Anti-collision car guard system, method and turning center for a numerically controlled turning center

Abstract

The application relates to a collision-preventing vehicle protection system, a method and a turning center for a numerical control turning center, the system comprising a multi-source fusion perception unit, a digital twin pre-judgment controller, an active avoidance servo actuator, a hierarchical linkage braking mechanism, a self-adaptive hierarchical energy absorption assembly and an intelligent monitoring terminal. The multi-source fusion perception unit is used for collecting machine tool operation condition data in real time, the digital twin pre-judgment controller is used for completing state mapping and three-level collision risk judgment, and hierarchical output of early warning, avoidance and braking control signals is realized, so that man-machine early warning prompt, servo track active correction and electromechanical linkage emergency braking protection are realized. End face composite energy absorption and guide rail end hydraulic buffer constitute a three-level self-adaptive energy absorption structure, and control closed loop is formed in cooperation with impact force sensing feedback. The application solves the problems of traditional machine tool collision-preventing pre-judgment lag, single protection mode, large braking impact and no closed-loop self-adaptive adjustment, and effectively improves the safety and structural stability of numerical control machine tool machining operation.

Description

Technical Field

[0001] This application relates to the field of safety protection technology for CNC turning equipment, specifically to a collision protection system, method, and turning center for CNC turning centers. Background Technology

[0002] The precision of the moving parts, such as the spindle and turret, in a CNC turning center directly determines the machining quality. However, during high-speed machining, factors such as workpiece clamping deviations, abnormal tool parameters, G-code programming errors, and servo response delays can easily lead to collisions between the spindle and turret, the spindle and workpiece, or the turret and workpiece or fixture. Such accidents not only damage core components such as the spindle guideways and render the workpiece unusable, but also threaten the safety of operators and cause significant economic losses.

[0003] Existing collision avoidance technologies for CNC turning centers suffer from several core deficiencies, failing to meet the safety protection requirements of high-speed, high-precision machining. Firstly, their collision prediction capabilities are weak. Most technologies rely on static G-code verification or single-sensor detection, failing to integrate real-time motion data with machine tool operating conditions to build dynamic prediction models. This prevents accurate early identification of collision risks, allowing only a passive response after a collision occurs. Secondly, active avoidance mechanisms are lacking. Existing protection primarily relies on emergency braking, lacking dynamic trajectory correction functions based on real-time risks, easily leading to machining interruptions or workpiece damage. Thirdly, the adaptability of energy-absorbing structures is poor. Using fixed-parameter buffer elements such as springs or single dampers cannot adaptively adjust energy absorption efficiency according to the magnitude of collision energy, resulting in insufficient or excessive protection. Fourthly, system coordination is poor. Modules such as sensing, braking, energy absorption, and monitoring operate independently, lacking unified collaborative control logic. This leads to delayed protection responses and a lack of full-process data traceability, hindering accident review and machine tool maintenance. Some existing technologies employ multi-sensor fusion to detect collisions, but lack digital twin technology for dynamic prediction; some technologies employ multi-level energy-absorbing structures, but their energy absorption parameters are fixed and cannot adapt to collisions of varying intensities; still others possess basic data recording capabilities, but lack a comprehensive collaborative system encompassing perception, prediction, avoidance, braking, energy absorption, and tracing. Therefore, developing an integrated protection system and method that integrates four core functions—multi-source perception and prediction, active avoidance and braking, adaptive graded energy absorption, and intelligent monitoring and tracing—is crucial to addressing the pain points of existing technologies. Summary of the Invention

[0004] This application mainly addresses the technical problems of existing collision avoidance technologies for CNC turning centers, such as low prediction accuracy, lack of active avoidance, poor energy absorption adaptability, insufficient system coordination, and lack of full-process traceability.

[0005] This application provides an intelligent adaptive anti-collision safety protection system for CNC turning centers, which is used to prevent collisions between the spindle, turret, workpiece and fixture of the CNC turning center. The intelligent adaptive anti-collision safety protection system for CNC turning centers includes a multi-source fusion sensing unit, a digital twin predictive controller, an active avoidance servo actuator, a graded linkage braking mechanism, an adaptive graded energy absorption component and an intelligent monitoring terminal. The components form a closed-loop collaborative control system through an electrical signal transmission link. The multi-source fusion sensing unit includes three laser rangefinders arranged in an equilateral triangle topology, absolute encoders integrated into the output shafts of the X-axis and Z-axis servo motors, an industrial vision component fixed above the turret by a bracket, a vibration sensor threaded to the front end face of the spindle, and a pressure sensor embedded inside the tool holder. The three laser rangefinders are respectively fixed at the top center of the spindle box, the side center of the turret, and the front side of the bed, and their scanning fields of view overlap to form a blind-spot-free detection field covering the working area of ​​all moving parts. The digital twin prediction controller is installed inside the electrical cabinet via a standard guide rail. Its input is electrically connected to the signal output of all sensing units, and its output is electrically connected to the active avoidance servo actuator, the graded linkage braking mechanism, and the intelligent monitoring terminal, respectively. The digital twin prediction controller has a built-in real-time digital twin model of the CNC turning center, which is used to fuse multi-source sensing data and G-code parsing results to predict collision risks and output corresponding control signals. The active avoidance servo actuator communicates with the servo driver of the CNC system via an industrial fieldbus, and is used to receive avoidance commands from the digital twin predictive controller and dynamically correct the motion trajectory of the servo axis. The graded linkage braking mechanism includes an electromagnetic mechanical brake fixed to the ends of the X-axis guide rail and the Z-axis guide rail respectively, and an emergency tool release mechanism integrated into the end of the spindle; the control end of the electromagnetic mechanical brake is electrically connected in parallel to the braking signal output end of the digital twin prediction controller, and the control end of the emergency tool release mechanism is electrically connected to the same trigger signal output end as the control end of the electromagnetic mechanical brake, so as to realize the synchronous triggering of the braking action and the tool release action. The adaptive graded energy absorption assembly includes a primary elastic buffer layer bonded to the end face of the turret, a secondary honeycomb damping energy absorption plate fixed to the front face of the spindle box by fasteners, and a tertiary hydraulic buffer fixed to the end of the Z-axis guide rail by a flange; the primary elastic buffer layer has a built-in micro pressure sensor, the signal output of which is electrically connected to the feedback input of the digital twin prediction controller. The intelligent monitoring terminal is embedded in the machine tool operation panel. Its input end is electrically connected to the status signal output end of the digital twin prediction controller, which is used to display the equipment operating status and collision risk level in real time. Its output end is electrically connected in reverse to the parameter optimization port of the digital twin prediction controller.

[0006] In the aforementioned intelligent adaptive anti-collision vehicle safety protection system for CNC turning centers, as a preferred embodiment, the scanning range of the three laser rangefinders forms an overlapping coverage area in the machining area of ​​the turret and the workpiece, which is used to realize cross-verification and redundancy detection of the position information of moving parts.

[0007] In the aforementioned intelligent adaptive collision avoidance safety protection system for CNC turning centers, as a preferred solution, the digital twin predictive controller outputs three levels of control signals: a warning signal, an avoidance signal, and a braking signal, which correspond to preset three levels of collision risk thresholds.

[0008] In the aforementioned intelligent adaptive anti-collision vehicle safety protection system for CNC turning centers, as a preferred embodiment, the graded linkage braking mechanism further includes a servo soft braking module integrated within the servo driver; when the digital twin prediction controller outputs an avoidance signal, the servo soft braking module is activated, enabling the servo axis to achieve smooth deceleration; when the digital twin prediction controller outputs a braking signal, the electromagnetic mechanical brake is activated, simultaneously triggering the emergency tool release mechanism.

[0009] In the aforementioned intelligent adaptive collision avoidance safety protection system for CNC turning centers, as a preferred embodiment, the energy absorption process of the adaptive graded energy absorption component is adaptively matched with the magnitude of the collision impact force: when the collision impact force is lower than the first threshold, only the first-level elastic buffer layer participates in energy absorption; when the collision impact force is between the first threshold and the second threshold, the first-level elastic buffer layer and the second-level honeycomb damping energy absorption plate jointly participate in energy absorption; when the collision impact force is higher than the second threshold, the third-level hydraulic buffer is activated and absorbs the residual collision energy.

[0010] In the aforementioned intelligent adaptive anti-collision safety protection system for CNC turning centers, as a preferred embodiment, the emergency tool release mechanism includes a tool release cylinder, a pull rod, and a disc spring assembly. The piston rod of the tool release cylinder is connected to the disc spring assembly via the pull rod, and is used to push the pull rod to compress the disc spring assembly under the action of a trigger signal, thereby achieving rapid tool release.

[0011] In the aforementioned intelligent adaptive collision avoidance safety protection system for CNC turning centers, as a preferred solution, the active avoidance servo actuator generates the optimal avoidance trajectory by parsing the currently executed G-code segment, and adjusts the movement path of the turret without interrupting the machining process.

[0012] In the aforementioned intelligent adaptive collision avoidance vehicle safety protection system for CNC turning centers, as a preferred embodiment, the intelligent monitoring terminal includes a data storage module for recording full-process event data such as collision risk values, braking moments, and energy absorption process data, and feeding back key operating data to the digital twin prediction controller for iterative optimization of the collision prediction algorithm parameters.

[0013] This application also provides an intelligent adaptive collision avoidance method for CNC turning centers, based on the above-mentioned safety protection system, including the following steps: The multi-source fusion sensing unit collects real-time data on the position, speed, vibration, pressure, and workpiece status of the moving parts of the machine tool and transmits it to the digital twin predictive controller. The digital twin predictive controller constructs a real-time digital twin model that is synchronously mapped to the physical machine tool, integrates multi-source perception data and G-code parsing results, predicts collision risks and outputs control signals of the corresponding level; When an avoidance signal is output, the active avoidance servo actuator dynamically corrects the turret's movement trajectory and simultaneously activates the servo soft braking module. When a braking signal is output, the electromagnetic mechanical brake is activated, which simultaneously triggers the emergency tool release mechanism to quickly disengage the tool. If a collision occurs, the adaptive graded energy absorption component absorbs the collision energy in stages according to the magnitude of the impact force. The pressure sensor built into the first-level elastic buffer layer collects the impact force data in real time and feeds it back to the digital twin prediction controller. The intelligent monitoring terminal displays the real-time operating status of the equipment, stores the event data of the entire process, and feeds back key operating data to the digital twin predictive controller.

[0014] This application also provides a CNC turning center, including a bed, a spindle box, a turret, a feed mechanism, and the intelligent adaptive anti-collision safety protection system described above.

[0015] According to the above embodiments, the anti-collision protection system, method, and turning center for CNC turning centers utilize the collaboration of a multi-source fusion sensing unit and a digital twin predictive controller. A blind-spot-free detection field is formed using laser rangefinders arranged in an equilateral triangular topology. Combined with cross-validation and redundant detection of multi-source sensor data, a real-time digital twin model is constructed, and working condition data and G-code parsing results are fused to predict collision risks. Compared to traditional single-sensor detection or static G-code verification, this system can identify dynamic collision risks in advance, significantly reducing the probability of collisions and moving the protection checkpoint forward. The active avoidance servo actuator dynamically corrects the servo axis motion trajectory based on the risk level. When trajectory correction is ineffective, a graded linkage braking mechanism is activated. By sharing the same trigger signal output circuit structure between the electromagnetic mechanical brake and the emergency tool release mechanism, synchronous triggering of braking and tool release actions is achieved, overcoming the limitations of traditional passive braking. This avoids workpiece scrapping caused by machining interruption and prevents hard adhesion between the tool and workpiece during collisions. This system reduces damage to core components such as the spindle and turret from collisions, balancing machining efficiency and equipment safety. The adaptive graded energy absorption component, combined with the initial impact force data collected by the pressure sensor built into the primary elastic buffer layer, absorbs collision energy in stages through a three-stage energy absorption structure. It dynamically matches the energy absorption efficiency according to the magnitude of the impact force, solving the problem of insufficient or excessive protection by traditional fixed-parameter buffer elements. This effectively weakens the impact force and maximizes the protection of the machine tool's core components. Each core component forms a closed-loop collaborative control system through electrical signal transmission links, avoiding the shortcomings of traditional technologies where modules are independent and response is lagging. The intelligent monitoring terminal integrates the entire process operation data, enabling real-time status monitoring, data storage, and remote transmission. Simultaneously, it feeds back key operating data to the digital twin predictive controller, assisting in iterative optimization of the collision prediction algorithm parameters. It also provides accurate data support for accident review, machine tool maintenance, and process optimization, improving the long-term adaptability and ease of maintenance of the protection system. Attached Figure Description

[0016] Figure 1 A schematic diagram showing the distribution of the intelligent adaptive anti-collision vehicle safety protection system for CNC turning centers provided in this embodiment of the application; Figure 2 This is a structural block diagram of the intelligent adaptive anti-collision vehicle safety protection system for CNC turning centers provided in the embodiments of this application; Figure 3 A flowchart of the intelligent adaptive anti-collision safety protection system for CNC turning centers provided in the embodiments of this application; Figure 4 A block diagram of a graded linkage braking mechanism provided in an embodiment of this application; Figure 5 A block diagram of the adaptive graded energy absorption component provided in the embodiments of this application.

[0017] In the diagram: 1. Multi-source fusion sensing unit; 101. Laser ranging sensor group; 102. Absolute encoder group; 103. Industrial vision component; 104. Vibration sensor; 105. Pressure sensor; 2. Digital twin predictive controller; 201. Real-time digital twin model; 202. Three-level risk assessment module; 3. Active avoidance servo actuator; 301. G-code parsing module; 302. Trajectory correction module; 4. Graded linkage braking mechanism; 401. Servo soft braking module 402a, X-axis electromagnetic mechanical brake; 402b, Z-axis electromagnetic mechanical brake; 403, emergency knife release mechanism; 4031, knife release cylinder; 4032, pull rod; 4033, disc spring assembly; 5, adaptive graded energy absorption assembly; 501, primary elastic buffer layer; 5011, miniature pressure sensor; 502, secondary honeycomb damping energy absorption plate; 503, tertiary hydraulic buffer; 6, intelligent monitoring terminal; 601, data storage module; 602, status display module. Detailed Implementation

[0018] The present application will now be described in further detail with reference to specific embodiments and accompanying drawings. Similar elements in different embodiments are referred to by associated and similar element designations.

[0019] In the following embodiments, many details are described in order to enable a better understanding of this application. However, those skilled in the art will readily recognize that some of these features may be omitted in different circumstances, or may be replaced by other elements, materials, or methods.

[0020] In some cases, certain operations related to this application are not shown or described in the specification. This is to avoid the core parts of this application being overwhelmed by excessive description. For those skilled in the art, it is not necessary to describe these related operations in detail. They can fully understand the related operations based on the description in the specification and general technical knowledge in the field.

[0021] Furthermore, the features, operations, or characteristics described in the specification can be combined in any suitable manner to form various embodiments. At the same time, the steps or actions in the method description can be rearranged or adjusted in a manner obvious to those skilled in the art. Therefore, the various orders in the specification and drawings are only for the clear description of a particular embodiment and do not imply a necessary order, unless otherwise stated that a particular order must be followed.

[0022] The serial numbers assigned to components in this document, such as "first" and "second," are used only to distinguish the described objects and have no sequential or technical meaning. The terms "connection" and "linkage" used in this application, unless otherwise specified, include both direct and indirect connections (linkages).

[0023] Please refer to Figure 1 and Figure 2 To address the shortcomings of existing collision avoidance technologies for CNC turning centers, such as low prediction accuracy, lack of active avoidance, poor energy absorption adaptability, insufficient system coordination, and lack of full-process traceability, this invention provides an intelligent adaptive collision avoidance safety protection system for CNC turning centers. This system prevents collisions between the spindle, turret, workpiece, and fixture of the CNC turning center. It constructs a core structure consisting of six collaborative components: a multi-source fusion sensing unit, a digital twin prediction controller, an active avoidance servo actuator, a graded linkage braking mechanism, an adaptive graded energy absorption component, and an intelligent monitoring terminal. This forms a complete intelligent collision avoidance system encompassing perception, prediction, avoidance, braking, energy absorption, and traceability. Through multi-source data acquisition and digital twin modeling, it achieves early prediction of collision risks. Based on the risk level, it dynamically corrects the trajectory or initiates graded braking, while a three-level adaptive energy absorption structure absorbs collision energy. Simultaneously, it completes full-process data monitoring and traceability, improving protection reliability and processing continuity, and reducing equipment damage and maintenance costs.

[0024] Each core component forms a closed-loop collaborative control system through electrical signal transmission links: the signal output of the multi-source fusion sensing unit is electrically connected to the input of the digital twin predictive controller; the output of the digital twin predictive controller is electrically connected to the active avoidance servo actuator, the graded linkage braking mechanism, and the intelligent monitoring terminal, respectively; the active avoidance servo actuator is communicatively connected to the servo driver of the CNC system; the feedback of the graded linkage braking mechanism is electrically connected to the adaptive graded energy absorption component; the signal output of the adaptive graded energy absorption component is electrically connected to the feedback input of the digital twin predictive controller; and the output of the intelligent monitoring terminal is electrically connected in reverse to the parameter optimization port of the digital twin predictive controller.

[0025] In some embodiments, the multi-source fusion sensing unit is used to collect full-dimensional working condition data, including three high-precision laser rangefinders arranged in an equilateral triangle topology, an absolute encoder integrated into the tail of the X-axis and Z-axis servo motors, an industrial vision component mounted on the turret via a bracket, a vibration sensor fixed to the spindle via a threaded connection, and a pressure sensor embedded in the tool holder.

[0026] In some embodiments, the multi-source fusion sensing unit adopts a multi-source fusion design of laser rangefinder, servo encoder, industrial vision, and working condition sensor. Three high-precision laser rangefinders are installed in a triangular distributed configuration, fixed to the top of the spindle box, the side of the turret, and the front of the bed, respectively. The laser rangefinder on the top of the spindle box has a metal housing, 50mm in diameter, and is fixed with M8 bolts. Its scanning range covers the turret and workpiece area, with a scanning angle of 120°, a measurement accuracy of ±0.01mm, and a scanning frequency ≥100Hz. The laser rangefinder on the side of the turret is identical in specifications, scanning the gap between the spindle and the guide rail with a scanning angle of 90°. The laser rangefinder at the front of the bed is identical in specifications, scanning the workpiece clamping area with a scanning angle of 150°. The scanning fields of view of the three laser rangefinders overlap, forming a blind-spot-free detection field covering the working area of ​​all moving parts, used for cross-validation and redundant detection of the position information of moving parts.

[0027] Both the X-axis and Z-axis servo motors integrate absolute encoders at their tails. These encoders are black cylindrical, 40mm in diameter, and equipped with 10-pin aviation connectors. They acquire axis motion speed, acceleration, and position data in real time, with a sampling frequency ≥1kHz. The industrial vision component includes a 2-megapixel industrial camera and a ring LED light source. The industrial camera is a silver cube with 60mm sides, mounted above the tool turret with a bracket. The lens faces the workpiece, and the field of view is 200×150mm, used to identify workpiece clamping deviations and abnormal tool extension lengths. The ring LED light source is white and 80mm in diameter. The condition sensing component includes a spindle vibration sensor and a tool turret pressure sensor. The spindle vibration sensor is 15mm in diameter and 30mm in length, fixed by a threaded connection. The tool turret pressure sensor is 5mm in diameter and embedded in the tool holder, acquiring cutting vibration and tool clamping pressure data respectively. All sensor data is transmitted to the digital twin predictive controller via shielded cables.

[0028] In some embodiments, the digital twin prediction controller is mounted inside an electrical cabinet via a 35mm standard guide rail. It incorporates an industrial-grade embedded processor to construct a real-time digital twin model of the CNC turning center. This model integrates multi-source sensing data and G-code parsing results to predict collision risks and outputs corresponding control signals. The control signals are divided into three levels: warning signals, avoidance signals, and braking signals, each corresponding to a preset three-level collision risk threshold.

[0029] In some embodiments, the core function of the digital twin predictive controller is to construct a real-time digital twin model of the CNC turning center, achieving synchronous mapping of the virtual and physical machine tool states. This is based on an improved RRT. The algorithm integrates multi-source sensor data with the G-code parsing results output by the CNC system to predict the intersection points of the motion trajectories between the spindle and the turret, the spindle and the workpiece, and the turret and the workpiece or fixture 200-500ms in advance. Three risk thresholds are set: a warning threshold (collision risk value ≥40%), an avoidance threshold (collision risk value ≥60%), and a braking threshold (collision risk value ≥80%). When the detected data reaches the corresponding threshold, a trigger signal is output to the active avoidance servo actuator and the graded linkage braking mechanism. The digital twin model interface displays a 3D model of the machine tool on the left, with the spindle in red and the turret in blue, and the motion trajectory followed by a dashed line. The right side displays real-time sensor data, including the coordinates of the laser rangefinder sensor, servo axis speed and acceleration, and visual deviation values. A progress bar at the bottom displays the remaining prediction time.

[0030] In some embodiments, the active avoidance servo actuator communicates with the servo driver of the CNC system via an industrial fieldbus, and is used to receive avoidance commands from the digital twin predictive controller and dynamically correct the motion trajectory of the servo axis. The active avoidance servo actuator generates the optimal avoidance trajectory by parsing the currently executed G-code segment, and adjusts the turret's motion path without interrupting the machining process.

[0031] In some embodiments, the active avoidance servo actuator is an independent metal-cased controller, measuring 200×150×80mm. An embedded display on the front shows the current G-code segment and the corrected trajectory parameters, with the correction parameter accuracy adjustable to 0.001mm. A precision adjustment knob on the side offers three settings: high, medium, and low. Its core function is to receive risk signals from the digital twin predictive controller, automatically analyze the current G-code segment, generate the optimal avoidance trajectory, and send it to the servo driver via the CNC system interface module. This enables real-time correction of the motion trajectory without interrupting machining. The CNC system interface module uses a custom ladder diagram module on a green PCB board, measuring 150×100mm. It integrates two RS485 communication interfaces and three analog output interfaces, mounted on a guide rail inside the electrical cabinet. This allows for high-speed signal interaction with the CNC system and the digital twin predictive controller, with a communication latency ≤10ms.

[0032] Please refer to Figure 4 In some embodiments, the graded linkage braking mechanism includes a servo soft braking module integrated within the servo driver, electromagnetic mechanical brakes respectively fixed to the ends of the X-axis and Z-axis guide rails, and an emergency tool release mechanism integrated into the spindle end. The control terminal of the electromagnetic mechanical brake is electrically connected in parallel to the braking signal output terminal of the digital twin predictive controller, and the control terminal of the emergency tool release mechanism is electrically connected to the same trigger signal output terminal as the control terminal of the electromagnetic mechanical brake, realizing synchronous triggering of the braking action and the tool release action.

[0033] In some embodiments, the graded linkage braking mechanism includes two stages: servo soft braking and electromagnetic mechanical braking. The servo soft braking relies on the IGBT power module inside the servo driver. The servo driver is a black cuboid measuring 180×120×60mm. It adjusts the output voltage via a PWM signal to achieve smooth deceleration of the axis movement, with a deceleration time adjustable from 50-200ms. The electromagnetic mechanical brake is cylindrical, 60mm in diameter, equipped with a red coil, and installed at the ends of the X-axis and Z-axis guideways. When energized, the brake pads separate from the guideways; when de-energized, a spring pushes the brake pads to clamp the guideways. The braking gap is controlled between 0.1-0.3mm by an adjusting bolt. Servo soft braking is activated when an avoidance threshold is reached, and electromagnetic mechanical braking is activated when a braking threshold is reached.

[0034] The emergency tool release mechanism is integrated into the end of the spindle and includes a pull rod, a three-piece stacked disc spring assembly, and a tool release cylinder. The pull rod is red, the disc spring assembly is blue, and the tool release cylinder is black with a diameter of 80mm. The piston rod of the tool release cylinder is connected to the disc spring assembly via the pull rod. When the braking threshold is triggered, the tool release cylinder and the electromagnetic brake are simultaneously vented, pushing the pull rod to compress the disc spring assembly, achieving rapid tool release. The tool release stroke is 5mm, preventing the tool from hardly sticking to the workpiece during collision.

[0035] Please refer to Figure 5 In some embodiments, the adaptive graded energy absorption assembly includes a primary elastic buffer layer bonded to the turret end face, a secondary honeycomb damping energy absorption plate fixed to the front end face of the spindle box by fasteners, and a tertiary hydraulic buffer fixed to the end of the Z-axis guide rail by a flange. The primary elastic buffer layer has a built-in miniature pressure sensor, the signal output of which is electrically connected to the feedback input of the digital twin predictive controller. The energy absorption process of the adaptive graded energy absorption assembly is adaptively matched to the magnitude of the collision impact force: when the collision impact force is lower than a first threshold, only the primary elastic buffer layer participates in energy absorption; when the collision impact force is between the first and second thresholds, the primary elastic buffer layer and the secondary honeycomb damping energy absorption plate jointly participate in energy absorption; when the collision impact force is higher than the second threshold, the tertiary hydraulic buffer is activated and absorbs the residual collision energy.

[0036] In some embodiments, the primary elastic buffer layer is a high-elasticity polyurethane buffer pad, yellow in color, 20mm thick, with a Shore hardness of 60A, adhered to the end face of the turret, and with a grid-like anti-slip texture on the surface. The buffer pad contains four miniature pressure sensors, distributed at the four corners. These miniature pressure sensors are black dots, 5mm in diameter, used to collect the initial impact force of the collision, with a detection range of 0-10kN. The data is fed back to the digital twin predictive controller, providing a basis for adjusting energy absorption parameters.

[0037] The secondary honeycomb damping energy-absorbing plate is installed on the front face of the spindle box. It consists of an aluminum alloy honeycomb core, methyl silicone oil damping material, and a 0.5mm thick stainless steel outer layer. The aluminum alloy honeycomb core is silver, 50mm thick, and has a honeycomb aperture of 10×10mm. The methyl silicone oil damping material is blue and translucent and fills the honeycomb holes. It is fixed with M5 countersunk screws, and limit blocks are provided at the edges to prevent excessive deformation. When the impact force is >5kN, the honeycomb core undergoes controlled collapse. The damping material absorbs energy through friction and compression. The maximum deformation under a 5kN force is 30mm, and the energy absorption efficiency is ≥60%.

[0038] The three-stage hydraulic damper is installed at the end of the Z-axis guide rail. It is a gray cylindrical structure with a total length of 150mm, a cylinder diameter of 40mm, a silver piston rod with a diameter of 20mm, and a black rubber buffer head with a diameter of 50mm connected to the end. Internally, it achieves buffering through the throttling effect of hydraulic oil, with a stroke of 80mm, a damping coefficient of 1000N・s / m, and a maximum buffering force of 20kN. When the axis movement exceeds the braking stroke, the slider impacts the damper, and the residual energy is further absorbed through the controlled flow of hydraulic oil. The energy transfer path is as follows: the impact force acts on the primary buffer pad to absorb 10% of the energy, then it is transferred to the secondary honeycomb damping energy-absorbing plate to absorb 60% of the energy, and finally the tertiary hydraulic damper absorbs 30% of the energy, resulting in a final residual energy ≤1kN.

[0039] In some embodiments, the intelligent monitoring terminal is embedded in the machine tool operation panel, and its input terminal is electrically connected to the status signal output terminal of the digital twin prediction controller for real-time display of equipment operating status and collision risk level. The intelligent monitoring terminal includes a data storage module for recording full-process event data such as collision risk value, braking time, and energy absorption process data, and feeding back key operating data to the parameter optimization port of the digital twin prediction controller for iterative optimization of the collision prediction algorithm parameters.

[0040] In some embodiments, the intelligent monitoring terminal uses a 10.1-inch industrial capacitive touchscreen with a black bezel, measuring 260×160mm, embedded in the machine tool operation panel, with a resolution of 1280×800 and a display brightness of 500cd / m². The top of the interface features a status bar displaying real-time time, device number, and operating status (green for normal, yellow for warning, and red for fault). The left side has four sub-monitoring windows in a 2×2 layout, displaying the laser rangefinder sensor point cloud map, servo axis position curve, workpiece visual image, and cutting vibration spectrum, respectively. The right side is a data panel, including a circular risk level dashboard with a range of 0-100%, a red warning line of 80%, a table of the five most recent events (including time, type, and processing result), and a bar chart of risk events for the week. The bottom has operation buttons, including parameter settings, data export, and remote assistance.

[0041] The data storage module includes a metal-cased data acquisition box measuring 120×80×60mm, installed inside the electrical cabinet. The front panel features eight sensor interfaces, clearly indicating their corresponding sensor types, one RJ45 Ethernet port, and a green indicator light. An internal SD card slot supports up to 64GB of storage. It can automatically record comprehensive data on events such as risk warnings, avoidance adjustments, braking, and collisions, including time, location, speed, acceleration, impact force, and operating parameters. The storage capacity is ≥100,000 records, and it supports exporting data in Excel format.

[0042] The remote communication module uses a white 4G DTU module, measuring 70×50×30mm. It is fixed to the top of the electrical cabinet with a bracket and equipped with a black external antenna, 150mm in length. A SIM card slot is located on the side, supporting full network compatibility. It can upload real-time monitoring data and historical event data to a cloud monitoring platform, supporting remote reception of early warning information and equipment status via mobile APP and computer, enabling remote assistance and equipment cluster management.

[0043] Please refer to Figure 3 The present invention also provides an intelligent adaptive collision avoidance method for CNC turning centers based on the above-mentioned safety protection system, the collision avoidance method comprising the following steps: Step S301: The multi-source fusion sensing unit collects full-dimensional operating condition data, constructs a real-time digital twin model, integrates operating condition data, G-code parsing results, and key monitoring data fed back by the intelligent monitoring terminal, predicts collision risks, and outputs risk level signals and original operating condition data.

[0044] In some embodiments, a multi-source fusion sensing unit collects comprehensive working condition data, a laser rangefinder collects the relative positions of moving parts, an absolute encoder collects axis motion parameters, an industrial vision component collects the workpiece and tool status, and a working condition sensing component collects cutting condition data. The collected comprehensive working condition data, along with key monitoring data from the intelligent monitoring terminal, is transmitted to the digital twin predictive controller, synchronously mapping the CNC turning center's physical state in the real-time digital twin model. By fusing working condition data, G-code parsing results, and key monitoring data, and through an improved RRT... The algorithm predicts the intersection of motion trajectories and outputs corresponding risk level signals and raw operating data to the active avoidance servo actuator, graded linkage braking mechanism, and intelligent monitoring terminal based on the triggered three-level risk threshold.

[0045] Step S302: The active avoidance servo actuator receives the risk level signal and the original working condition data, performs dynamic correction of motion trajectory or graded braking operation according to the risk level, and outputs braking status signal synchronously. When braking, it links with emergency tool release action.

[0046] In some embodiments, the active avoidance servo actuator receives risk level signals and raw operating data, and performs corresponding operations according to the risk level. When a warning threshold is triggered, the active avoidance servo actuator starts preprocessing and parses the current G-code segment; when an avoidance threshold is triggered, the active avoidance servo actuator generates the optimal avoidance trajectory and sends it to the servo driver through the CNC system interface module, adjusting the motion trajectory in real time without interrupting machining. If the risk threshold is still triggered after trajectory correction, the actuator switches to graded braking operation. When the avoidance threshold is triggered, the servo soft braking of the graded linkage braking mechanism is activated to achieve smooth deceleration of the axis motion; when the braking threshold is triggered, the electromagnetic mechanical braking is activated, and the emergency tool release mechanism is triggered simultaneously. The emergency tool release mechanism pushes the pull rod to compress the disc spring assembly through the tool release cylinder, achieving rapid tool disengagement, and operates synchronously with the electromagnetic mechanical braking to avoid hard adhesion between the tool and the workpiece during collision. During braking, the braking status signal is synchronously output to the adaptive graded energy absorption component and the intelligent monitoring terminal.

[0047] Step S303: The adaptive graded energy absorption component receives the braking state signal, combines it with the initial impact force data of the collision collected by itself, and absorbs the collision energy in a graded manner through a multi-level energy absorption structure, and outputs the energy absorption process data.

[0048] In some embodiments, the adaptive graded energy absorption component receives braking status signals. When a collision occurs due to brake failure, the collision force first acts on the primary elastic buffer layer. An integrated micro-pressure sensor collects the initial impact force data and feeds it back to the digital twin predictive controller. When the impact force reaches a preset condition, the secondary honeycomb damping energy absorption plate undergoes controlled collapse, absorbing the collision energy through the honeycomb core and damping material. If the shaft movement exceeds the braking stroke, it impacts the tertiary hydraulic buffer, absorbing residual energy through the throttling effect of hydraulic oil. This achieves graded adaptive absorption of collision energy, while simultaneously outputting energy absorption process data to the intelligent monitoring terminal.

[0049] Step S304: The intelligent monitoring terminal integrates data from the entire process to achieve equipment operation status monitoring, data storage and remote transmission, while also feeding back key monitoring data to the digital twin predictive controller.

[0050] In some embodiments, the intelligent monitoring terminal integrates risk level signals, braking status signals, energy absorption process data, and full-process operating condition data, enabling real-time monitoring via an industrial capacitive touchscreen. A data storage module stores the data. A remote communication module uploads the data to a cloud-based monitoring platform, supporting remote access and management. Simultaneously, it filters key monitoring data and feeds it back to the digital twin predictive controller to assist in optimizing the accuracy of risk prediction. Those skilled in the art will understand that all or part of the functions of the various methods in the above embodiments can be implemented by hardware or by computer programs. When all or part of the functions in the above embodiments are implemented by computer programs, the program can be stored in a computer-readable storage medium, which may include: read-only memory, random access memory, disk, optical disk, hard disk, etc., and the program is executed by a computer to achieve the above functions. For example, the program can be stored in the memory of a device, and when the program in the memory is executed by the processor, all or part of the above functions can be achieved. In addition, when all or part of the functions in the above embodiments are implemented by computer programs, the program can also be stored in a server, another computer, disk, optical disk, flash drive, or external hard drive, etc., and can be downloaded or copied to the memory of a local device, or the system of the local device can be updated. When the program in the memory is executed by the processor, all or part of the functions in the above embodiments can be achieved.

[0051] The above examples illustrate this application only to aid understanding and are not intended to limit its scope. Those skilled in the art to which this application pertains can make various simple deductions, modifications, or substitutions based on the ideas presented.

Claims

1. A smart adaptive anti-collision safety protection system for CNC turning centers, used to prevent collisions between the spindle, turret, workpiece, and fixture of a CNC turning center, characterized in that, The intelligent adaptive anti-collision vehicle safety protection system of the CNC turning center includes a multi-source fusion sensing unit, a digital twin predictive controller, an active avoidance servo actuator, a graded linkage braking mechanism, an adaptive graded energy absorption component, and an intelligent monitoring terminal. The components form a closed-loop collaborative control system through an electrical signal transmission link. The multi-source fusion sensing unit is used to collect data on the position, motion state, and stress conditions of the moving parts of the machine tool. The digital twin prediction controller has a built-in real-time digital twin model of the CNC turning center, which is used to integrate multi-source perception data to predict collision risks and output control signals of corresponding levels. The active avoidance servo actuator is used to receive avoidance commands and dynamically correct the motion trajectory of the servo axis. The graded linkage braking mechanism is used to perform graded braking and emergency knife release linkage actions according to the control signal; The adaptive graded energy absorption component is used to absorb impact energy in grades according to the magnitude of the impact force. The intelligent monitoring terminal is used to display the operating status in real time and realize full-process data traceability and parameter interaction.

2. The intelligent adaptive anti-collision safety protection system for CNC turning centers as described in claim 1, characterized in that, The multi-source fusion sensing unit includes a laser rangefinder, an absolute encoder integrated into the output shafts of the X-axis servo motor and the Z-axis servo motor, an industrial vision component fixed above the turret, a vibration sensor located on the front end of the spindle, and a pressure sensor embedded inside the tool holder.

3. The intelligent adaptive anti-collision safety protection system for CNC turning centers as described in claim 2, characterized in that, The laser rangefinder consists of three sensors arranged in an equilateral triangle topology, fixed at the top center of the spindle box, the side center of the turret, and the front side of the bed, respectively. The scanning fields of the three laser rangefinders overlap to form a blind-spot-free detection field covering the working area of ​​all moving parts. Their scanning range forms an overlapping coverage area in the processing area, which is used to achieve cross-verification and redundant detection of the position information of moving parts.

4. The intelligent adaptive anti-collision safety protection system for CNC turning centers as described in claim 1, characterized in that, The digital twin prediction controller integrates multi-source perception data and G-code parsing results to predict collision risks and outputs three-level control signals, including: warning signal, avoidance signal and braking signal; the three-level control signals correspond to preset three-level collision risk thresholds.

5. The intelligent adaptive anti-collision safety protection system for CNC turning centers as described in claim 4, characterized in that, The graded linkage braking mechanism includes a servo soft braking module integrated inside the servo driver, an electromagnetic mechanical brake fixed to the ends of the X-axis guide rail and the Z-axis guide rail respectively, and an emergency tool release mechanism integrated to the end of the spindle. When the digital twin predictive controller outputs an avoidance signal, the active avoidance servo actuator analyzes the current G-code segment to generate the optimal avoidance trajectory, corrects the servo axis motion path without interrupting the machining process, and at the same time, the servo soft braking module is activated to enable the servo axis to decelerate smoothly; when the digital twin predictive controller outputs a braking signal, the electromagnetic mechanical brake is activated, and at the same time, the emergency tool release mechanism is triggered to synchronize the action, realizing the synchronous triggering of the braking action and the tool release action.

6. The intelligent adaptive anti-collision safety protection system for CNC turning centers according to claim 5, characterized in that, The emergency tool release mechanism includes a tool release cylinder, a pull rod, and a disc spring assembly. The piston rod of the tool release cylinder is connected to the disc spring assembly via the pull rod, and is used to push the pull rod to compress the disc spring assembly under the action of a trigger signal, thereby realizing the rapid release of the tool.

7. The intelligent adaptive anti-collision safety protection system for CNC turning centers as described in claim 1, characterized in that, The adaptive graded energy absorption assembly includes a primary elastic buffer layer disposed on the end face of the turret, a secondary honeycomb damping energy absorption plate fixed on the front face of the spindle box, and a tertiary hydraulic buffer fixed on the end of the Z-axis guide rail; the primary elastic buffer layer has a built-in micro pressure sensor, the signal output of which is electrically connected to the feedback input of the digital twin prediction controller. The energy absorption process is adaptively matched with the magnitude of the impact force: when the impact force is below the first threshold, only the first-level elastic buffer layer participates in energy absorption; when the impact force is between the first and second thresholds, the first-level elastic buffer layer and the second-level honeycomb damping energy absorption plate participate in energy absorption together; when the impact force is above the second threshold, the third-level hydraulic buffer is activated and absorbs the residual impact energy.

8. The intelligent adaptive anti-collision safety protection system for CNC turning centers as described in claim 1, characterized in that, The intelligent monitoring terminal includes a data storage module for recording full-process event data such as collision risk value, braking time, and energy absorption process data, and feeds back key operating data to the digital twin prediction controller for iterative optimization of the collision prediction algorithm parameters.

9. A smart adaptive collision avoidance method for CNC turning centers, based on the safety protection system according to any one of claims 1 to 8, characterized in that, Includes the following steps: The multi-source fusion sensing unit collects real-time data on the position, speed, vibration, pressure, and workpiece status of the moving parts of the machine tool and transmits it to the digital twin predictive controller. The digital twin predictive controller constructs a real-time digital twin model that is synchronously mapped to the physical machine tool, integrates multi-source perception data and G-code parsing results, predicts collision risks and outputs control signals of the corresponding level; When an avoidance signal is output, the active avoidance servo actuator dynamically corrects the turret's movement trajectory and simultaneously activates the servo soft braking module. When a braking signal is output, the electromagnetic mechanical brake is activated, which simultaneously triggers the emergency tool release mechanism to quickly disengage the tool. If a collision occurs, the adaptive graded energy absorption component absorbs the collision energy in stages according to the magnitude of the impact force. The pressure sensor built into the first-level elastic buffer layer collects the impact force data in real time and feeds it back to the digital twin prediction controller. The intelligent monitoring terminal displays the real-time operating status of the equipment, stores the event data of the entire process, and feeds back key operating data to the digital twin predictive controller.

10. A CNC turning center, characterized in that, It includes a bed, a spindle box, a turret, a feed mechanism, and an intelligent adaptive anti-collision safety protection system as described in any one of claims 1 to 8.

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