used to plan a multi-line cutting path on the workpiece aluminum plate model according to the aluminum plate cutting scheme, map the scanning range of each high-speed camera onto the workpiece aluminum plate model, and then select the multi-line cutting path close to the center of the scanning range and bind it to the corresponding high-speed camera according to the relative position of the multi-line cutting path and the scanning range of each high-speed camera, and then send the multi-line cutting path to the multi-line cutting machine for execution. At the same time, the multi-line cutting path is adjusted according to the cutting adjustment scheme from the multi-dimensional anomaly analysis module. The multi-dimensional anomaly analysis module is used to perform multi-dimensional segmentation on the workpiece aluminum plate model with multi-line cutting paths, divide the anomaly analysis area, and then perform anomaly analysis on each anomaly analysis area according to the aluminum plate cutting scheme, and generate a cutting adjustment scheme based on the anomaly analysis results.

[0006] Furthermore, the scanning range of the high-speed camera is fixed, while the scanning ranges of adjacent high-speed cameras partially overlap, and according to the spatial distribution, the overlapping scanning ranges of adjacent high-speed cameras combine to cover the scanning range of the camera in the middle position. The multi-wire cutting machine consists of a lifting platform and a wiring device, wherein each wiring device consists of multiple metal wires and a rotating wheel.

[0007] Furthermore, the process of establishing a workpiece aluminum plate model based on point cloud data includes: Using the center of the lifting platform of the multi-wire cutting machine as the origin of the world coordinate system, a right-handed Cartesian world coordinate system is established. Then, based on the external parameters of each high-speed camera obtained during the previous camera calibration, a rigid transformation is performed on the point cloud data in each local coordinate system. Through rotation and translation operations, all point cloud data are transformed into the world coordinate system, thus completing the coordinate unification. The point cloud data of the overlapping area of ​​adjacent cameras are registered and calibrated. The corresponding feature points of the point cloud data in the overlapping area are found. The optimal registration parameters are solved by the least squares method to achieve accurate stitching of the point cloud data in the overlapping area. All point cloud data from single angles are merged into a point cloud dataset. The point cloud dataset is triangulated and meshed to form an initial three-dimensional mesh model of the workpiece aluminum plate. The initial three-dimensional mesh model is then smoothed and holes are repaired to construct the workpiece aluminum plate model.

[0008] Furthermore, the aluminum plate cutting plan is pre-set by staff based on the processing requirements of the aluminum plate, the specifications of the finished product, and the subsequent use scenarios. The aluminum plate cutting plan is imported into the adaptive cutting decision module in the form of a digital file.

[0009] The further planning process for the multi-line cutting path includes: The core parameters are extracted from the aluminum plate cutting scheme. Combined with the three-dimensional geometric features of the workpiece aluminum plate model, the constraints of the path planning are set. Based on the analyzed aluminum plate cutting scheme and the set constraints, the optimal path nodes of each single cutting path are obtained. The starting point, inflection point and ending point of the path are determined. The discrete path nodes are connected into a continuous and smooth single cutting path. Multiple single cutting paths are distributed in parallel and at equal intervals to form the initial multi-line cutting path. Check whether the initially planned single cutting paths overlap with the edges and surface defect areas of the workpiece aluminum plate model, and adjust the multi-line cutting paths based on the test results; The scanning range of each high-speed camera is mapped onto the workpiece aluminum plate model according to the coordinate mapping relationship, forming a model scanning area corresponding to the high-speed camera. The multi-line cutting path near the center of the scanning range is bound to the corresponding high-speed camera.

[0010] Furthermore, the multi-wire cutting path is converted into motion control commands that the multi-wire cutting machine can recognize, and the motion control commands are sent to the multi-wire cutting machine in real time to drive the cutting machine to perform aluminum plate cutting operations according to the cutting path; During the aluminum plate cutting operation, the adaptive cutting decision module receives the cutting adjustment plan from the multi-dimensional anomaly analysis module, and then adjusts the multi-line cutting path in real time according to the cutting adjustment plan.

[0011] Furthermore, the process of multi-dimensional segmentation of the workpiece aluminum plate model with multi-line cutting paths includes: Based on the binding relationship between the high-speed camera and the multi-line cutting path, the cutting areas of each high-speed camera binding part are extracted from the multi-dimensional segmented aluminum plate model of the workpiece and recorded as the anomaly analysis area. Each anomaly analysis region corresponds one-to-one with a high-speed camera, and the spatial range of the anomaly analysis region perfectly matches the scanning range of the corresponding high-speed camera, ensuring that the real-time monitoring data collected by the high-speed camera can fully cover the region. At the same time, each anomaly analysis region is further decomposed into several smaller sub-analysis units according to the results of multi-dimensional segmentation, and each sub-analysis unit corresponds to a combination of a spatial unit and a temporal unit.

[0012] Furthermore, the process of performing anomaly analysis on each anomaly analysis area based on the aluminum plate cutting scheme includes: The cutting status of each sub-analysis unit in each anomaly analysis area is judged one by one. The judgment mainly includes two core indicators: whether the cutting line corresponds to the cutting path and whether the cutting depth meets the requirements. If both indicators meet the requirements, the cutting status of the sub-analysis unit is judged to be normal. If either indicator does not meet the requirements, the cutting anomaly of the sub-analysis unit is judged to exist. When determining whether a cutting line corresponds to a cutting path, the spatial coordinates of the actual cutting line extracted from the real-time point cloud dataset are compared point by point with the spatial coordinates of the standard cutting path planned by the adaptive cutting decision module. The offsets of the actual cutting line and the standard cutting path in the X and Y axes are obtained, an offset threshold is set, and the relationship between the offset threshold and the offset size is used to determine whether the standard is met. When determining whether the cutting depth meets the standard, the actual cutting depth of the aluminum plate reflected in the real-time point cloud data is compared with the standard cutting depth set in the aluminum plate cutting scheme. The difference between the actual cutting depth and the standard cutting depth is obtained, a depth difference threshold is set, and the standard is determined based on the relationship between the difference and the depth difference threshold.

[0013] Furthermore, the process of generating a cutting adjustment plan based on the anomaly analysis results includes: Based on the results of the cutting status judgment, a cutting adjustment plan is generated. If the position of the cutting line deviates from the cutting path abnormally, the spatial offset parameters that need to be adjusted for a single cutting path are obtained according to the offset direction and offset amount of the actual cutting line and the standard cutting path, including the offset distance and offset direction in the X-axis and Y-axis directions. At the same time, based on the location of the abnormal area, the specific segment of the single cutting path that needs to be adjusted is determined. For cases where the cutting depth is below standard or abnormal, the height parameters that the lifting platform needs to be adjusted and the correction parameters for the metal wire cutting depth are obtained based on the deviation between the actual cutting depth and the standard cutting depth. If the actual cutting depth is too shallow, the lowering height of the lifting platform and the increase in the metal wire rotation speed are planned. If the actual cutting depth is too deep, the rising height of the lifting platform and the decrease in the metal wire rotation speed are planned. If multiple sub-analysis units in the same anomaly analysis area show consecutive anomalies, the root cause of the anomaly should be further analyzed. If it is caused by a local deviation in the cutting path planning, the path adjustment parameters should be set as the focus in the cutting adjustment plan. If it is caused by a deviation in the equipment operating parameters, the equipment control parameters should be set in the cutting adjustment plan at the same time. The technical effects and advantages provided by the present invention in the above technical solution are as follows: This invention generates a real-time model of an aluminum plate workpiece, providing an accurate digital twin foundation for cutting decisions. Based on this model, an initial path is planned. More innovatively, a specific cutting path is dynamically linked to a high-speed camera with the optimal viewing angle, achieving precise coordination between execution and monitoring. When a local deviation is detected, an adjustment plan is immediately generated and fed back to the decision-making module, fine-tuning the individual cutting path to form a real-time dynamic optimization closed loop. This ensures that the cutting path always follows the true shape of the workpiece, improving the overall consistency and accuracy of the cutting dimensions. Attached Figure Description

[0014] 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.

[0015] Figure 1 This is a system block diagram of a multi-wire cutting positioning control system for aluminum plate manufacturing according to the present invention.

[0016] Figure 2 This is a flowchart 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] Please see Figure 1 and Figure 2 As shown, a multi-wire cutting positioning control system for aluminum plate manufacturing includes a workpiece topology module, an adaptive cutting decision module, and a multi-dimensional anomaly analysis module. The workpiece topology module is used to scan the workpiece aluminum plate on the multi-wire cutting machine from different angles using multiple high-speed cameras, generate point cloud data at each angle, and build a workpiece aluminum plate model based on the point cloud data. The adaptive cutting decision module is used to plan a multi-line cutting path on the workpiece aluminum plate model according to the aluminum plate cutting scheme, map the scanning range of each high-speed camera onto the workpiece aluminum plate model, and then select the multi-line cutting path close to the center of the scanning range and bind it to the corresponding high-speed camera according to the relative position of the multi-line cutting path and the scanning range of each high-speed camera, and then send the multi-line cutting path to the multi-line cutting machine for execution. At the same time, the multi-line cutting path is adjusted according to the cutting adjustment scheme from the multi-dimensional anomaly analysis module. The multi-dimensional anomaly analysis module is used to perform multi-dimensional segmentation on the workpiece aluminum plate model with multi-line cutting paths, divide the anomaly analysis area, and then perform anomaly analysis on each anomaly analysis area according to the aluminum plate cutting scheme, and generate a cutting adjustment scheme based on the anomaly analysis results.

[0019] Furthermore, the working principle of the present invention will be illustrated below through embodiments: The workpiece topology module is communicatively connected to m high-speed cameras, where m is a natural number greater than 5. Each high-speed camera has a fixed scanning range, and all high-speed cameras are industrial-grade high-resolution high-speed area array cameras with a scanning frame rate of no less than 200fps and a pixel resolution of no less than 12 million. They can clearly capture the subtle features of the surface and edges of the workpiece aluminum plate. The lens focal length of the camera is adapted and selected according to the aluminum plate processing specifications to ensure that the point cloud data acquisition accuracy error within the scanning range does not exceed 0.01mm. Meanwhile, the scanning ranges of adjacent high-speed cameras partially overlap, with the width of the overlapping area accounting for 20%-30% of the scanning width of a single camera. Furthermore, based on the spatial distribution, the overlapping scanning ranges of adjacent high-speed cameras combine to cover the scanning range of the camera in the middle position. This arrangement is used to avoid the occurrence of scanning blind spots. At the same time, redundant acquisition of point cloud data in the overlapping area provides data support for the subsequent fusion and calibration of multi-angle point cloud data, ensuring the continuity and integrity of the workpiece aluminum plate model. All high-speed cameras are fixed around the processing area of ​​the multi-wire cutting machine using adjustable industrial brackets. The shooting angle and height of the high-speed cameras can be precisely adjusted according to the size and placement of the workpiece aluminum plate. Before starting the equipment, all high-speed cameras must be calibrated to complete the calibration of internal and external parameters to ensure that the scanning coordinate system of each high-speed camera is consistent. The multi-wire cutting machine consists of a lifting platform and a wiring device. Each wiring device consists of multiple metal wires and a rotating wheel. The metal wires are high-hardness diamond cutting wires. Each metal wire is wound parallel and equidistantly on the rotating wheel. The rotating wheel is driven by a servo motor to select the high-speed rotation of the metal wires. The rotation speed can be steplessly adjusted according to the cutting requirements. The lifting platform is a high-precision electro-hydraulic lifting platform used to place aluminum workpieces. The lifting platform has built-in high-precision displacement and pressure sensors, which can detect the placement position of the aluminum workpiece and the pressure on the platform in real time, avoiding the aluminum workpiece from being misplaced or unevenly stressed. At the same time, the lifting platform can precisely control the relative height of the workpiece relative to the wiring device according to the instructions of the control system, with an adjustment accuracy of up to 0.005mm, so as to achieve precise control of the cutting depth. The wiring device and the lifting platform work together to complete the multi-line cutting operation of the aluminum workpiece. The motion parameters of both are uniformly scheduled by the control system to ensure the synchronization and coordination of the cutting action. The workpiece topology module acquires point cloud data of the workpiece aluminum plate using a high-speed camera, and then establishes a workpiece aluminum plate model based on the point cloud data. The process includes: Since each high-speed camera scans the aluminum plate from different angles, the point cloud data it acquires is based on its own local coordinate system. Direct fusion would result in coordinate system confusion and model misalignment. Therefore, it is necessary to transform all point cloud data in the local coordinate system into a unified world coordinate system. First, a right-handed Cartesian world coordinate system is established with the center of the lifting platform of the multi-wire cutting machine as the origin of the world coordinate system, the length of the lifting platform as the X-axis, the width as the Y-axis, and the vertical height as the Z-axis. Then, based on the external parameters of each high-speed camera obtained during the previous camera calibration, including the rotation matrix and translation vector, a rigid transformation is performed on the point cloud data in each local coordinate system. Through rotation and translation operations, all point cloud data is transformed into the world coordinate system, thus completing the coordinate unification. After all point cloud data has undergone coordinate transformation, the iterative nearest point algorithm is used to register and calibrate the point cloud data in the overlapping area of ​​adjacent cameras. The corresponding feature points of the point cloud data in the overlapping area are found, and the optimal registration parameters are solved by the least squares method to achieve accurate stitching of the point cloud data in the overlapping area, eliminating data gaps and overlapping redundancy. Then, a global stitching algorithm is used to merge all single-angle point cloud data into a complete point cloud dataset. The point cloud dataset completely covers the entire spatial area of ​​the workpiece aluminum plate and accurately reflects the three-dimensional geometric features of the workpiece aluminum plate, including the aluminum plate's shape, thickness, surface flatness, edge contour, etc. The fused point cloud dataset is triangulated and meshed. Based on the spatial distribution characteristics of the point cloud data, continuous triangular patches are constructed to form the initial 3D mesh model of the workpiece aluminum plate. The initial 3D mesh model is then smoothed and hole repaired. For minor burrs and unevenness on the model surface, the Laplacian smoothing algorithm is used for iterative smoothing to make the model surface more closely match the actual surface condition of the workpiece aluminum plate. For holes in the model caused by factors such as aluminum plate surface occlusion and camera scanning angle limitations, hole filling point clouds are generated based on the point cloud data characteristics around the hole to complete the hole repair. Finally, a high-precision, blind-spot-free, and distortion-free workpiece aluminum plate model is constructed. The workpiece aluminum plate model can synchronize the spatial position and geometric features of the workpiece aluminum plate in real time, providing an accurate digital twin basis for subsequent cutting path planning.

[0020] Furthermore, before and during the processing of the workpiece aluminum plate on the multi-wire cutting machine, the workpiece topology module updates the workpiece aluminum plate model in real time and synchronizes the workpiece aluminum plate model with the adaptive cutting decision module in real time. When the adaptive cutting decision module receives the first workpiece aluminum plate model, it plans a multi-line cutting path on the workpiece aluminum plate model according to the aluminum plate cutting scheme. The aluminum plate cutting plan is pre-set by staff based on the processing requirements, finished product specifications, and subsequent usage scenarios of the aluminum plate. It includes key parameters such as cutting size, cutting shape, cutting depth, cutting spacing, and cutting sequence. The aluminum plate cutting plan is imported into the adaptive cutting decision module in the form of a digital file. The adaptive cutting decision module can automatically identify the various parameters in the plan and convert them into numerical indicators for model planning. The multi-line cutting path consists of multiple single cutting paths. Each single cutting path is distributed on the workpiece aluminum plate model according to the aluminum plate cutting scheme. The number and spacing of the single cutting paths correspond one-to-one with the number and spacing of the metal lines in the wiring device, ensuring that the cutting path matches the actual cutting tool. Each single cutting path is a continuous spatial broken line or curve. Its starting point, ending point, and inflection point are all set according to the aluminum plate cutting scheme. The planning of the single cutting path must follow the principles of shortest path, fewest inflection points, and avoiding defect areas on the surface of the workpiece aluminum plate, so as to maximize cutting efficiency while ensuring cutting accuracy.

[0021] The multi-line cutting path planning process includes: The adaptive cutting decision module first extracts core parameters such as cutting size, cutting depth, and cutting spacing from the aluminum plate cutting scheme. Combining the three-dimensional geometric features of the workpiece aluminum plate model, it sets the constraints for path planning, including the spatial range of the cutting path, the curvature of the inflection point, and the path spacing error. The setting of the constraints strictly follows the precision standards for industrial aluminum plate processing to ensure that the planned cutting path meets the actual processing requirements. Based on the analyzed aluminum plate cutting scheme and the set constraints, the optimal path nodes of each single cutting path are first obtained, the starting point, inflection point and ending point of the path are determined, and the discrete path nodes are connected into a continuous and smooth single cutting path. Multiple single cutting paths are distributed in parallel and at equal intervals to form the initial multi-line cutting path. The initial multi-wire cutting path is optimized and adjusted. First, it is checked whether each of the initially planned single cutting paths overlaps with the edge or surface defect area of ​​the workpiece aluminum plate model. If so, the single cutting path is locally offset to avoid defect areas and invalid edge areas. Then, according to the motion characteristics of the multi-wire cutting machine, the inflection points of the single cutting paths are rounded to reduce the impact of the cutting machine at the inflection points and ensure the smoothness of the cutting process. At the same time, the length of each single cutting path is balanced to avoid some paths being too long and some paths being too short, thereby improving cutting efficiency and equipment utilization. The optimized multi-wire cutting path must simultaneously meet the requirements of accuracy, equipment compatibility, and efficiency. The scanning range of each high-speed camera is precisely mapped onto the aluminum plate model of the workpiece according to the coordinate mapping relationship, forming a model scanning area corresponding to each high-speed camera. Each model scanning area has a clear spatial coordinate range. Then, the relative position of each single cutting path in the multi-line cutting path and each model scanning area is analyzed one by one. The spatial distance between the midpoint of the single cutting path and the center of each model scanning area is calculated. The multi-line cutting path that is closest to the center of the scanning range is selected and bound to the corresponding high-speed camera. In principle, one high-speed camera can be bound to 1-5 single cutting paths. The specific number is determined according to the scanning range of the camera and the distribution density of the single cutting paths. By binding high-speed cameras to cutting paths, the visual monitoring of the cutting area is customized, ensuring that the cutting process of each cutting path can be clearly and accurately captured by the corresponding high-speed camera, providing high-quality real-time monitoring data for subsequent multi-dimensional anomaly analysis.

[0022] After the multi-wire cutting path planning is completed and the high-speed camera is bound together, the adaptive cutting decision module converts the planned multi-wire cutting path into motion control commands that the multi-wire cutting machine can recognize. The motion control commands include the height adjustment parameters of the lifting platform, the motion trajectory parameters of the wiring device, and the rotation speed parameters of the metal wire. The motion control commands are sent to the multi-wire cutting machine in real time to drive the cutting machine to perform aluminum plate cutting operations according to the cutting path. During aluminum plate cutting, the adaptive cutting decision module maintains constant bidirectional communication with the multi-dimensional anomaly analysis module, receiving cutting adjustment plans from the multi-dimensional anomaly analysis module in real time. If the cutting adjustment plan shows anomalies such as offset of the cutting path or insufficient cutting depth in a certain area, the adaptive cutting decision module will dynamically adjust the corresponding single cutting path in the multi-line cutting path in real time according to the specific parameters in the adjustment plan, including spatial position offset of the path, cutting depth correction, and cutting speed adjustment. If the anomaly is caused by deviation of equipment operating parameters, the module will directly generate equipment control decisions, precisely controlling the position of the metal wire, correcting the offset error of the metal wire, and controlling the rotation speed of the metal wire to adapt to the processing requirements of different cutting areas. At the same time, the height of the lifting platform will be adjusted to achieve real-time correction of the cutting depth, ensuring that the cutting process always follows the preset accuracy standard.

[0023] Furthermore, the multi-dimensional anomaly analysis module performs multi-dimensional segmentation on the workpiece aluminum plate model undergoing multi-line cutting. The segmentation dimensions include three spatial dimensions (X-axis, Y-axis, and Z-axis) and a cutting time dimension. The spatial dimension segmentation uses the single cutting path of the multi-line cutting path as the segmentation benchmark. The workpiece aluminum plate model is divided into several equally wide cutting columns along the X-axis according to the spacing of the single cutting path, several equally long cutting rows along the Y-axis according to the movement direction of the cutting path, and several equally thick cutting layers along the Z-axis according to the cutting depth of the aluminum plate. The segmentation accuracy of the cutting columns, cutting rows, and cutting layers is consistent with the acquisition accuracy of the point cloud data, ensuring that each segmented spatial unit can accurately correspond to the actual cutting area. The cutting time dimension uses the scanning frequency of the high-speed camera as the unit. According to the execution order of the cutting path, the cutting process is divided into several continuous time units. Each time unit corresponds to one high-speed camera scan and point cloud data acquisition. Through multi-dimensional segmentation of space and time, the entire workpiece aluminum plate model and cutting process are decomposed into multiple refined analysis units. Based on the binding relationship between the high-speed camera and the multi-line cutting path, the cutting areas of each high-speed camera binding part are extracted from the multi-dimensional segmented aluminum plate model of the workpiece and recorded as the anomaly analysis area. Each anomaly analysis area corresponds one-to-one with a high-speed camera, and the spatial range of the anomaly analysis area perfectly matches the scanning range of the corresponding high-speed camera, ensuring that the real-time monitoring data collected by the high-speed camera can fully cover the area. At the same time, each anomaly analysis area is further decomposed into several smaller sub-analysis units according to the results of multi-dimensional segmentation. Each sub-analysis unit corresponds to a combination of a spatial unit and a temporal unit. The sub-analysis unit is the smallest unit of anomaly analysis, and its size is set according to the cutting accuracy requirements, generally 0.5mm×0.5mm×0.5mm. Through the fine division of the anomaly analysis area, the precise location of cutting anomalies can be achieved, ensuring that the specific cutting location and cutting time when the anomaly occurs can be accurately identified. Whenever the workpiece aluminum plate model is updated, the cutting scheme of the aluminum plate is used as the judgment standard to judge the cutting status of each sub-analysis unit in each anomaly analysis area. The judgment content mainly includes two core indicators: first, whether the cutting line corresponds to the cutting path; second, whether the cutting depth meets the standard. If both indicators meet the requirements, the cutting status of the sub-analysis unit is judged to be normal. If either indicator does not meet the requirements, the sub-analysis unit is judged to have a cutting anomaly. The multi-dimensional anomaly analysis module records and statistically analyzes the judgment results of all sub-analysis units in real time, and accurately marks the spatial location and time stage of the abnormal sub-analysis units. When determining whether the cutting line corresponds to the cutting path, the spatial coordinates of the actual cutting line extracted from the real-time point cloud dataset are compared point by point with the spatial coordinates of the standard cutting path planned by the adaptive cutting decision module. The offset of the actual cutting line from the standard cutting path in the X and Y axes is calculated, and an offset threshold is set. This threshold is set according to the accuracy requirements of aluminum plate cutting, and is generally 0.02mm-0.05mm. If the offset of the actual cutting line at all points is less than or equal to the offset threshold, it is determined that the cutting line corresponds to the cutting path and the cutting position is normal. If the offset of a certain point or a certain segment is greater than the offset threshold, it is determined that the cutting line deviates from the cutting path and there is an abnormal position. At the same time, the direction of the offset, the magnitude of the offset, and the spatial range of the offset area are recorded. When determining whether the cutting depth meets the standard, the actual cutting depth of the aluminum plate reflected in the real-time point cloud data is compared with the standard cutting depth set in the aluminum plate cutting scheme. The difference between the actual cutting depth and the standard cutting depth is calculated, and a depth difference threshold is set. The depth difference threshold is set according to the precision requirements of aluminum plate processing, and is generally 0.01mm-0.03mm. If the difference between the actual cutting depth and the standard cutting depth is less than or equal to the depth difference threshold, the cutting depth is considered to meet the standard. If the difference is greater than the depth difference threshold, including cases where the actual cutting depth is too deep or too shallow, the cutting depth is considered to be substandard and there is a depth abnormality. At the same time, the value of the depth deviation, the area of ​​the deviation, and the duration of the deviation are recorded. Based on the results of the cutting status assessment, a comprehensive analysis is conducted on the sub-analysis units and abnormal analysis areas with anomalies. Combining factors such as the type, level, spatial location, and time stage of the anomaly, a targeted cutting adjustment plan is generated. The cutting adjustment plan is generated in the form of a digital file, which contains core content such as the precise coordinates of the abnormal area, the type and level of the anomaly, the specific parameters of the path adjustment, and the numerical indicators of equipment control. All adjustment parameters in the plan are obtained through quantitative calculation to ensure the accuracy and effectiveness of the adjustment. When the cutting line deviates from the cutting path in an abnormal position, the multi-dimensional anomaly analysis module calculates the spatial offset parameters that need to be adjusted for a single cutting path based on the offset direction and amount of the actual cutting line from the standard cutting path. This includes the offset distance and offset direction in the X and Y axes. At the same time, based on the location of the abnormal area, the module determines the specific segment of the single cutting path that needs to be adjusted, ensuring that the path adjustment only targets the abnormal area and does not affect the processing of the normal cutting area. For cases where the cutting depth is below standard, the height parameters of the lifting platform and the correction parameters of the metal wire cutting depth are obtained based on the deviation between the actual cutting depth and the standard cutting depth. If the actual cutting depth is too shallow, the lowering height of the lifting platform and the increase in the rotation speed of the metal wire are planned. If the actual cutting depth is too deep, the rising height of the lifting platform and the decrease in the rotation speed of the metal wire are planned to ensure that the cutting depth can be quickly corrected to the standard range. If multiple sub-analysis units in the same anomaly analysis area show consecutive anomalies, further analysis should be conducted to determine the root cause of the anomaly. If the anomaly is caused by a local deviation in the cutting path planning, the path adjustment parameters should be set in the cutting adjustment plan. If the anomaly is caused by a deviation in equipment operating parameters, such as metal wire offset, unstable speed, or lifting platform height error, the equipment control parameters should be set in the cutting adjustment plan to specify the metal wire position correction value, speed adjustment range, and lifting platform height adjustment amount. After the cutting adjustment plan is generated, it is sent to the adaptive cutting decision module in real time. At the same time, the cutting status of abnormal areas is continuously tracked and monitored, and real-time cutting data after adjustment is collected to judge the effect of adjustment. If the abnormality disappears after adjustment and the cutting status returns to normal, the sending of the adjustment plan is stopped. If the abnormality still exists after adjustment, the cutting adjustment plan is iteratively optimized based on the new monitoring data until the abnormality disappears and the cutting status returns to normal.

[0024] 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 multi-wire cutting positioning control system for aluminum plate manufacturing, characterized in that, This includes a workpiece topology module, an adaptive cutting decision module, and a multi-dimensional anomaly analysis module; The workpiece topology module is used to scan the workpiece aluminum plate on the multi-wire cutting machine from different angles using multiple high-speed cameras, generate point cloud data at each angle, and build a workpiece aluminum plate model based on the point cloud data. The adaptive cutting decision module is used to plan a multi-line cutting path on the workpiece aluminum plate model according to the aluminum plate cutting scheme, map the scanning range of each high-speed camera onto the workpiece aluminum plate model, and then select the multi-line cutting path close to the center of the scanning range and bind it to the corresponding high-speed camera according to the relative position of the multi-line cutting path and the scanning range of each high-speed camera, and then send the multi-line cutting path to the multi-line cutting machine for execution. At the same time, the multi-line cutting path is adjusted according to the cutting adjustment scheme from the multi-dimensional anomaly analysis module. The multi-dimensional anomaly analysis module is used to perform multi-dimensional segmentation on the workpiece aluminum plate model with multi-line cutting paths, divide the anomaly analysis area, and then perform anomaly analysis on each anomaly analysis area according to the aluminum plate cutting scheme, and generate a cutting adjustment scheme based on the anomaly analysis results.

2. The multi-wire cutting positioning control system for aluminum plate manufacturing according to claim 1, characterized in that, The scanning range of the high-speed camera is fixed, while the scanning ranges of adjacent high-speed cameras partially overlap. Furthermore, based on the spatial distribution, the overlapping scanning ranges of adjacent high-speed cameras combine to cover the scanning range of the camera in the middle position. The multi-wire cutting machine consists of a lifting platform and a wiring device, wherein each wiring device consists of multiple metal wires and a rotating wheel.

3. A multi-wire cutting positioning control system for aluminum plate manufacturing according to claim 2, characterized in that, The process of creating a workpiece aluminum plate model based on point cloud data includes: Using the center of the lifting platform of the multi-wire cutting machine as the origin of the world coordinate system, a right-handed Cartesian world coordinate system is established. Then, based on the external parameters of each high-speed camera obtained during the previous camera calibration, a rigid transformation is performed on the point cloud data in each local coordinate system. Through rotation and translation operations, all point cloud data are transformed into the world coordinate system, thus completing the coordinate unification. The point cloud data of the overlapping area of ​​adjacent cameras are registered and calibrated. The corresponding feature points of the point cloud data in the overlapping area are found. The optimal registration parameters are solved by the least squares method to achieve accurate stitching of the point cloud data in the overlapping area. All point cloud data from single angles are merged into a point cloud dataset. The point cloud dataset is triangulated and meshed to form an initial three-dimensional mesh model of the workpiece aluminum plate. The initial three-dimensional mesh model is then smoothed and holes are repaired to construct the workpiece aluminum plate model.

4. A multi-wire cutting positioning control system for aluminum plate manufacturing according to claim 3, characterized in that, The aluminum plate cutting plan is pre-set by staff based on the processing requirements, finished product specifications, and subsequent usage scenarios of the aluminum plate. The aluminum plate cutting plan is imported into the adaptive cutting decision module in the form of a digital file.

5. A multi-wire cutting positioning control system for aluminum plate manufacturing according to claim 4, characterized in that, The planning process for the multi-line cutting path includes: The core parameters are extracted from the aluminum plate cutting scheme. Combined with the three-dimensional geometric features of the workpiece aluminum plate model, the constraints of the path planning are set. Based on the analyzed aluminum plate cutting scheme and the set constraints, the optimal path nodes of each single cutting path are obtained. The starting point, inflection point and ending point of the path are determined. The discrete path nodes are connected into a continuous and smooth single cutting path. Multiple single cutting paths are distributed in parallel and at equal intervals to form the initial multi-line cutting path. Check whether the initially planned single cutting paths overlap with the edges and surface defect areas of the workpiece aluminum plate model, and adjust the multi-line cutting paths based on the test results; The scanning range of each high-speed camera is mapped onto the workpiece aluminum plate model according to the coordinate mapping relationship, forming a model scanning area corresponding to the high-speed camera. The multi-line cutting path near the center of the scanning range is bound to the corresponding high-speed camera.

6. A multi-wire cutting positioning control system for aluminum plate manufacturing according to claim 5, characterized in that, The multi-wire cutting path is converted into motion control commands that the multi-wire cutting machine can recognize. The motion control commands are sent to the multi-wire cutting machine in real time, driving the cutting machine to perform aluminum plate cutting operations according to the cutting path. During the aluminum plate cutting operation, the adaptive cutting decision module receives the cutting adjustment plan from the multi-dimensional anomaly analysis module, and then adjusts the multi-line cutting path in real time according to the cutting adjustment plan.

7. A multi-wire cutting positioning control system for aluminum plate manufacturing according to claim 6, characterized in that, The process of performing multi-dimensional segmentation on an aluminum plate model with multi-line cutting paths includes: Based on the binding relationship between the high-speed camera and the multi-line cutting path, the cutting areas of each high-speed camera binding part are extracted from the multi-dimensional segmented aluminum plate model of the workpiece and recorded as the anomaly analysis area. Each anomaly analysis region corresponds one-to-one with a high-speed camera, and the spatial range of the anomaly analysis region perfectly matches the scanning range of the corresponding high-speed camera, ensuring that the real-time monitoring data collected by the high-speed camera can fully cover the region. At the same time, each anomaly analysis region is further decomposed into several smaller sub-analysis units according to the results of multi-dimensional segmentation, and each sub-analysis unit corresponds to a combination of a spatial unit and a temporal unit.

8. A multi-wire cutting positioning control system for aluminum plate manufacturing according to claim 7, characterized in that, The process of performing anomaly analysis on each anomaly analysis area based on the aluminum plate cutting scheme includes: The cutting status of each sub-analysis unit in each anomaly analysis area is judged one by one. The judgment mainly includes two core indicators: whether the cutting line corresponds to the cutting path and whether the cutting depth meets the requirements. If both indicators meet the requirements, the cutting status of the sub-analysis unit is judged to be normal. If either indicator does not meet the requirements, the cutting anomaly of the sub-analysis unit is judged to exist. When determining whether a cutting line corresponds to a cutting path, the spatial coordinates of the actual cutting line extracted from the real-time point cloud dataset are compared point by point with the spatial coordinates of the standard cutting path planned by the adaptive cutting decision module. The offsets of the actual cutting line and the standard cutting path in the X and Y axes are obtained, an offset threshold is set, and the relationship between the offset threshold and the offset size is used to determine whether the standard is met. When determining whether the cutting depth meets the standard, the actual cutting depth of the aluminum plate reflected in the real-time point cloud data is compared with the standard cutting depth set in the aluminum plate cutting scheme. The difference between the actual cutting depth and the standard cutting depth is obtained, a depth difference threshold is set, and the standard is determined based on the relationship between the difference and the depth difference threshold.

9. A multi-wire cutting positioning control system for aluminum plate manufacturing according to claim 8, characterized in that, The process of generating a cutting adjustment plan based on anomaly analysis results includes: Based on the results of the cutting status judgment, a cutting adjustment plan is generated. If the position of the cutting line deviates from the cutting path abnormally, the spatial offset parameters that need to be adjusted for a single cutting path are obtained according to the offset direction and offset amount of the actual cutting line and the standard cutting path, including the offset distance and offset direction in the X-axis and Y-axis directions. At the same time, based on the location of the abnormal area, the specific segment of the single cutting path that needs to be adjusted is determined. For cases where the cutting depth is below standard or abnormal, the height parameters that the lifting platform needs to be adjusted and the correction parameters for the metal wire cutting depth are obtained based on the deviation between the actual cutting depth and the standard cutting depth. If the actual cutting depth is too shallow, the lowering height of the lifting platform and the increase in the metal wire rotation speed are planned. If the actual cutting depth is too deep, the rising height of the lifting platform and the decrease in the metal wire rotation speed are planned. If multiple sub-analysis units in the same anomaly analysis area show consecutive anomalies, the root cause of the anomaly should be further analyzed. If it is caused by a local deviation in the cutting path planning, the path adjustment parameters should be set as the focus in the cutting adjustment plan. If it is caused by a deviation in the equipment operating parameters, the equipment control parameters should be set in the cutting adjustment plan at the same time.

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