Compound numerical control machine tool for processing motor shaft alternate slot

Abstract

The present application relates to motor shaft processing and numerical control machine tool technical field, and disclose a composite numerical control machine tool for processing motor shaft alternate groove, for solving the problem of groove phase angle, groove bottom depth and groove side symmetry error accumulation, and then affecting the assembly consistency, transmission reliability and motor shaft high-speed running stability of the matching parts;The method, through the axis reference establishment module, clamping indexing control module, first groove processing detection module, reference transmission correction module, compensation processing execution module and final inspection review module, the axis reference, angular orientation, groove surface detection and compensation processing data in the process of flat middle flat motor shaft alternate groove processing are continuously associated, and the angular orientation positioning and feeding reference of the subsequent alternate groove are corrected according to the first alternate groove measured reference;The present application can improve the alternate groove processing consistency, transmission matching reliability and motor shaft running stability.

Description

Technical Field

[0001] This invention relates to the field of motor shaft machining and CNC machine tool technology, specifically to a composite CNC machine tool for machining alternating grooves on motor shafts. Background Technology

[0002] The motor shaft is a key component for transmitting torque between the motor and the load. Its shaft extension or mating section usually requires machining of keyways, flat sections, or multiple grooves to achieve circumferential positioning and anti-rotation connection. In the prior art, CN102328122B discloses a machining device and method for machining tangential keyways of a motor shaft, which improves the positioning and machining accuracy of the tangential keyway by using a positioning plate and positioning block; CN104439456B discloses a machining method for double keyways distributed at 180° on the extension end of a large motor shaft, which ensures the symmetry of the double keyways by using the same calibration tool reference surface and dial indicator verification.

[0003] The above-mentioned solutions can improve the problems of low machining accuracy and long machining cycle in ordinary scribing and indexing machining, but they are mainly applicable to the machining of fixed-angle keyways or symmetrical double keyways, and still mainly rely on mechanical alignment, fixture positioning, and post-machining verification. For flat-in-flat motor shafts, multiple flat slots or slot surfaces are usually arranged alternately along different shaft segments and different circumferential positions. During the machining process, the radial runout of the shaft, the clamping and indexing clearance, the lateral force offset of the tool, and the actual deviation of the machined slot surface will all affect the angular positioning and dimensional control of the subsequent slot surface. If the axis reference, the machined slot surface reference, and the subsequent alternating slot machining reference cannot be continuously transferred and corrected in real time during the same machining process, it is easy to cause the accumulation of errors in the phase angle between slots, the bottom depth of the slot, and the symmetry of the slot side, which will affect the assembly consistency of mating parts, the torque transmission reliability, and the high-speed running stability of the motor shaft. Therefore, it is urgent to propose a composite CNC machine tool and process for the alternating slot machining of flat-in-flat motor shafts, which can improve the machining consistency of alternating slots and the torque transmission reliability of the motor shaft through unified reference establishment, online slot surface detection, indexing verification, and compensation machining. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a composite CNC machine tool for machining alternating grooves on motor shafts, thus solving the problems mentioned in the background section.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] Composite CNC machine tools for machining alternating grooves on motor shafts include:

[0007] Axis reference establishment module: used to collect radial runout data of each shaft segment of the motor shaft, and establish a unified axis reference that runs through each shaft segment based on the radial runout data;

[0008] Clamping and indexing control module: used to control the clamping, auxiliary support and circumferential indexing of the motor shaft according to a unified axis reference, and record the angular position corresponding to each circumferential indexing.

[0009] First groove processing and detection module: used to process the first alternating groove and collect the groove surface position, groove bottom depth and groove side orientation data of the first alternating groove;

[0010] Reference transfer and correction module: used to correspond the detection data of the first alternating groove with the angular position of the circumferential indexing, and establish the angular positioning and feed reference for the subsequent alternating grooves;

[0011] Compensation machining execution module: used to adjust the tool feed path, groove bottom machining position and groove side trimming path according to the angular positioning and feed reference of the subsequent alternating grooves;

[0012] Final inspection and verification module: used to collect the final inspection data of each alternating slot and associate the final inspection data with the corresponding processing process data and write it into the same processing task record.

[0013] Preferably, the axis reference establishment module includes:

[0014] Axial measuring points are arranged according to the clamping section, the flat groove machining section, the transition section and the support section. Radial displacement data is collected in combination with the spindle encoder angle under the low-speed rotation state of the motor shaft.

[0015] Consistency verification is performed on the radial displacement curves of adjacent rotation cycles;

[0016] Abnormal sampling points are marked and excluded. A unified axis reference is established based on the rotation center offset of stable measuring points, and an axis reference data package is generated.

[0017] Write the radial runout peak value into the local compensation area or output a mark prohibiting indexing.

[0018] Preferably, the clamping and indexing control module includes:

[0019] Read the machining permission mark, local compensation area record, and axis direction vector from the axis reference data packet;

[0020] Based on the slot plan, clamping and indexing instructions are generated, and the tail-end auxiliary support mechanism, intermediate follow-up support mechanism and circumferential indexing mechanism are controlled according to the pre-clamping, axis alignment, clamping locking, circumferential indexing and angular verification status.

[0021] When the difference between the measured circumferential angle and the target circumferential angle exceeds the preset range, reverse fine-tuning or locking re-check will be performed.

[0022] Preferably, the first slot processing and inspection module includes:

[0023] Read the axis reference data packet and angular position record, and call the machining process card when both the machining permission mark and the angular position record are valid;

[0024] The process involves sequentially performing tool verification, roughing, finishing, cleaning the tank, scanning the tank surface, and classifying the inspection data.

[0025] The first measured reference data packet is generated based on the groove depth deviation, groove side position deviation, and measurement quality mark, and then sent to the reference transfer and correction module.

[0026] Preferably, the reference transfer correction module includes:

[0027] Associate the first slot measured reference data package with the angular position record under the same processing task;

[0028] Based on the reference, the system switches to normal transmission state, compensated transmission state, or processing stop state using the marker, and generates subsequent slot reference mapping table and subsequent slot reference instruction package based on the measured angular azimuth of the first slot, the position of the slot centerline, and the position of the slot bottom.

[0029] Preferably, the compensation processing execution module includes:

[0030] Read subsequent slot reference instruction packets and angular position records, and generate machining execution data after machining permission is valid and angular direction is locked;

[0031] The subsequent alternating groove processing is carried out according to the compensation preparation, trial cutting approach, layer cutting, groove side trimming, groove bottom trimming and processing result confirmation status;

[0032] Adjust the feed rate, perform retraction and chip removal, and return to the support to check the mark or compensate for the over-limit status based on the spindle load, vibration displacement, and compensation over-limit status.

[0033] The preferred final inspection and verification module includes:

[0034] The machining task number, motor shaft number, unified axis reference version and slot number are used to associate axis reference data, angular position records, first slot measured reference data and subsequent slot machining process data;

[0035] The measurement sections of each alternating groove are located according to the unified axis reference, and the phase angle between grooves, groove bottom depth, groove side symmetry and groove width are checked.

[0036] Output a repair instruction, a retest mark, or an abnormal sealing mark according to the review status.

[0037] Compared with the prior art, the present invention provides a composite CNC machine tool for machining alternating grooves on motor shafts, which has the following advantages: 1. This invention, through the continuous coordination of establishing an axis reference, clamping and indexing verification, online detection of the first slot, reference transfer correction, compensation machining execution, and final inspection verification, can integrate the radial runout of each segment of the motor shaft, clamping and indexing errors, tool lateral force offset, and actual deviations of the machined slot surface into the same machining task for unified processing; subsequent alternating slot machining no longer relies solely on theoretical indexing angles, but combines a unified axis reference and the measured reference of the first alternating slot to determine angular positioning, feed position, and slot side trimming direction, thereby reducing the accumulation of errors in inter-slot phase angle, slot bottom depth, and slot side symmetry, ultimately improving the consistency of alternating slot machining of flat-in-flat motor shafts, the consistency of mating parts assembly, torque transmission reliability, and high-speed operation stability; 2. This invention, by uniformly writing the axis reference data package, angular position record, first groove measured reference data package, subsequent groove reference instruction package, compensation machining process data, and final inspection data into the same machining task record, can form a complete data chain from clamping measurement, indexing positioning, groove surface inspection, reference transfer, compensation machining to final inspection and verification. When measurement abnormalities, indexing deviations, compensation exceeding limits, load abnormalities, or vibration exceeding limits occur during machining, re-measurement, fine-tuning, rework, or abnormal sealing can be performed according to the corresponding status mark, preventing abnormal references or abnormal compensation amounts from continuing to participate in subsequent groove machining, ultimately improving the traceability of the machining process, the accuracy of abnormal handling, and the stability of batch machining quality. Attached Figure Description

[0038] Figure 1 This is a schematic diagram of the composite CNC machine tool structure used for machining alternating grooves on motor shafts according to the present invention. Detailed Implementation

[0039] 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, and 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.

[0040] Example 1: Figure 1 A composite CNC machine tool for machining alternating grooves on motor shafts is provided, including:

[0041] Axis reference establishment module: Used to collect radial runout data of each shaft segment of the motor shaft, and establish a unified axis reference running through each shaft segment based on the radial runout data. Specifically, the implementation is as follows:

[0042] The radial runout data of each shaft segment of the motor shaft is collected, and a unified axis reference is established through each shaft segment based on the radial runout data. The axis reference establishment module is arranged in the data processing layer of the CNC system of the composite CNC machine tool and is communicatively connected to the online measurement unit, the spindle encoder and the clamping and indexing control module. The online measurement unit can be selected as a contact probe, a laser displacement sensor or a combination of both, and is used to collect the radial displacement changes of each shaft segment when the motor shaft is rotating at low speed.

[0043] The input data is the shaft segment runout acquisition record. The shaft segment runout acquisition record includes at least the following fields: machining task number, motor shaft number, shaft segment number, axial measuring point coordinates, spindle encoder angle, radial displacement value, sampling time, ambient temperature or measurement area temperature, and data quality flag. The machining task number is used to associate the clamping, indexing, slotting, and final inspection data of the same motor shaft. The shaft segment number is used to distinguish the front clamping segment, the flat slotting segment, the intermediate transition segment, and the tail support segment. The spindle encoder angle is used to map the radial displacement value to the circumferential position of the motor shaft.

[0044] Axial measuring points are arranged according to the motor shaft structure at the front clamping section, the first flat groove machining section, the middle transition section, the second flat groove machining section, and the tail support section. The spacing between measuring points near the flat groove machining area is 5mm to 20mm, and the spacing between measuring points far from the flat groove machining area is 20mm to 50mm. When the length of a single flat groove is less than 10mm, measuring points are set at least three positions: before the groove, in the groove, and after the groove. A smaller measuring point spacing is used near the flat groove machining area to facilitate the identification of local bending, clamping stress release, and shaft transition runout near the groove section. A larger measuring point spacing is used far from the flat groove machining area, mainly to confirm the overall axial trend of the motor shaft, thereby reducing invalid sampling.

[0045] When acquiring data at low spindle speeds, the rotational speed is between 30 r / min and 80 r / min, and the spindle encoder angle sampling interval is between 1° and 2°. Each measuring point is acquired for at least two complete rotation cycles. 30 r / min to 80 r / min falls within the low-speed rotation range for online measurement of shaft parts. Speeds below 30 r / min increase the acquisition time for a single motor shaft, while speeds above 80 r / min can easily cause dynamic oscillations in slender motor shafts, and contact probes or laser displacement sensors are also prone to following errors. When the angle sampling interval is between 1° and 2°, 180 to 360 radial displacement sampling points can be formed per rotation cycle, which can meet the needs of radial runout curve identification and circumferential reference continuity judgment.

[0046] Consistency verification is performed on the radial displacement curves of two adjacent rotation cycles at the same measuring point. The stability threshold is set to 2 to 3 times the repeatability accuracy of the online measurement unit after calibration with a standard mandrel or gauge block, preferably 0.005 mm. The repeat acquisition threshold is set to 3 times the stability threshold, preferably 0.015 mm. When the radial displacement difference at the same angular position is not greater than the stability threshold, the corresponding measuring point is marked as a stable measuring point. When the radial displacement difference is greater than the stability threshold but not greater than the repeat acquisition threshold, repeat acquisition is triggered. When the radial displacement difference is greater than the repeat acquisition threshold, a measuring point cleaning and re-acquisition mark or a clamping reset mark is output. The above thresholds are set based on the repeatability capability of the online measurement unit and are used to distinguish between normal measurement fluctuations, unstable measurement states, and clamping abnormalities.

[0047] For abnormal sampling points in the acquisition curve, the axis reference establishment module identifies them based on the continuity of adjacent angle points. When the radial displacement difference of a single sampling point relative to the adjacent angle points is greater than three times the standard deviation of the radial displacement of the current measurement point in the same period, and the adjacent angle points do not show continuous changes in the same direction, the sampling point is marked as a burr point, and the axial measurement point coordinates and spindle encoder angle corresponding to the burr point are recorded in the data quality mark. Burr points do not participate in the unified axis reference establishment, but are retained in the original acquisition record for easy tracking of measurement status later.

[0048] The rotation center offset corresponding to each stable measuring point is extracted. The line connecting the centers of the front clamping section and the tail support section is taken as the initial axis. Then, based on the center offsets of the first flat groove machining section, the second flat groove machining section, and the intermediate transition section, the direction of the initial axis and the local offset of each axis segment are corrected to form a unified axis reference that runs through each axis segment. The unified axis reference includes at least the following data items: reference origin, axis direction vector, center offset of each axis segment, radial runout peak value of each measuring point, reference confidence level, and machining permission mark.

[0049] When the peak-to-peak radial runout of any flat groove machining segment is greater than 0.05 mm, and the peak-to-peak radial runout of the front clamping segment and the rear support segment is less than 0.02 mm, the axis reference establishment module determines it as a local bending state of the shaft and writes the corresponding shaft segment into the local compensation area. The local compensation area includes at least the shaft segment number, axial range, maximum peak-to-peak radial runout, compensation priority, and whether machining is allowed. 0.05 mm is used to identify local sway states that are sufficient to affect the bottom depth and side symmetry of the flat groove, and 0.02 mm is used to determine whether the clamping and support references at both ends are in a stable state.

[0050] When the peak-to-peak radial runout of the front clamping section exceeds 0.03mm, the axis reference establishment module determines it to be in a clamping eccentric state and outputs a prohibition mark for indexing to the clamping indexing control module; 0.03mm is used to identify whether the main clamping reference deviates significantly from the unified axis reference; when the clamping section deviation exceeds this range, the subsequent circumferential indexing and groove surface machining will simultaneously carry over the reference deviation, making it unsuitable to continue indexing; when the radial runout tolerance given in the machining drawing or process card is stricter than the above value, the stricter threshold in the machining drawing or process card is used for judgment;

[0051] The axis reference establishment module outputs an axis reference data package, which includes at least the following fields: machining task number, motor axis number, unified axis reference version, reference origin, axis direction vector, center offset of each axis segment, local compensation area record, reference reliability level, machining permission mark, and generation time. The axis reference data package is sent to the clamping and indexing control module for subsequent clamping, auxiliary support, and circumferential indexing; it is sent to the first slot machining and detection module for tool feed reference during the machining of the first flat slot; and it is sent to the final inspection and verification module for unified comparison reference during the final slot inspection.

[0052] The establishment time for the axis reference of a single motor shaft can be selected from 20s to 60s; when the number of measuring points increases, repeated acquisition is triggered, or the length of the motor shaft is large, it can be extended to 90s; this time range matches the acquisition rules of low-speed rotation of 30r / min to 80r / min and at least two rotation cycles for each measuring point; the buffer data capacity is no less than 50,000 sampling points; under the conditions of 10 measuring points, 360 angle sampling points for each measuring point, and acquisition of two rotation cycles, the basic number of sampling points is about 7,200, and 50,000 sampling points can cover the data traceability requirements of multi-axis segment acquisition, repeated acquisition, abnormal point recording, and the same processing task.

[0053] Clamping and indexing control module: Used to control the clamping, auxiliary support, and circumferential indexing of the motor shaft according to a unified axis reference, and to record the angular position corresponding to each circumferential indexing. Specifically, it is implemented as follows:

[0054] The clamping, auxiliary support, and circumferential indexing of the motor shaft are controlled according to a unified axis reference, and the angular position corresponding to each circumferential indexing is recorded. The clamping and indexing control module is connected to the spindle clamping mechanism, the tail-end auxiliary support mechanism, the intermediate follower support mechanism, the circumferential indexing mechanism, the online measurement unit, and the CNC system to complete clamping, support, indexing, locking, and angular verification within the same machining task.

[0055] The module receives the axis reference data packet output by the axis reference establishment module and reads the unified axis reference version, reference origin, axis direction vector, center offset of each axis segment, local compensation area record, reference reliability level, and machining permission mark. When the machining permission mark is "machining prohibited," the clamping and indexing control module does not generate circumferential indexing instructions and outputs a clamping reset mark or support recheck mark. When the machining permission mark is "machining permitted," the clamping and indexing control module generates clamping and indexing instructions according to the slot plan.

[0056] The slot plan should include at least the following fields: slot number, design circumferential angle, design axial position, slot width, slot depth, slot length, machining sequence, and reference source. The clamping and indexing command should include at least the following fields: machining task number, current slot number, target circumferential angle, clamping pressure or equivalent clamping force, tail end clamping force, follower support position, circumferential locking status, indexing permission mark, and angular verification mark. The reference source is used to distinguish whether the current slot is positioned based on a unified axis reference or based on data output from the reference transfer and correction module for correction positioning.

[0057] For flat-medium flat motor shafts with diameters ranging from 8mm to 40mm, when the spindle clamping mechanism uses hydraulic clamping, the hydraulic clamping pressure is set between 0.25MPa and 0.8MPa. This range is suitable for flat groove machining of common motor shafts such as small servo motors, pump motors, and geared motors. When the clamping pressure is below 0.25MPa, the tangential and lateral forces generated by milling can easily cause micro-rotation of the motor shaft. When the clamping pressure is above 0.8MPa, small-diameter shaft sections are prone to clamping indentations or elastic deformation. When using pneumatic or electric clamping, the clamping control quantity can be converted into an equivalent clamping force, with the clamping torque being greater than the milling torque as the setting basis.

[0058] The tail end auxiliary support clamping force is set in segments according to the motor shaft diameter; for motor shafts with a diameter of 8mm to 15mm, the tail end auxiliary support clamping force is 150N to 300N; for motor shafts with a diameter greater than 15mm and not greater than 40mm, the tail end auxiliary support clamping force is 300N to 800N; this setting is used to limit tail end swing and avoid excessive clamping force causing axial bending of the slender shaft;

[0059] The preload of the intermediate follower support is between 0.005mm and 0.03mm. This preload is lower than the 0.05mm threshold used in the axis reference establishment module to identify local runout of the flat groove machining section. It can provide auxiliary support for slender shafts and reduce interference with the unified axis reference. For motor shafts with smaller diameters or larger length-to-diameter ratios, the preload is closer to the lower limit. For motor shafts with larger diameters or larger groove cutting forces, the preload is closer to the upper limit.

[0060] The clamping and indexing control module operates in the following states sequentially: ready-to-clamp, pre-clamp, axis alignment, clamping and locking, circumferential indexing, and angular verification. Upon entering the pre-clamping state, the clamping and indexing control module adjusts the tail-end auxiliary support and intermediate follow-up support according to the unified axis reference, ensuring that the deviation of the support center from the unified axis reference is no greater than 0.01mm. This 0.01mm deviation is higher than the online measurement stability threshold of 0.005mm and lower than the clamping disturbance verification threshold of 0.02mm, making it suitable as a control limit for support alignment.

[0061] After entering the clamping and locking state, the clamping and indexing control module calls the online measurement unit to remeasure the radial runout of the front clamping section, the shaft section where the flat groove to be processed is located, and the tail support section, and compares the center offset change of the same shaft section before and after clamping; when the center offset change is not greater than 0.008mm, it is allowed to enter the circumferential indexing state; when the center offset change is greater than 0.008mm but not greater than 0.02mm, the clamping pressure is reduced by 5% to 15% and re-aligned; when the center offset change is greater than 0.02mm, a clamping abnormality status is output; 0.008mm is higher than the online measurement stability threshold of 0.005mm, which is used to accommodate the small elastic changes caused by the clamping action; 0.02mm corresponds to the stability limit of the clamping and support reference at both ends, and is used to determine whether the clamping disturbance has affected the subsequent indexing process;

[0062] After the clamping pressure is adjusted, the clamping and indexing control module re-measures the radial runout of the key axis segment, and the pressure adjustment is not exceeded twice. If the center offset change is still greater than 0.02mm after two adjustments, the clamping and indexing control module outputs a clamping abnormality status and suspends the generation of circumferential indexing commands. Under the clamping abnormality status, the CNC system retains the current machining task number, axis reference version, clamping pressure, support position and re-measurement data for re-clamping and machining traceability.

[0063] The circumferential indexing mechanism can be selected as a servo C-axis, a direct-drive rotary table, or an indexing plate with an encoder. The angle feedback resolution is no less than 0.005°, and the repeatability error is no greater than 0.02°. For motor shafts with diameters from 8mm to 40mm, 0.02° corresponds to a circumferential displacement of approximately 0.001mm to 0.007mm, which can meet the angular verification requirements for the symmetry of the flat slot side and the phase relationship between slots. The angle feedback resolution of 0.005° is less than the repeatability error, which can support the circumferential indexing mechanism to perform fine-tuning of the angle.

[0064] When machining the first alternating groove, the clamping and indexing control module records the initial angular position corresponding to the unified axis reference as the zero position, and generates the target circumferential angle according to the design circumferential angle in the groove plan; when machining subsequent alternating grooves, if the reference transfer correction module outputs the angular positioning reference, the clamping and indexing control module corrects the target circumferential angle according to the angular positioning reference, and marks the angle in the angular position record as having adopted the reference transfer correction data;

[0065] After each circumferential indexing is completed, the clamping and indexing control module reads the readback angle of the spindle encoder or the indexing mechanism encoder and forms an angular position record. The angular position record includes at least the following fields: machining task number, motor shaft number, unified axis reference version, slot number, target circumferential angle, measured circumferential angle, angle difference, circumferential locking status, clamping pressure or equivalent clamping force, tail end clamping force, follower support position, reference source, and timestamp.

[0066] When the difference between the measured circumferential angle and the target circumferential angle is no greater than 0.02°, the angular position record is marked as valid; when the angle difference is greater than 0.02° but no greater than 0.06°, the clamping and indexing control module performs reverse fine-tuning; when the angle difference is greater than 0.06°, the clamping and indexing control module enters the locking and rechecking state and suspends sending processing permission to the first slot processing detection module or the compensation processing execution module; 0.02° corresponds to the repeatability error of the circumferential indexing mechanism and is used as the effective indexing limit; 0.06° is 3 times the effective indexing limit and is used to distinguish between angular deviations that can be corrected by fine-tuning and indexing anomalies that require rechecking the locking state;

[0067] The reverse fine-tuning is performed by correcting the difference between the measured circumferential angle and the target circumferential angle. The amount of fine-tuning in a single instance shall not exceed the current angle difference, and the number of fine-tunings shall not exceed 2. After each fine-tuning, the clamping and indexing control module rereads the encoder angle and updates the angular position record. If the angle difference is still greater than 0.02° after two fine-tunings, the clamping and indexing control module enters the locking and rechecking state.

[0068] In the locking check state, the clamping indexing control module checks the locking signal of the circumferential indexing mechanism, the encoder readback angle, the clamping pressure or equivalent clamping force, the tail end clamping force, and the position of the follower support. If the angle difference recovers to within 0.02° after the check, the machining permission is restored. If the angle difference is still greater than 0.02° after the check, or if the circumferential locking signal is abnormal, a mark prohibiting indexing machining is output, and the current angular position record and abnormal status data are retained.

[0069] The angular position record output by the clamping and indexing control module is sent to the first slot machining and detection module to determine the machining start point and angular reference of the first alternating slot; it is sent to the reference transfer and correction module to establish the inter-slot phase relationship between the first alternating slot and subsequent alternating slots; and it is sent to the final inspection and verification module to compare the actual circumferential position of each alternating slot during the final slot inspection.

[0070] The first groove machining and inspection module is used to perform machining on the first alternating groove and collect data on the groove surface position, groove bottom depth, and groove side orientation. Specifically, it is implemented as follows:

[0071] The first alternating groove is machined, and the groove surface position, groove bottom depth and groove side orientation data are collected. The first groove machining and detection module is connected to the machine tool spindle, tool magazine, feed axis, online probe, air blowing cleaning unit, machining data acquisition unit and CNC system. Under the constraints of unified axis reference and angular position recording, the first alternating groove machining and online detection are performed.

[0072] The first slot machining detection module receives the axis reference data packet output by the axis reference establishment module and reads the unified axis reference version, reference origin, axis direction vector, local compensation area record, reference reliability level, and machining permission mark. The first slot machining detection module also receives the angular position record output by the clamping and indexing control module and reads the slot number, target circumferential angle, measured circumferential angle, angle difference, circumferential locking status, and reference source. When the machining permission mark is set to prohibit machining, or the angular position record is not marked as valid, the first slot machining detection module does not output the first alternating slot machining instruction and returns a machining waiting mark to the CNC system.

[0073] The first alternating slot machining instruction is generated based on the machining process card. The machining process card can be generated or called by the CNC system based on the motor shaft drawing, slot plan and tool magazine status. The machining process card includes at least the following fields: slot number, slot width, slot depth, slot length, slot bottom fillet, axial start point, axial end point, tool number, spindle speed, feed rate, single depth of cut, finishing allowance, and inspection scan interval.

[0074] For flat-in-flat motor shafts with diameters ranging from 8mm to 40mm, the width of the first alternating slot is 2mm to 12mm, the depth is 0.3mm to 4mm, and the length is 5mm to 60mm. These dimensions correspond to anti-rotation flat slots, shallow keyways, and local positioning slots on motor shafts such as small servo motors, pump motors, and geared motors. A slot depth of 0.3mm to 4mm is lower than the radius of the corresponding shaft diameter, which can reduce the weakening of the shaft section's strength. A slot length of 5mm to 60mm can cover the short flat end and the long flat mating section. When the machining drawings or process cards specify special slot shapes or stricter dimensional requirements, follow the machining drawings or process cards.

[0075] The end mill diameter is set in segments according to the groove width; when the groove width is no more than 3mm, the end mill diameter is 0.2mm to 0.4mm smaller than the groove width; when the groove width is greater than 3mm but no more than 12mm, the end mill diameter is 0.4mm to 1mm smaller than the groove width. This clearance is used to reserve the finishing allowance on the groove side, the radial runout allowance of the tool, and the online compensation allowance, so as to avoid the tool diameter being too close to the groove width, resulting in insufficient finishing space on the groove side.

[0076] When using carbide end mills, the spindle speed should be between 3000 r / min and 12000 r / min, the roughing feed rate between 50 mm / min and 300 mm / min, the depth of cut per pass between 0.05 mm and 0.3 mm, and the finishing allowance between 0.02 mm and 0.08 mm. This parameter range is suitable for medium-to-high-speed milling of carbon steel, alloy steel, or quenched and tempered steel motor shafts with small-diameter end mills. When the tool diameter is greater than 8 mm or a high-speed steel tool is used, the spindle speed should be reduced according to the tool material and the allowable linear speed.

[0077] The roughing feed rate is used to control the instantaneous lateral force during the first alternating groove machining. When the groove width is small, the shaft diameter is small, or the length-to-diameter ratio of the motor shaft is large, the feed rate is close to 50 mm / min. When the groove width is large, the shaft diameter is large, or the auxiliary support has good rigidity, the feed rate is close to 300 mm / min. The single cutting depth of 0.05 mm to 0.3 mm is used for layered material removal to reduce the force on the groove side and allow the shaft section to elastically deflect the tool. When the groove depth is not greater than 1 mm, the single cutting depth is close to 0.05 mm to 0.15 mm. When the groove depth is greater than 1 mm, the single cutting depth can be 0.15 mm to 0.3 mm.

[0078] The finishing allowance of 0.02mm to 0.08mm is greater than the online measurement stability threshold of 0.005mm and is used to reserve material for the finishing of the groove bottom and sides; for narrow grooves with a width of less than 3mm, the finishing allowance is close to 0.02mm to 0.04mm; for flat grooves with a larger width, the finishing allowance is close to 0.04mm to 0.08mm; the finishing allowance is related to the tool radius compensation value, the groove side finishing path and the groove bottom finishing path, and is used for subsequent inspection data classification and reference transfer;

[0079] The processing states of the first groove processing and detection module are as follows: tool confirmation state, roughing state, finishing state, groove cleaning state, groove surface scanning state, and detection result classification state. After entering the tool confirmation state, the first groove processing and detection module reads the tool radius compensation value, tool length compensation value, and tool wear record. When the tool radius wear value is greater than 0.03mm, the first groove processing and detection module performs tool compensation update or tool change and does not directly continue processing the first alternating groove. 0.03mm is less than the upper limit of the finishing allowance of 0.08mm, but it is close to the control requirement of 0.02mm for the groove side position deviation. Continuing to process it is easy to cause the groove width and groove side position deviation to get out of control.

[0080] When entering the cleaning state inside the tank, the blowing pressure of the air cleaning unit is between 0.2MPa and 0.5MPa, and the blowing time is between 1s and 3s. 0.2MPa to 0.5MPa is the commonly used pressure range for compressed air cleaning of CNC machine tools. If the pressure is lower than 0.2MPa, it is not easy to remove fine chips inside the tank, and if the pressure is higher than 0.5MPa, it is easy to cause vibration of small shaft sections or chip splashing. 1s to 3s can cover the cleaning needs inside the tank within a range of 5mm to 60mm in tank length.

[0081] The trough surface scanning uses a unified axial reference and angular position recording as coordinate references, and sets multiple axial measurement sections along the length of the first alternating trough. When the trough length is no more than 20 mm, the spacing between the measurement sections is 0.5 mm to 1 mm; when the trough length is greater than 20 mm, the spacing between the measurement sections is 1 mm to 2 mm. This setting is used to balance detection time and trough surface morphology recognition accuracy. Data is collected from at least three positions: the left trough side, the right trough side, and the trough bottom at each measurement section.

[0082] The position of the first alternating groove is characterized by the coordinates of the left groove side surface, the coordinates of the right groove side surface, and the position of the groove centerline; the groove bottom depth is characterized by the radial distance of the groove bottom coordinates relative to the unified axis reference; the groove side surface orientation is characterized by the orientation deviation of the groove side surface normal vector or the groove side surface relative to the circumferential angle of the target; the first groove detection data includes at least the following fields: groove number, axial section coordinates, coordinates of the left groove side surface, coordinates of the right groove side surface, groove bottom coordinates, groove side surface normal vector, measured groove width, measured groove depth, measurement quality mark, and tool status mark;

[0083] When the difference in the bottom coordinates of the groove obtained by scanning the same measurement section twice is greater than 0.01mm, or the change in the coordinates of the left and right groove sides is greater than 0.015mm, or an abnormality occurs in the online probe, the first groove processing detection module marks the measurement quality of the section as low confidence. Both 0.01mm and 0.015mm are higher than the online measurement stability threshold of 0.005mm, which are used to identify the influence of debris in the groove, abnormal probe contact, abnormal laser reflection, or local burrs on the groove surface on the detection results.

[0084] When a single measurement section is marked as low confidence, the first groove processing and detection module controls the air blowing cleaning unit to perform secondary cleaning and rescan the section; when three consecutive measurement sections are marked as low confidence, the first groove processing and detection module switches the groove surface scanning state to the retest waiting state and outputs a manual verification mark or an offline retest mark; in the retest waiting state, the first groove detection data is not used as the reference source for subsequent alternating grooves;

[0085] The first groove inspection data is graded based on the groove depth deviation and the groove side position deviation. When the groove depth deviation is no greater than 0.015mm and the groove side position deviation is no greater than 0.02mm, the first groove inspection data is marked as usable as a subsequent reference. When the groove depth deviation is greater than 0.015mm but no greater than 0.04mm, or the groove side position deviation is greater than 0.02mm but no greater than 0.05mm, the first groove inspection data is marked as a compensable reference. When the groove depth deviation is greater than 0.04mm or the groove side position deviation is greater than 0.05mm, the first groove processing inspection module outputs an abnormal groove surface mark to the reference correction module. 0.015mm is considered a first groove deviation that can be directly used as a reference. The groove depth deviation limit for subsequent benchmarks is three times the online measurement stability threshold of 0.005 mm, which can eliminate the influence of normal measurement fluctuations on the judgment result; 0.04 mm serves as the upper limit of groove depth deviation for compensable benchmarks, which is lower than the 0.05 mm threshold used to identify local runout in the axis benchmark establishment module, indicating that the deviation is still within the range that can be transferred and compensated by subsequent benchmarks; the groove side position deviation of 0.02 mm corresponds to the clamping disturbance review threshold in the clamping and indexing control module, and is used to maintain the benchmark reliability of the first groove side position; 0.05 mm corresponds to the local runout identification threshold, and is used to distinguish between compensable deviations and abnormal groove surfaces;

[0086] The first slot machining and inspection module outputs the first slot measured reference data package; the first slot measured reference data package includes at least the machining task number, motor shaft number, unified axis reference version, slot number, angular position record, left slot side coordinates, right slot side coordinates, slot bottom coordinates, slot side normal vector, measured slot width, measured slot depth, tool compensation value, inspection reliability level, reference usage mark, generation time, etc.; the reference usage mark is used to distinguish between references that can be used as subsequent references, compensable references, and abnormal slot surfaces;

[0087] The measured reference data packet of the first slot is sent to the reference transfer and correction module to establish the angular positioning and feed reference between the first alternating slot and the subsequent alternating slots; at the same time, it is written into the same machining task record so that the machining process, angular position, tool compensation and detection reliability level of the first alternating slot are associated with the machining data of the subsequent alternating slots.

[0088] The reference transfer and correction module is used to correlate the detection data of the first alternating groove with the angular position of the circumferential indexing, and to establish the angular positioning and feed reference for subsequent alternating grooves. Specifically, it is implemented as follows:

[0089] The detection data of the first alternating groove is correlated with the angular position of the circumferential indexing, and the angular positioning and feed reference of the subsequent alternating grooves are established; the reference transfer and correction module is set in the machining planning layer of the CNC system and is connected to the first groove machining detection module, the clamping and indexing control module, the compensation machining execution module and the machining task database.

[0090] The module receives the first groove measured reference data packet output by the first groove machining and inspection module, and reads the machining task number, motor shaft number, unified axis reference version, groove number, angular position record, left groove side coordinates, right groove side coordinates, groove bottom coordinates, groove side normal vector, groove width measured value, groove depth measured value, inspection reliability level, and reference usage mark; the reference transfer and correction module also receives the angular position record output by the clamping and indexing control module, and reads the target circumferential angle, measured circumferential angle, angle difference, circumferential locking status, and reference source;

[0091] The first slot measured reference data package and angular position record are associated with the same machining task number, motor shaft number, unified axis reference version and slot number; after successful association, the reference transfer correction module writes the measured slot side orientation, slot center line position, slot bottom position and corresponding measured circumferential angle of the first alternating slot into the current machining task record; when association fails, the reference transfer correction module does not generate subsequent slot reference instruction packages and outputs a data association anomaly mark to the CNC system;

[0092] Read the design parameters of the subsequent alternating grooves; the design parameters of the subsequent alternating grooves shall include at least the following fields: subsequent groove number, design circumferential angle, design axial position, design groove width, design groove depth, design groove length, angular relationship between grooves, machining sequence, tolerance grade, etc.; the angular relationship between grooves is used to determine the target phase relationship between the first alternating groove and the subsequent alternating grooves, and the tolerance grade is used to determine the allowable range of subsequent angular correction and feed correction.

[0093] The reference transfer correction module can read the current thermal status data of the machine tool. The current thermal status data of the machine tool includes at least the fields of spindle temperature, bed temperature, ambient temperature, and continuous machining time. When the spindle temperature changes by more than 5°C relative to the spindle temperature when the axis reference was established, or when the continuous machining time exceeds 30 minutes, the reference transfer correction module will increase the correction level by one level and require the compensation machining execution module to verify the tool feed start point before subsequent slot machining. 5°C is used to identify the perceptible impact of machine tool thermal expansion on the tool position and spindle end position, and 30 minutes corresponds to the time interval during continuous milling when the thermal status of the spindle, tool, and fixture gradually changes.

[0094] The branching process is performed based on the reference usage mark in the first groove measured reference data package. When the reference usage mark indicates that it can be used as a subsequent reference, the reference transfer correction module writes the measured groove side orientation, groove centerline position, and groove bottom position of the first alternating groove into the reference mapping table of the subsequent alternating groove, and marks the correction level as normal transfer. When the reference usage mark indicates that it is a compensable reference, the reference transfer correction module generates angular correction, axial correction, groove depth correction, and groove side correction based on the measured deviation of the first alternating groove, and marks the correction level as compensated transfer. When the reference usage mark indicates an abnormal groove surface, the reference transfer correction module outputs a prohibition mark for subsequent processing and transfers the current task to a processing stop state.

[0095] The angular correction is determined based on the difference between the measured angular azimuth of the first alternating groove and the designed circumferential angle of the first alternating groove; the axial correction is determined based on the difference between the measured axial position of the centerline of the first alternating groove and the designed axial position; the groove depth correction is determined based on the difference between the measured bottom position of the first alternating groove and the designed bottom position; the groove side correction is determined based on the deviation of the left and right groove sides from the designed groove side positions; the target angular azimuth of subsequent alternating grooves is determined based on the designed circumferential angle of the first alternating groove, the design angular relationship between grooves, and the angular correction, so that the angular positioning of subsequent alternating grooves is based on the measured reference of the first alternating groove.

[0096] The subsequent alternating slot reference mapping table should include at least the following fields: subsequent slot number, first slot reference section, first slot measured angular azimuth, first slot centerline position, first slot bottom position, subsequent slot target angular azimuth, angular correction, axial correction, slot depth correction, slot side correction, reference source, correction level, and processing permit mark. The first slot reference section should preferably be the measurement section with the highest detection confidence level and close to the axial center of the first alternating slot. When the middle section is marked as low confidence, the average position of two adjacent high confidence sections should be selected as the first slot reference section.

[0097] The allowable range for angular correction is ±0.15°. This range is greater than the locking check threshold of 0.06° in the clamping and indexing control module, and can cover the actual orientation deviation of the groove surface after the first alternating groove is machined and the reference deviation caused by local elastic tool deflection. This range can also be determined according to 5 to 8 times the repeatability error of the circumferential indexing mechanism of 0.02°. If ±0.15° is within this range, it can avoid the obvious abnormal machining error of the first groove from being passed on to the subsequent alternating groove.

[0098] The allowable range for groove depth correction is ±0.05mm. This range corresponds to the 0.05mm threshold used in the axis reference establishment module to identify local runout of the flat groove machining section, and is slightly higher than the upper limit of 0.04mm for groove depth deviation of the compensable reference in the first groove machining detection module. It can cover the compensable margin in subsequent groove feed correction. When the groove depth correction exceeds ±0.05mm, it indicates that the bottom position of the first groove or the current shaft section status has exceeded the normal compensation capability, and the deviation will not be transmitted to subsequent grooves.

[0099] The allowable range for the correction amount on the side of the groove is ±0.03mm. This range is higher than the deviation of the side of the groove that can be directly used as the reference for the next groove by 0.02mm, and lower than the boundary for judging abnormal groove surfaces by 0.05mm. It is used to control the correction of the side of the groove within the middle range of the compensable range, so as to avoid excessive correction of the groove width, groove side contact allowance or anti-rotation mating surface in the future.

[0100] When the angular correction, groove depth correction, and groove side correction all fall within their respective allowable ranges, the reference transfer and correction module generates a subsequent groove reference instruction package. When any correction exceeds the allowable range, the reference transfer and correction module enters a retest waiting state and calls the first groove processing and detection module to re-acquire the key section of the first alternating groove. When the correction returns to the allowable range after retesting, a subsequent groove reference instruction package is regenerated. When the correction still exceeds the allowable range after retesting, the reference transfer and correction module enters a processing stop state and outputs an abnormal groove surface mark or a rework judgment mark.

[0101] The reference transfer correction module has several state branches, including normal transfer state, compensated transfer state, retest waiting state, and machining stop state. In the normal transfer state, the target angular orientation of the subsequent alternating slot is determined according to the measured reference of the first alternating slot and the design angle relationship between slots. In the compensated transfer state, the reference transfer correction module synchronously corrects the target circumferential angle, axial feed start point, target position at the bottom of the slot, and side trimming direction of the subsequent alternating slot based on the measured deviation of the first alternating slot. In the retest waiting state, the reference instruction package for the subsequent slot is not output. In the machining stop state, the reference transfer correction module locks the machining permission mark in the reference instruction package for the subsequent slot and prohibits the output of the target indexing angle to the clamping indexing control module.

[0102] The subsequent slot reference instruction package should include at least the following fields: machining task number, motor shaft number, unified axis reference version, subsequent slot sequence number, target indexing angle, allowable angular difference, axial feed start point, target position of slot bottom, side trimming direction of slot, correction level, reference source, machining permission mark, and generation time. The allowable angular difference corresponds to the effective indexing limit in the clamping indexing control module and can be selected as 0.02°. When the correction level is compensation transfer and the machine tool thermal condition is abnormal, the allowable angular difference is not relaxed, and the tool feed start point must be checked before subsequent machining.

[0103] The subsequent groove reference instruction package is sent to the clamping and indexing control module to generate the circumferential indexing target angle of the subsequent alternating groove; at the same time, it is sent to the compensation machining execution module to generate the tool feed path, groove bottom machining position and groove side trimming direction of the subsequent alternating groove; the reference transfer and correction module also writes the subsequent alternating groove reference mapping table and the subsequent groove reference instruction package into the same machining task record, so that the first alternating groove measured reference, unified axis reference, angular position record and subsequent alternating groove compensation reference are associated in the same data chain.

[0104] Compensation machining execution module: Used to adjust the tool feed path, groove bottom machining position, and groove side trimming path based on the angular positioning and feed reference of subsequent alternating grooves. Specifically, it is implemented as follows:

[0105] Based on the angular positioning and feed reference of the subsequent alternating slots, the tool feed path, the bottom machining position of the slot, and the side trimming path of the slot are adjusted. The compensation machining execution module communicates with the CNC interpolation unit, the tool compensation unit, the spindle load acquisition unit, the vibration monitoring unit, the cooling chip removal unit, and the CNC system. Under the constraints of the subsequent slot reference instruction package and the angular verification result, the compensation machining of the subsequent alternating slots is performed.

[0106] The module receives the subsequent slot reference instruction package output by the reference transfer and correction module, and reads the machining task number, motor shaft number, unified axis reference version, subsequent slot sequence number, target circumferential angle, allowable angular difference, axial feed start point, target position of slot bottom, groove side trimming direction, correction level, reference source, and machining permission mark. If the machining permission mark is marked as prohibited from machining, or the angular position record fed back by the clamping and indexing control module is not marked as valid, the compensation machining execution module does not output tool movement instructions and returns a compensation machining waiting mark to the CNC system.

[0107] When the angle difference between the measured circumferential angle and the target circumferential angle is not greater than the allowable angle difference, the compensation machining execution module enters the angular locking state; the allowable angle difference corresponds to the effective indexing limit in the clamping indexing control module, and the selectable value is 0.02°, which is used to control the machining starting point of the subsequent alternating groove to be consistent with the target circumferential angle output by the reference transfer correction module;

[0108] The compensation machining execution module generates machining execution data; the machining execution data includes at least the following fields: machining task number, motor axis number, unified axis reference version, subsequent groove sequence number, target circumferential angle, measured circumferential angle, toolpath segment number, radial feed compensation amount, axial compensation amount, groove depth compensation amount, groove side compensation amount, feed rate, spindle speed rate, compensation source, and execution status; the compensation source is used to record whether the current compensation amount comes from normal transfer, compensation transfer, thermal state verification, or tool compensation update;

[0109] The radial feed compensation is determined by the difference between the target position of the groove bottom and the current radial feed reference of the tool; the axial compensation is determined by the difference between the axial feed start point in the subsequent groove reference instruction package and the designed axial start point in the machining process card; the groove depth compensation is determined by the difference between the target position of the groove bottom and the designed groove bottom position of the subsequent alternating grooves; the groove side compensation is determined by the groove side trimming direction and the groove side correction amount, and is used to generate the trimming path of the left groove side or the right groove side.

[0110] The execution states of the compensation machining execution module are as follows: compensation preparation state, angular locking state, trial cutting approach state, layered cutting state, groove side trimming state, groove bottom trimming state, and machining result confirmation state. When entering the compensation preparation state, the compensation machining execution module checks the machining permission mark, unified axis reference version, and tool compensation status in the subsequent groove reference instruction package. If the machining permission is not obtained or the tool compensation status is abnormal, no tool movement instruction is output.

[0111] When entering the trial cut approach state, the tool approaches the starting point of the subsequent alternating groove at 20% to 40% of the normal feed rate; this range is used to reduce the impact load at the moment of tool entry; below 20% will significantly increase the machining cycle time, and above 40% will result in a large change in the lateral force when the tool contacts the starting point of the groove, which can easily cause the slender motor shaft to deflect or vibrate.

[0112] For subsequent alternating grooves, the compensation machining execution module adjusts the machining position of the groove bottom according to the groove depth compensation amount, adjusts the trimming path of the left or right groove side according to the groove side compensation amount, and adjusts the groove length start and end points according to the axial compensation amount. When the groove side trimming direction points to the left groove side, a left groove side trimming path is generated. When the groove side trimming direction points to the right groove side, a right groove side trimming path is generated. When there are deviations on both the left and right groove sides, the side with the larger absolute value of the deviation is trimmed first, and the groove width allowance is checked after trimming.

[0113] When the groove depth compensation is less than 0.01mm, the compensation machining execution module merges the compensation into the finishing allowance. 0.01mm is approximately twice the online measurement stability threshold of 0.005mm, which is a small compensation that can be absorbed by the finishing allowance. Generating a separate groove bottom trimming path would increase the path complexity. When the groove depth compensation is between 0.01mm and 0.05mm, the compensation machining execution module generates a separate groove bottom trimming path. 0.05mm corresponds to the upper limit of the groove depth correction allowed in the reference transfer correction module and is used to distinguish between normal compensation machining and compensation exceeding the limit.

[0114] When the groove depth compensation is greater than 0.05mm, the compensation machining execution module enters the compensation over-limit state, does not output the cutting command for the corresponding subsequent alternating groove, and returns the compensation over-limit mark or rework judgment request to the reference transmission correction module; in the compensation over-limit state, the machining permission mark in the current subsequent groove reference command package is locked, and the machining execution data will be regenerated after the retest or rework judgment is completed.

[0115] The groove side trimming path can adopt a single-sided micro-cutting method, with a single-sided trimming amount ranging from 0.005mm to 0.03mm and a trimming feed rate ranging from 30mm / min to 150mm / min. 0.005mm corresponds to the online measurement stability threshold; trimming amounts below this value are difficult to be stably reflected in the test results. 0.03mm corresponds to the upper limit of the groove side correction amount allowed in the reference transfer correction module, which can avoid single-sided overcutting leading to groove width deviation or loose fit. The trimming feed rate is lower than or close to the lower half of the roughing feed rate, which is suitable for micro-trimming of the groove side. For narrow grooves, small-diameter shafts, or shaft sections with a large length-to-diameter ratio, the feed rate should be closer to the lower limit; for wide grooves or shaft sections with good support rigidity, the feed rate should be closer to the upper limit.

[0116] During the layered cutting, groove side trimming, and groove bottom trimming processes, the cooling and chip removal unit outputs coolant or compressed air according to the machining process card. When the spindle load or vibration is abnormal, the compensation machining execution module prioritizes controlling the cooling and chip removal unit to clean the chips in the groove before determining whether to resume cutting, so as to reduce the impact of chip accumulation on groove side trimming and groove bottom depth control.

[0117] The feed rate is adjusted according to the spindle load status; when the spindle load exceeds 120% of the current slot's normal cutting load reference and lasts for more than 0.5s, the compensation machining execution module lowers the feed rate; the current slot's normal cutting load reference is determined by the average spindle load of the same tool within the previous stable cutting time window, which can be selected from 2s to 5s; 0.5s is used to eliminate instantaneous impacts on the cutting teeth and short-term load spikes, reflecting continuous cutting abnormalities;

[0118] When the spindle load is greater than 120% but not greater than 150% of the normal cutting load reference, the feed rate is reduced by 10% to 20%; when the spindle load is greater than 150% of the normal cutting load reference, the feed rate is reduced by 20% to 30%, and the system enters load observation mode; in load observation mode, the compensation machining execution module continues to collect the spindle load curve; if the load recovers to within 120% of the normal cutting load reference, machining continues; if the load continues to exceed 150%, cutting is paused and chip removal and cleaning are performed;

[0119] The vibration protection branch is set according to the vibration displacement amplitude output by the vibration monitoring unit; when the vibration displacement amplitude is greater than 0.02mm and lasts for more than 1s, the compensation machining execution module pauses cutting, retracts the tool by 0.5mm to 2mm, and controls the cooling chip removal unit to clean the chips in the groove again; 0.02mm corresponds to the clamping disturbance recheck threshold in the clamping and indexing control module. If this amplitude is exceeded, the machining vibration may affect the side position of the groove and the bottom depth of the groove; lasting for 1s is used to eliminate single-point impact or sensor noise;

[0120] A retraction amount of 0.5mm to 2mm, which is greater than the single cutting depth of 0.05mm to 0.3mm, allows the tool to disengage from the current cutting contact zone. When machining narrow grooves or small-diameter tools, the retraction amount is close to 0.5mm. When machining wide grooves, larger-diameter tools, or when chip removal is difficult in the groove, the retraction amount is close to 2mm. After the retraction and chip removal are completed, the compensation machining execution module re-enters the trial cutting approach state and resumes machining according to the reduced feed rate.

[0121] If the same subsequent alternating groove, under the same layered cutting state or the same dressing state, experiences a vibration displacement amplitude greater than 0.02 mm and lasts for more than 1 second after pausing, retracting the tool, and blowing away chips, it is recorded as continuous vibration exceeding the limit. If vibration exceeds the limit twice in a row, the compensation machining execution module returns a support rigidity insufficient mark to the reference transmission correction module and requests the clamping indexing control module to check the position of the intermediate follower support or the status of the tail auxiliary support.

[0122] After entering the processing result confirmation state, the compensation processing execution module checks the tool path execution completion mark, spindle load curve, vibration status, number of abnormal pauses, and compensation amount execution value; if there are unexecuted path segments, incomplete compensation amounts, or unhandled abnormal pauses, the compensation processing execution module does not output a completion mark and marks the current subsequent alternating slot as pending verification.

[0123] After each subsequent alternating groove is completed, output the subsequent groove machining process data; the subsequent groove machining process data shall include at least the following fields: machining task number, motor shaft number, unified axis reference version, subsequent groove sequence number, actual tool path, radial feed compensation execution value, axial compensation execution value, groove depth compensation execution value, groove side compensation execution value, spindle load curve, vibration status, number of abnormal pauses, dressing path number, completion mark, generation time, etc.

[0124] The subsequent groove processing data is sent to the final inspection and verification module to verify the final phase relationship, groove bottom depth relationship and groove side relationship of each alternating groove; at the same time, it is written into the same processing task record, so that the reference source, angular verification result, compensation execution status, load change and vibration state of the subsequent alternating groove are associated with the axis reference, the measured reference of the first groove and the reference transfer correction data.

[0125] Final inspection verification module: Used to collect final inspection data from each alternating slot and associate the final inspection data with the corresponding processing data into the same processing task record. Specifically, the implementation is as follows:

[0126] Collect the final inspection data of each alternating groove and associate the final inspection data with the corresponding machining process data and write it into the same machining task record; the final inspection verification module is arranged in the online inspection station after machining is completed, and can also share the online probe, laser displacement sensor and spindle encoder with the machine tool's internal measurement unit to verify the actual circumferential position, groove bottom depth, groove side position and groove width of each alternating groove under a unified axis reference;

[0127] The system receives axis reference data packets, angular position records, first slot measured reference data packets, subsequent slot reference instruction packets, subsequent slot machining process data, and machining process cards, and associates the data through machining task number, motor shaft number, unified axis reference version, and slot sequence number. After successful association, the final inspection and verification module generates a final inspection acquisition task. If the association fails, the final inspection and verification module does not output the final inspection judgment result and returns a data association anomaly flag to the CNC system.

[0128] The final inspection data collection task should include at least the following fields: machining task number, motor shaft number, unified axis reference version, slot number list, slot design parameters, coordinates of final inspection measurement points, angular verification method, slot bottom verification method, side verification method, judgment threshold, and number of re-inspections. The slot design parameters are used to provide the design circumferential angle, design slot width, design slot depth, design slot length, and inter-slot angular relationship for each alternating slot. The judgment threshold should preferably adopt the tolerance requirements given in the machining drawings or machining process cards.

[0129] During final inspection and verification, the final inspection and verification module repositions the measurement sections of each alternating groove according to a unified axis reference. For alternating grooves with a length not exceeding 40mm, the measurement sections are set at least at three positions: the front end, the middle, and the rear end of the groove, to cover the groove surface condition in the infeed area, the middle cutting area, and the retraction area. For alternating grooves with a length exceeding 40mm, the spacing between the measurement sections is no more than 10mm, to identify possible groove bottom depth drift and groove side orientation changes during long groove machining. This spacing is greater than the online reference scanning spacing of the first groove, which is suitable for the comprehensive requirements of detection efficiency and verification accuracy in the final inspection stage.

[0130] The final inspection data should include at least the following fields: tank number, measurement section coordinates, measured position of the tank bottom, measured position of the left tank side, measured position of the right tank side, azimuth of the tank centerline, measured tank width, measured tank depth, inter-tank phase angle, measurement quality mark, and verification status. The inter-tank phase angle is obtained by comparing the azimuth of the centerline of each alternating tank with the corresponding designed inter-tank angle. The symmetry deviation of the tank side is determined by the positional deviation of the measured positions of the left and right tank side relative to the tank centerline.

[0131] When the machining drawings or machining process cards do not provide clear judgment thresholds, the phase angle deviation between slots shall not exceed 0.05°, the depth deviation of the slot bottom shall not exceed 0.02mm, the symmetry deviation of the slot side shall not exceed 0.03mm, and the slot width deviation shall not exceed 0.02mm. The phase angle deviation between slots of 0.05° is higher than the effective indexing limit of 0.02° in the clamping indexing control module, which can accommodate cutting deflection and fluctuations in the final inspection quantity; at the same time, it is lower than the locking re-inspection threshold of 0.06°, which can avoid including indexing locking abnormalities in the acceptable range.

[0132] The groove bottom depth deviation of 0.02mm is higher than the groove depth deviation limit of 0.015mm for the first groove, which can be directly used as the subsequent reference, and can accommodate small cutting fluctuations in subsequent compensation machining; at the same time, it is lower than the upper limit of groove depth deviation of the first groove that can be compensated as the reference, which is 0.04mm, to prevent the groove bottom depth deviation from being judged as qualified after entering the compensation boundary; the groove side symmetry deviation of 0.03mm corresponds to the upper limit of the groove side correction amount allowed in the reference transfer correction module, and is lower than the abnormal groove surface judgment boundary of 0.05mm; the groove width deviation of 0.02mm corresponds to the groove side position deviation limit of the first groove that can be directly used as the subsequent reference, and is used to maintain the stability of the gap between the mating part and the flat groove;

[0133] For small-diameter high-speed motor shafts, the inter-slot phase angle deviation threshold can be tightened to 0.03°. Small-diameter high-speed motor shafts are more sensitive to rotational balance and mating phase, and tightening the angular threshold can reduce the impact of inter-slot phase deviation on high-speed operation stability. For ordinary drive shafts, the inter-slot phase angle deviation threshold can be relaxed to 0.08°. 0.08° is still lower than the allowable upper limit of ±0.15° for angular correction in the reference transfer correction module, and will not treat obvious reference abnormalities as a qualified state.

[0134] The final inspection and verification module is set to pass, repairable, retest, and abnormal storage status. When all final inspection data falls within the corresponding judgment threshold, the final inspection and verification module marks the verification status as pass. When there is a machinable allowance of no more than 0.02mm only in the bottom depth or on one side of the groove, the final inspection and verification module generates a rework instruction and sends it to the compensation machining execution module. 0.02mm corresponds to the default threshold for the deviation of the bottom depth and the width of the groove in the final inspection, indicating that there is still residual material that can be removed by a small amount of rework. If this allowance is exceeded, continued rework may lead to the groove width being out of tolerance or the bottom of the groove being overcut.

[0135] The rework instruction includes at least the following fields: processing task number, motor shaft number, unified axis reference version, slot number, rework location, rework type, maximum rework quantity, rework path direction, and rework permission mark. The rework type may include minor trimming of the slot bottom, trimming of the left slot side, and trimming of the right slot side. After the compensation processing execution module completes the rework, the final inspection and verification module re-collects the final inspection data of the corresponding slot and writes the data before and after the rework into the same processing task record.

[0136] When the measurement quality mark is abnormal, but no compensation overrun, continuous overload, or continuous vibration overrun occurs in the subsequent tank processing data, the final inspection and verification module enters the retest state. Before the retest, the final inspection and verification module calls the air cleaning unit to clean the corresponding tank and calls the online measurement unit to perform probe calibration. The number of retests can be selected as 1 to 2. When the measurement quality returns to normal after the retest, the final inspection is judged according to the retest data. If the measurement quality is still abnormal after the retest, the final inspection and verification module outputs a manual verification mark or enters the abnormal storage state.

[0137] When the phase angle deviation between slots exceeds 0.12°, the final inspection and verification module enters an abnormal storage state. 0.12° is approximately 6 times the effective indexing limit of 0.02° and close to the allowable upper limit of ±0.15° for angular correction in the reference transfer correction module, indicating that the phase deviation between slots is approaching a range that cannot be stably corrected by subsequent compensation. In the abnormal storage state, the final inspection and verification module locks the final state of the processing task, prohibits further automatic rework, and writes the abnormal data, processing data, and final inspection data into the abnormal record area.

[0138] When the bottom depth deviation directions of multiple alternating grooves are inconsistent, the final inspection and verification module enters an abnormal storage state. Inconsistent bottom depth deviation directions mean that in at least two alternating grooves, the measured bottom position of one groove is deeper than the designed bottom position, and the measured bottom position of the other groove is shallower than the designed bottom position, and the absolute value of both deviations is greater than 0.02mm. This state indicates that the bottom deviation is not caused by a single tool compensation direction, but may be related to reference transfer, clamping support, or machining vibration, and is not suitable for continued automatic rework.

[0139] The final inspection and verification module outputs the same machining task record; the same machining task record includes at least the following fields: machining task number, motor shaft number, unified axis reference version, angular position of each indexing, first slot measured reference data package, subsequent slot reference instruction package, subsequent slot machining process data, final inspection data, abnormal handling record, rework record, final status, generation time, etc.; the machining task number is used as the primary key, and the motor shaft number and slot sequence number are used as indexes to associate the axis reference, clamping indexing, first slot detection, reference transfer, compensation machining and final inspection and verification data of the same flat-in-flat motor shaft;

[0140] The same machining task record is written to the local industrial control computer or manufacturing execution system through the machine tool data interface; the final inspection and verification module retains the generation time, reference version and status mark of each data packet when writing the record, so that each alternating slot of the same motor shaft can be traced according to the machining sequence, and provides a data basis for subsequent quality analysis, rework judgment and batch process optimization.

[0141] In one embodiment, a composite CNC machine tool is used to process a flat-medium flat motor shaft with a diameter of 20mm. The mating section of the motor shaft is provided with a first alternating groove and a second alternating groove arranged at different circumferential positions. Before processing, the axis reference establishment module collects radial runout data of the front clamping section, the first flat groove processing section, the intermediate transition section, the second flat groove processing section, and the tail support section through an online measurement unit, and establishes a unified axis reference through each shaft section based on the rotation center offset of each measuring point. The clamping and indexing control module controls the spindle clamping, the tail auxiliary support, and the intermediate follower support according to the unified axis reference, and records the circumferential position corresponding to the first alternating groove after the angular verification is valid. The first groove processing and detection module mills the first alternating groove according to the processing process card, and collects the groove bottom position, left groove side position, and right groove side position of the first alternating groove online. The system generates a first groove measured reference data package based on the orientation of the groove side and the groove side. The reference transfer and correction module associates the first groove measured reference data package with the corresponding angular position record, and determines the target circumferential angle, axial feed start point, groove bottom target position, and groove side trimming direction of the second alternating groove based on the measured groove side orientation, groove centerline position, and groove bottom position of the first alternating groove. After the angular direction is locked, the compensation machining execution module performs compensation machining of the second alternating groove, and adjusts the feed rate, retraction distance, and chip removal action according to the spindle load state and vibration state. After the machining of each alternating groove is completed, the final inspection and verification module verifies the groove phase angle, groove bottom depth, groove side symmetry, and groove width of each groove according to the unified axis reference, and associates the axis reference, indexing record, first groove detection data, subsequent groove compensation data, and final inspection data into the same machining task record.

[0142] It should be noted that this invention can be deployed on the device itself to realize embedded applications, or it can run on a PC or other terminal with a user interface, thereby meeting various hardware environments and usage requirements.

[0143] The above embodiments can be implemented in whole or in part by software, hardware, firmware, or any other combination. When implemented in software, the above embodiments can be implemented in whole or in part by a computer program product. The computer program product includes one or more computer instructions or computer programs. When the computer instructions or computer programs are loaded or executed on a computer, the processes or functions of the embodiments of this application are implemented in whole or in part. The computer can be a general-purpose computer, a special-purpose computer, a computer network, or other programmable device. The computer instructions can be stored in a computer-readable storage medium or transmitted from one computer-readable storage medium to another. For example, the computer instructions can be transmitted wirelessly or wiredly from one website, computer, server, or data center to another website, computer, server, or data center. Wired methods include optical fiber, twisted pair, coaxial cable, etc. Wireless methods include infrared, microwave, etc. Available media include any available media that can be accessed by a computer or data storage devices such as servers and data centers that contain one or more sets of available media. Available media can be magnetic media (floppy disks, hard disks, magnetic tapes), optical media (DVDs), or semiconductor media. Semiconductor media can be solid-state drives.

[0144] 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.

[0145] In conclusion, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A composite CNC machine tool for machining alternating grooves on motor shafts, characterized in that, include: Axis reference establishment module: used to collect radial runout data of each shaft segment of the motor shaft, and establish a unified axis reference that runs through each shaft segment based on the radial runout data; Clamping and indexing control module: used to control the clamping, auxiliary support and circumferential indexing of the motor shaft according to a unified axis reference, and record the angular position corresponding to each circumferential indexing. First groove processing and detection module: used to process the first alternating groove and collect the groove surface position, groove bottom depth and groove side orientation data of the first alternating groove; Reference transfer and correction module: used to correspond the detection data of the first alternating groove with the angular position of the circumferential indexing, and establish the angular positioning and feed reference for the subsequent alternating grooves; Compensation machining execution module: used to adjust the tool feed path, groove bottom machining position and groove side trimming path according to the angular positioning and feed reference of the subsequent alternating grooves; Final inspection and verification module: used to collect the final inspection data of each alternating slot and associate the final inspection data with the corresponding processing process data and write it into the same processing task record.

2. The composite CNC machine tool for machining alternating grooves on a motor shaft according to claim 1, characterized in that, The axis reference establishment module includes: Axial measuring points are arranged according to the clamping section, the flat groove machining section, the transition section and the support section. Radial displacement data is collected in combination with the spindle encoder angle under the low-speed rotation state of the motor shaft. Consistency verification is performed on the radial displacement curves of adjacent rotation cycles; Abnormal sampling points are marked and excluded. A unified axis reference is established based on the rotation center offset of stable measuring points, and an axis reference data package is generated. Write the radial runout peak value into the local compensation area or output a mark prohibiting indexing.

3. The composite CNC machine tool for machining alternating grooves on a motor shaft according to claim 1, characterized in that, The clamping and indexing control module includes: Read the machining permission mark, local compensation area record, and axis direction vector from the axis reference data packet; Based on the slot plan, clamping and indexing instructions are generated, and the tail-end auxiliary support mechanism, intermediate follow-up support mechanism and circumferential indexing mechanism are controlled according to the pre-clamping, axis alignment, clamping locking, circumferential indexing and angular verification status. When the difference between the measured circumferential angle and the target circumferential angle exceeds the preset range, reverse fine-tuning or locking re-check will be performed.

4. The composite CNC machine tool for machining alternating grooves on a motor shaft according to claim 1, characterized in that, The first slot processing and inspection module includes: Read the axis reference data packet and angular position record, and call the machining process card when both the machining permission mark and the angular position record are valid; The process involves sequentially performing tool verification, roughing, finishing, cleaning the tank, scanning the tank surface, and classifying the inspection data. The first measured reference data packet is generated based on the groove depth deviation, groove side position deviation, and measurement quality mark, and then sent to the reference transfer and correction module.

5. The composite CNC machine tool for machining alternating grooves on a motor shaft according to claim 1, characterized in that, The reference transfer correction module includes: Associate the first slot measured reference data package with the angular position record under the same processing task; Based on the reference, the system switches to normal transmission state, compensated transmission state, or processing stop state using the marker, and generates subsequent slot reference mapping table and subsequent slot reference instruction package based on the measured angular azimuth of the first slot, the position of the slot centerline, and the position of the slot bottom.

6. The composite CNC machine tool for machining alternating grooves on a motor shaft according to claim 1, characterized in that, The compensation processing execution module includes: Read subsequent slot reference instruction packets and angular position records, and generate machining execution data after machining permission is valid and angular direction is locked; The subsequent alternating groove processing is carried out according to the compensation preparation, trial cutting approach, layer cutting, groove side trimming, groove bottom trimming and processing result confirmation status; Adjust the feed rate, perform retraction and chip removal, and return to the support to check the mark or compensate for the over-limit status based on the spindle load, vibration displacement, and compensation over-limit status.

7. The composite CNC machine tool for machining alternating grooves on a motor shaft according to claim 1, characterized in that, The final inspection and review module includes: The machining task number, motor shaft number, unified axis reference version and slot number are used to associate axis reference data, angular position records, first slot measured reference data and subsequent slot machining process data; The measurement sections of each alternating groove are located according to the unified axis reference, and the phase angle between grooves, groove bottom depth, groove side symmetry and groove width are checked. Output a repair instruction, a retest mark, or an abnormal sealing mark according to the review status.

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