Servo straightening press adaptive pressure application system for high-neck flange machining

Abstract

The application discloses a servo straightening press self-adaptive pressure applying system for high-neck flange machining and belongs to the technical field of intelligent manufacturing equipment. The system specifically comprises an online scanning module, a cooperative pressing module, a pressure regulating module and an evaluation module. Initial controlled pressure field is generated by scanning the end face topography data of the high-neck flange. The servo straightening press applies force and displacement at the action point of the high-neck flange according to the initial controlled pressure field, and a pressure deformation curve is constructed. The pressure regulating module dynamically corrects the deviation in the pressure applying process by comparing the actual curve with the expected characteristics. The flange flatness is evaluated after each pressing cycle, and the controlled pressure field of the next cycle is re-planned until the flange flatness reaches the standard. The application effectively deals with the material performance fluctuation of the high-neck flange, improves the consistency and stability of the correction accuracy, can achieve higher flatness with fewer cycle times, and improves the product quality and production efficiency.

Description

Technical Field

[0001] This invention relates to an adaptive pressure system for a servo straightening press used in the processing of high-neck flanges, belonging to the field of intelligent manufacturing technology for equipment. Background Technology

[0002] High-neck flanges are connecting parts with a neck height significantly higher than ordinary flanges. The flatness accuracy of their end faces directly affects the sealing performance and connection reliability of the entire structure. These flanges are usually made of rolled or forged steel plates. During the cooling and residual stress release process after rolling, unpredictable planar warping is easily generated, resulting in low production efficiency, large fluctuations in the straightening effect, and difficulty in meeting the requirements of high precision, high consistency, and high efficiency for modern mass production.

[0003] In existing technologies, a three-dimensional point cloud of the flange is established, denoised, and segmented. Detection points are extracted from each segmented region, and a flange reference plane is fitted. The flange flatness is then calculated based on the fitting results. However, existing technologies suffer from the following problems: the pressing process lacks real-time control capabilities and cannot dynamically adjust the applied force, displacement, velocity, or the coordination relationship of the synergistic action points based on the mechanical response of the material feedback. This results in insufficient or over-correction, leading to unstable correction effects and accuracy. Summary of the Invention

[0004] The purpose of this invention is to provide an adaptive pressure system for a servo straightening press used in the processing of high-neck flanges, in order to solve the problems of unstable straightening effect and poor accuracy in the prior art.

[0005] To solve the above-mentioned technical problems, the present invention is implemented using the following technical solution.

[0006] A servo-driven straightening press adaptive pressure system for machining high-neck flanges, the system comprising:

[0007] The online scanning module is used to collect structural features and material data of high-neck flanges, analyze the warping distribution pattern by combining the morphological data obtained by visual measurement, construct an initial controlled pressure field, and generate the corresponding pressure deformation curve features.

[0008] The collaborative pressing module is used to drive the end control unit of the servo straightening press to apply pressure to the high neck flange according to the initial controlled pressure field, and apply auxiliary support force at the corresponding point on the back of the high neck flange, and collect the corresponding pressure value and displacement value to construct the pressure deformation curve.

[0009] The pressure regulating module is used to dynamically perform pressure field superposition, pressure holding time truncation, and pressure parameter adjustment operations by comparing the characteristics of the pressure deformation curve and the pressure deformation curve during the pressure application process.

[0010] The evaluation module is used to acquire the morphological data of the high-neck flange after pressure is applied, and to reprogram the initial controlled pressure field by evaluating the straightening effect until the flange flatness reaches the preset qualified threshold.

[0011] Furthermore, the online scanning module includes a topography scanning unit, a warpage analysis unit, a planning unit, and a feature analysis unit, including:

[0012] The topography scanning unit is used to acquire the material data of the high neck flange and to measure the end face of the high neck flange point by point to acquire the spatial coordinate data of each point to form topography data.

[0013] The warpage analysis unit is used to calculate the ideal reference plane based on the morphology data by least squares plane fitting, and to calculate the flatness error distribution map by point-by-point deviation, and to identify the warpage distribution pattern based on its spatial gradient change.

[0014] The planning unit is used to select the action point of the high neck flange according to the warping distribution pattern, determine the main pressure point and auxiliary support point required to construct the initial controlled pressure field, and calculate the pressure parameters, the target value of the indentation depth and the direction of action of each point in combination with the material data.

[0015] The feature analysis unit is used to predict the pressure and deformation relationship of the flange end face when an initial controlled pressure field is applied, based on pressure parameters, target value of indentation depth and direction of action, and to generate pressure deformation curve features. The points of action include main pressure points and auxiliary support points.

[0016] Furthermore, the feature analysis unit is configured with feature prediction logic, which includes:

[0017] Based on the pressure parameters, the target value of the indentation depth and the direction of action, the mechanical response of the entire high-neck flange end face under the action of the initial controlled pressure field is simulated to obtain the pressure reading sequence and the displacement reading sequence, and to construct the pressure deformation data sequence.

[0018] The first stiffness value of the high neck flange end face is extracted by differential calculation of the pressure deformation data sequence, and the starting point of the elastic-plastic transition is identified. The pressure value and deformation value at the starting point are used as the yield threshold group.

[0019] The yield threshold group statistical distribution of flanges of the same specification is obtained from the straightening database. The yield threshold group is corrected to generate a yield threshold interval that includes the center expected value and tolerance range. The straightening database is set according to the successful straightening data of flanges of the same specification.

[0020] The first stiffness value, yield threshold range, and deformation target are integrated and encapsulated into a pressure deformation curve feature, wherein the deformation target is set according to the indentation depth target value.

[0021] Furthermore, the collaborative pressing module includes an end-effector control unit, a constraint unit, an acquisition unit, and a curve construction unit, including:

[0022] The end control unit is used to control the main pressure head of the servo straightening press to move directly above the main pressure point according to the position of the main pressure point, and to control the corresponding auxiliary device to move to the corresponding auxiliary support point on the back of the high neck flange.

[0023] The constraint unit is used to apply pressure to the high neck flange through the main pressure fitting head, and increase the output force of the cooperative auxiliary device according to the pressure rise amplitude by a preset nonlinear gain coefficient to construct an axial pressure gradient field on the high neck flange.

[0024] The acquisition unit is used to acquire the main pressure sequence, main displacement sequence and auxiliary support force sequence of the main pressing head and the auxiliary device at a preset synchronization frequency.

[0025] The curve construction unit is used to generate a time-series index within the axial pressure gradient field by calculating the ratio of the auxiliary support force sequence to the main pressure sequence, and to generate a pressure deformation curve representing the flange response characteristics under the axial pressure gradient field.

[0026] Furthermore, the constraint unit is configured with constraint logic, which includes:

[0027] Based on the target pressure value and pressure application rate in the initial controlled pressure field, the main pressure fitting head is controlled to move along the flange axis and the pressure sensor data is read to obtain the main pressure that increases with time.

[0028] Calculate the target output force corresponding to the cooperative auxiliary device based on the main pressure and the preset nonlinear gain coefficient;

[0029] Feedback control is applied to the pressure controller of the auxiliary device based on the target output force, driving it to output real-time auxiliary support force, thereby forming an axial pressure gradient field in the local pressure area of ​​the high-neck flange.

[0030] Furthermore, the voltage regulation module includes a characteristic calculation unit, a deviation identification unit, a field adjustment unit, and a deformation control unit, including:

[0031] The feature calculation unit is used to calculate the instantaneous stiffness and cumulative deformation of the pressure deformation curve based on the auxiliary support force, main pressure sequence and main displacement sequence of each cooperating auxiliary device.

[0032] The deviation identification unit is used to compare the instantaneous stiffness and cumulative deformation with the corresponding pressure deformation curve characteristics in the initial controlled pressure field to determine the deviation type.

[0033] The field adjustment unit is used to calculate and adjust the force distribution ratio between the main pressure point and the auxiliary support point according to the magnitude and direction of the stiffness deviation if the deviation type is stiffness deviation.

[0034] The deformation control unit is used to dynamically truncate or extend the duration of the initial controlled pressure field if the deviation type is deformation endpoint offset. When the cumulative deformation reaches the target, the main pressure head is stopped and the pressure holding state is entered. When the pressure reaches the target but the cumulative deformation is insufficient, the current pressure is maintained and the holding time is extended until the cumulative deformation reaches the target.

[0035] Furthermore, the field adjustment unit also includes field adjustment logic, which includes:

[0036] Based on the stiffness deviation and its direction, and combined with the real-time pressure of the main pressure point and the cooperating auxiliary device, the pressure ratio relationship between each point of action in the initial controlled pressure field is calculated, and compared with the preset pressure ratio to identify the cooperating auxiliary device with the greatest influence of stiffness deviation.

[0037] For the most affected auxiliary device, adjust the target pressure setting without interrupting the application of the main pressure;

[0038] The system monitors the change trend of instantaneous stiffness of the pressure deformation curve at the main pressure point during adjustment. If the adjustment is corrected in the expected direction, the adjustment is maintained. If the adjustment is contrary to the expectation or overshoots, the system is restored to the state before adjustment until it is corrected to the preset range.

[0039] Furthermore, the field adjustment logic also includes field state analysis sub-logic, which includes:

[0040] Based on the current force values ​​of the main pressure point and the auxiliary support point, the pressure ratio is calculated to obtain a set of pressure ratios representing the pressure distribution state inside the initial controlled pressure field.

[0041] The pressure ratio in the pressure ratio set is compared with the pressure ratio target value of the corresponding coordinating auxiliary device preset at the main pressure point in the initial controlled pressure field, and the pressure ratio deviation value of the coordinating auxiliary device is calculated.

[0042] Multiply the pressure ratio deviation value by a preset influence coefficient that reflects the corresponding spatial location on the deformation stiffness at the main pressure point to obtain the influence index.

[0043] The coordinating assistant with the largest absolute value of the influence index is selected as the coordinating assistant with the greatest impact on stiffness deviation.

[0044] Furthermore, the evaluation module includes a retesting unit, a planning update unit, and an iterative unit, including:

[0045] The retesting unit is used to acquire the morphological data of the high-neck flange end face after the initial controlled pressure field is applied, quantify its actual straightening effect, and identify the residual error exceeding the standard area and the newly deformed area in combination with the preset qualified threshold.

[0046] The planning update unit is used to perform replanning on the initial controlled pressure field of the residual error exceeding the standard region and the newly deformed region based on the quantification results, so as to obtain the updated controlled pressure field.

[0047] The iterative unit is used to repeatedly apply pressure to the high neck flange end face according to the controlled pressure field until the flatness error value of the high neck flange end face is less than the qualified threshold.

[0048] Furthermore, the planning update unit also includes planning update logic, which includes:

[0049] Analyze the error pattern of the area where the residual error exceeds the standard, increase the pressure parameter of the original point of action or add a new point of action according to the amount of error, and generate the updated point of action and pressure parameter.

[0050] By analyzing the deformation characteristics and spatial correlation of the newly formed deformation region, a combination of action points is planned at symmetrical locations to generate a controlled pressure field for reverse compensation and adjust the pressure parameters of adjacent action points.

[0051] Compared with existing technologies, the beneficial effects achieved by this invention are as follows: The online scanning module scans the morphology of the high-neck flange and intelligently generates a controlled pressure field containing multiple action points working together. This field is executed by a servo straightening press of the collaborative pressing module. During the pressing process, the pressure parameters are dynamically adjusted using a pressure regulating module based on the real-time feedback pressure deformation curve. After each round of pressing, the morphology data of the high-neck flange is re-measured by an evaluation module. Based on its residual error, an optimized controlled pressure field is intelligently generated until the flatness of the high-neck flange meets the standard. This solves the problems of unstable straightening effect and poor accuracy in existing technologies, effectively addresses the fluctuations in the material properties of high-neck flanges, improves the consistency and stability of straightening accuracy, achieves higher flatness with fewer cycles, and improves product quality and production efficiency.

[0052] It should be understood that the above general description and the following detailed description are merely exemplary and explanatory, and are not intended to limit the technical solutions of this disclosure. Attached Figure Description

[0053] Figure 1 This invention provides a structural diagram of a servo-driven straightening press adaptive pressure application system for high-neck flange processing.

[0054] Figure 2 This is a schematic diagram of the warping mode provided by the present invention;

[0055] Figure 3A schematic diagram of the axial pressure gradient field provided by the present invention;

[0056] Figure 4 The flowchart illustrates the configuration strategy of the adaptive pressure application system for a servo straightening press used in high-neck flange processing, as provided by this invention. Detailed Implementation

[0057] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the embodiments of the present invention and the specific features in the embodiments are detailed descriptions of the technical solution of the present invention, rather than limitations thereof. In the absence of conflict, the embodiments of the present invention and the technical features in the embodiments can be combined with each other.

[0058] The term "and / or" simply describes the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A alone, A and B simultaneously, or B alone. Additionally, the character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0059] Example 1

[0060] Please see Figure 1 One embodiment of the present invention provides an adaptive pressure application system for a servo-driven straightening press used in high-neck flange processing, comprising an online scanning module, a collaborative pressing module, a pressure adjustment module, and an evaluation module.

[0061] The online scanning module is used to collect structural features and material data of high-neck flanges, analyze the warping distribution pattern by combining the morphological data obtained by visual measurement, construct an initial controlled pressure field, and generate the corresponding pressure deformation curve features.

[0062] The collaborative pressing module is used to drive the end control unit of the servo straightening press to apply pressure to the high neck flange according to the initial controlled pressure field, and apply auxiliary support force at the corresponding point on the back of the high neck flange, and collect the corresponding pressure value and displacement value to construct the pressure deformation curve.

[0063] The pressure regulating module is used to dynamically perform pressure field superposition, pressure holding time truncation, and pressure parameter adjustment operations by comparing the characteristics of the pressure deformation curve and the pressure deformation curve during the pressure application process.

[0064] The evaluation module is used to acquire the morphological data of the high-neck flange after pressure is applied, and to reprogram the initial controlled pressure field by evaluating the straightening effect until the flange flatness reaches the preset qualified threshold.

[0065] Furthermore, the online scanning module includes a topography scanning unit, a warpage analysis unit, a planning unit, and a feature analysis unit, wherein:

[0066] The topography scanning unit is used to acquire the material data of the high neck flange and to measure the end face of the high neck flange point by point to acquire the spatial coordinate data of each point to form topography data.

[0067] The warpage analysis unit is used to calculate the ideal reference plane based on the morphology data by least squares plane fitting, and to calculate the flatness error distribution map by point-by-point deviation, and to identify the warpage distribution pattern based on its spatial gradient change.

[0068] The planning unit is used to select the action point of the high neck flange according to the warping distribution pattern, determine the main pressure point and auxiliary support point required to construct the initial controlled pressure field, and calculate the pressure parameters, the target value of the indentation depth and the direction of action of each point in combination with the material data.

[0069] The feature analysis unit is used to predict the pressure and deformation relationship of the flange end face when an initial controlled pressure field is applied, based on pressure parameters, target value of indentation depth and direction of action, and to generate pressure deformation curve features. The points of action include main pressure points and auxiliary support points.

[0070] Furthermore, the collaborative pressing module includes an end-effector manipulation unit, a constraint unit, an acquisition unit, and a curve construction unit, wherein:

[0071] The end control unit is used to control the main pressure head of the servo straightening press to move directly above the main pressure point according to the position of the main pressure point, and to control the corresponding auxiliary device to move to the corresponding auxiliary support point on the back of the high neck flange.

[0072] The constraint unit is used to apply pressure to the high neck flange through the main pressure fitting head, and increase the output force of the cooperative auxiliary device according to the pressure rise amplitude by a preset nonlinear gain coefficient to construct an axial pressure gradient field on the high neck flange.

[0073] The acquisition unit is used to acquire the main pressure sequence, main displacement sequence and auxiliary support force sequence of the main pressing head and the auxiliary device at a preset synchronization frequency.

[0074] The curve construction unit is used to generate a time-series index within the axial pressure gradient field by calculating the ratio of the auxiliary support force sequence to the main pressure sequence, and to generate a pressure deformation curve representing the flange response characteristics under the axial pressure gradient field.

[0075] Furthermore, the voltage regulation module includes a characteristic calculation unit, a deviation identification unit, a field adjustment unit, and a deformation control unit, including:

[0076] The feature calculation unit is used to calculate the instantaneous stiffness and cumulative deformation of the pressure deformation curve based on the auxiliary support force, main pressure sequence and main displacement sequence of each cooperating auxiliary device.

[0077] The deviation identification unit is used to compare the instantaneous stiffness and cumulative deformation with the corresponding pressure deformation curve characteristics in the initial controlled pressure field to determine the deviation type.

[0078] The field adjustment unit is used to calculate and adjust the force distribution ratio between the main pressure point and the auxiliary support point according to the magnitude and direction of the stiffness deviation if the deviation type is stiffness deviation.

[0079] The deformation control unit is used to dynamically truncate or extend the duration of the initial controlled pressure field if the deviation type is deformation endpoint offset. When the cumulative deformation reaches the target, the main pressure head is stopped and the pressure holding state is entered. When the pressure reaches the target but the cumulative deformation is insufficient, the current pressure is maintained and the holding time is extended until the cumulative deformation reaches the target.

[0080] Furthermore, the evaluation module includes a retesting unit, a planning update unit, and an iterative unit, including:

[0081] The retesting unit is used to acquire the morphological data of the high-neck flange end face after the initial controlled pressure field is applied, quantify its actual straightening effect, and identify the residual error exceeding the standard area and the newly deformed area in combination with the preset qualified threshold.

[0082] The planning update unit is used to perform replanning on the initial controlled pressure field of the residual error exceeding the standard region and the newly deformed region based on the quantification results, so as to obtain the updated controlled pressure field.

[0083] The iterative unit is used to repeatedly apply pressure to the high neck flange end face according to the controlled pressure field until the flatness error value of the high neck flange end face is less than the qualified threshold.

[0084] Example 2

[0085] Please see Figures 2-4 The present invention provides an embodiment of a configuration strategy for an adaptive pressure system of a servo-driven straightening press for machining high-neck flanges, which is applied to the servo-driven straightening press adaptive pressure system for machining high-neck flanges. The strategy includes:

[0086] Step S1: Collect structural features and material data of the high-neck flange, analyze the warping distribution pattern by combining the morphological data obtained by visual measurement, construct an initial controlled pressure field, and generate the corresponding pressure deformation curve features.

[0087] The specific steps of step S1 are as follows:

[0088] Step S101: Obtain the material data of the high neck flange and measure the end face of the high neck flange point by point to obtain the spatial coordinate data of each point to form the morphology data.

[0089] In this embodiment, the high-neck flange to be processed is fixed on the worktable of the servo straightening press. Material data associated with the high-neck flange's specification code is read, including but not limited to elastic modulus, yield strength, Poisson's ratio, and the flange's nominal diameter and thickness. An industrial vision camera mounted on the side of the scanner is controlled to photograph the high-neck flange fixed on the worktable, acquiring a two-dimensional image of the flange end face. An image processing algorithm identifies the pixel coordinates of the inner and outer circular contours of the high-neck flange in the image. Combined with camera calibration parameters, the position and orientation of the high-neck flange in the two-dimensional working plane are calculated as the visual positioning result. This visual positioning result guides the initial movement position of the laser displacement scanner, enabling it to quickly align with the high-neck flange area and reduce idle travel. The laser displacement scanner mounted on the gantry is then driven to move to the zero point above the flange end face, and the laser displacement scanner is controlled to move radially along the flange. The laser displacement scanner moves in a stepwise direction while simultaneously rotating at a constant speed along the circumference of the flange at each radial position. During the scanning process, the laser displacement scanner emits a measuring laser at a constant sampling frequency and receives reflected light from the flange end face. It measures and records the axial distance of each scanning sampling point on the flange end face relative to the optical center of the scanner. The polar coordinates and corresponding axial distance data of each sampling point are converted into three-dimensional spatial coordinate data in a rectangular coordinate system. After the laser displacement scanner completes the scanning of the predetermined path of the entire flange end face area, it summarizes the three-dimensional spatial coordinate data of all sampling points to form the topographic data of the high-neck flange end face. The topographic data is specifically represented as three-dimensional point cloud data, such as (Xi, Yi, Zi), where i represents any point. The sampling frequency is, for example, 500 to 1000 Hz, determined according to the flange diameter and detection accuracy.

[0090] For example, in the visual measurement stage, a circular detection algorithm based on gradient direction cumulative voting is used, with a resolution of 2448. Taking a 2048-pixel grayscale image of a flange end face as an example, the algorithm input is a grayscale image after Gaussian filtering and edge enhancement, where the grayscale value of each pixel is between 0 and 255. An edge detection operator is used to traverse the image, extracting all pixels with a grayscale variation exceeding 50 as candidate edge points, and recording the position of each edge point, such as coordinates (1200, 1000), and its local grayscale gradient direction, such as an angle of 30 degrees with the horizontal direction. Next, the radius search range of the circle to be detected is set, assuming the inner... The outer circle radius is 200 to 400 pixels, and the inner circle radius is 800 to 1200 pixels. For each candidate edge point, the algorithm traverses the search range along its gradient direction and the opposite direction, based on the currently assumed radius value, with a step size of 10 pixels, to calculate the corresponding possible center positions. These center positions are then voted on in an accumulator array. For example, for an edge point with coordinates (1200, 1000) and a gradient direction of 30 degrees, when the radius is 300 pixels, the calculated center coordinates are approximately (1200-300). cos30 1000-300 sin30 That is, (940, 850), (1200+300) cos30 1000+300 sin30 The values ​​at (1460, 1150) are incremented by 1. After traversing all edge points and all radii, the positions in the accumulator whose counts exceed the preset threshold are identified as candidate circle centers. The preset threshold is set according to the size of the accumulator array and the completeness of the circular outline. Assuming that the total number of edge points is 15000 and a complete inner or outer circle outline consists of 3000 edge points, the threshold is set to 5000 to ensure that the detected circle centers have sufficient edge support.

[0091] Step S102: Based on the topography data, calculate the ideal reference plane by least squares plane fitting, and calculate the flatness error distribution map by point-by-point deviation, and identify the warping distribution pattern based on its spatial gradient change.

[0092] In this embodiment, topographic data is used as input for flatness analysis and warping pattern recognition. All measurement points (Xi, Yi, Zi) in the topographic data are taken as known quantities, where i represents any point. A plane equation is constructed, for example, Zi = aXi + bYi + c, where a, b, and c are the coefficients of the plane equation. This plane equation is an ideal equation; the actual measured point's Zi is usually not equal to the calculated value of the plane equation. Subtracting the two yields the deviation. The coefficients a, b, and c of the plane equation are solved using the least squares method to minimize the sum of squares of the differences between the measured point value Zi and aXi + bYi + c. The resulting Zi is the ideal reference plane for the flange end face. For each measurement point in the topographic data, the difference between its actual coordinates and the corresponding coordinates on the ideal reference plane is calculated to obtain the flatness error. Positive values ​​indicate convexity, and negative values ​​indicate concavity. All points are traversed to generate a set of flatness error values ​​corresponding to the measurement point positions in the topographic data, i.e., a flatness error distribution map. The spatial variation characteristics of the error distribution map are analyzed to identify warping patterns. The gradient rate of change of flatness error in the radial and circumferential directions of the flange is calculated. The warping distribution pattern is determined based on the radial and circumferential gradient rates. The radial gradient rate of change represents the amount of change along the radial direction of the flange, which describes how quickly the deviation changes with the radius. The circumferential gradient rate of change represents the amount of change along the tangent direction of the flange circumference, which describes how quickly the deviation changes with angular rotation. Warping distribution patterns include, but are not limited to, overall bending, local concavity, and wavy warping. By combining the analysis of specific geometric dimensions and deviation values, abstract morphological data is transformed into clear warping pattern classification results, improving the accuracy of straightening planning.

[0093] For example, suppose when processing a flange with a diameter of 2200mm that has deformed after rolling, the input is the three-dimensional coordinates of about 1000 measurement points on the flange end face. Through least squares plane fitting, an ideal reference plane is obtained, for example, Zi=0.001Xi-0.0005Yi+10.2. After calculating the deviation of all measurement points, it may be found that the deviation value shows a systematic change along one diameter direction of the flange. The average deviation on one side is +0.8mm, which is represented by a bulge, and the average deviation on the other side is -0.6mm, which is represented by a depression. The gradient change is continuous and gentle, and the gradient change in the circumferential direction is very small. This deviation distribution pattern is identified as overall bending or dish-shaped warping. If the deviation value changes abruptly only at a few adjacent points, for example, the deviation reaches -1.5mm in a 100mm diameter area, while the deviation in the surrounding area is within ±0.2mm, it means that the gradient change rate changes drastically at the boundary, and is identified as a local depression.

[0094] exist Figure 2In the middle, the left image shows overall bending, with the ellipse representing the flange end face. The small upward arrow on the left side of the ellipse indicates +0.03mm, and the small downward arrow on the other side indicates -0.05mm. The gentle curve in the ellipse represents a continuous gradient change. The right image shows local concavity, showing that only a small area on the flange is significantly concave, while the vast majority of the remaining area is basically flat. The circle represents the flange end face, and the smallest dashed circle in the circle represents a local concavity, defining a small area on the flange end face with a pit. The thick downward arrow indicates -0.1mm, and the largest dashed circle indicates that the surrounding deviation is within ±0.02mm, showing that apart from the pitted area, the flatness error of most other areas of the flange is within the extremely small range of ±0.2mm.

[0095] Step S103: Select the application point of the high neck flange according to the warping distribution pattern, determine the main pressure point and auxiliary support point required to construct the initial controlled pressure field, and calculate the pressure parameters, target value of the indentation depth and the direction of action of each point in combination with the material data.

[0096] In this embodiment, if the warping pattern is identified as overall bending, based on the characteristic of continuous gradient direction change in the flatness error distribution map, a main pressure point is selected at the center of the protruding area on the flange end face. Simultaneously, an auxiliary support point is selected directly below the center of the protruding area on the flange back side along the same diameter direction as the main pressure point. To prevent reverse warping of the flange edge area under the action of a single main pressure point, two additional auxiliary limiting points are selected on the flange back side at symmetrical positions on both sides of the main pressure point along the diameter direction, at a preset distance from the flange edge. The action direction of the two auxiliary limiting points is the same as that of the auxiliary support points, both pressing upwards against the flange back side to provide local constraint and limit the passive upward warping of the flange edge. The action direction of the main pressure point is vertical. The downward direction points to the flange end face. The auxiliary support points act vertically upwards, pressing against the back of the flange. Combining the material's elastic modulus, thickness, and the measured deviation at the main pressure point, the cantilever beam deflection calculation formula is used to inversely calculate the deflection. The specific calculation process of the cantilever beam deflection formula is as follows: multiply the elastic modulus by the moment of inertia of the section to obtain a comprehensive parameter characterizing the overall bending stiffness of the structure; divide this product with the deflection value by a coefficient proportional to the cube of the cantilever beam length of the servo straightening press to obtain the theoretical elastic restoring force; multiply this by a safety factor to obtain the initial pressure parameter of the main pressure point. The target value for the indentation depth is set to the measured positive deviation value at this point. The pressure parameters of the two auxiliary support points are set identically, and their values ​​are based on the flange diameter and the pressure parameters of the main pressure point. The system is configured to provide stable support and prevent the flange from tilting or twisting under pressure. If the warping pattern is identified as a local depression, two or three main pressure points are symmetrically selected at the edge of the depression area, with the direction of action vertically downwards. On the back of the flange, an auxiliary support point is selected directly below the geometric center enclosed by the lines connecting the main pressure points, with the direction of action vertically upwards. For each main pressure point, the target value of the indentation depth is calculated based on the overall morphology of the depression, using the amount of pressure required to allow surrounding material to flow towards the center and fill the depression. Combining the yield strength, depression area, and amount of pressure, the unit area pressure required for plastic forming is estimated using the formula. The specific calculation process is as follows: based on the yield strength of the high-neck flange, combined with the plasticity corresponding to the amount of pressure... The degree of strain is used to determine the approximate flow stress value of the material under this deformation condition. The flow stress value is multiplied by the equivalent bearing area of ​​the pit region to obtain the basic theoretical pressure required to cause plastic deformation in this region. Based on the force flow dispersion effect caused by the bending surface of the flange and the influence of mold contact friction, the basic theoretical pressure is multiplied by a forming resistance coefficient greater than 1 to obtain the initial pressure parameter of the main pressure point. The pressure parameter of the back auxiliary support point is set to 60% to 80% of the sum of the pressure parameters of all main pressure points to provide a concentrated reverse support force field to guide the material to flow upward and fill the depression. The deflection value is defined as the flatness deviation value of the measurement point. The preset distance is set according to the thickness and edge stiffness of the flange, and is assumed to be 1 of the flange thickness.The auxiliary limiting point should be 5 to 3 times the flange's radial width, or 5% to 10% of the flange's radial width, to ensure that it avoids stress concentration areas at the edge, while also preventing it from being too far from the edge and losing its restraint on reverse warping.

[0097] Step S104: Based on the pressure parameters, the target value of the indentation depth and the direction of action, predict the pressure and deformation relationship of the flange end face when the initial controlled pressure field is applied, and generate the pressure deformation curve characteristics. The points of action include the main pressure point and the auxiliary support point.

[0098] The specific steps of step S104 are as follows:

[0099] Step S1041: Based on the pressure parameters, the target value of the indentation depth and the direction of action, simulate the overall mechanical response of the high-neck flange end face under the action of the initial controlled pressure field, obtain the pressure reading sequence and the displacement reading sequence, and construct the pressure deformation data sequence.

[0100] In this embodiment, the coordinates of each point of application, pressure parameters, target indentation depth, and direction of application are used as inputs. Based on the nominal diameter and thickness of the high-neck flange, a three-dimensional geometric model is established in the simulation environment. This model is discretized using three-dimensional solid elements, and the mesh is locally refined in areas with large stress gradients. Reference points for applying loads are created at corresponding positions on the three-dimensional geometric model based on the coordinates of the points of application, and these reference points are kinematically coupled to the flange surface. Linear elastic material properties are assigned to the three-dimensional geometric model based on the elastic modulus, yield strength, and Poisson's ratio. The elastic stage follows Hooke's law, and the plastic stage adopts the Mizes yield criterion. A concentrated normal force load, starting from zero and increasing at a constant rate to the pressure parameter value, is applied at the reference point of the main pressure point according to the direction of application. This is applied to the auxiliary support... Normal support constraints are applied to the reference points of the support points. Fixed constraints are set in the assumed area in the three-dimensional geometric model that is in contact with the press table. Through linear static finite element calculation, the support reaction force data and displacement data along the direction of action of the reference points of the main pressure points are extracted during the load increase process. The number of load steps is divided into equidistant intervals of 10% of the target pressure, for example, 10-20 load steps, which form pressure reading sequences and displacement reading sequences respectively. The sequences aligned on the load steps are paired to form a pressure deformation data sequence. The boundary conditions of the three-dimensional geometric model are set to apply fixed constraints in the area in the flange model that is in contact with the press table to simulate the actual clamping state. At the coordinates of each point of action, the loading point is connected to the flange solid surface through multi-point constraint coupling to achieve accurate load transfer.

[0101] For example, consider a steel high-neck flange with a nominal diameter of 2.2m and a thickness of 80mm. Its warping mode is identified as overall bending. Based on this, the planning unit selects a primary pressure point and two symmetrical auxiliary support points. Input data includes the primary pressure point coordinates (0, 0), initial pressure parameter 240kN, target indentation depth 1.5mm, coordinates of the two auxiliary support points and their respective 120kN support force parameters, elastic modulus 210GPa, and yield strength 345MPa. The simulation environment establishes a flange model based on the flange's diameter and thickness, and creates loading points on the model corresponding to the coordinates of the primary pressure point and auxiliary support points. The solution is set to 10 load steps. In the first to tenth load steps, the concentrated force on the primary pressure point is linearly increased from 0kN to 240kN, while the support forces of the two auxiliary support points are simultaneously increased from 0kN to 120kN. In each load step, the finite element solver calculates the stress, strain, and displacement field of the entire flange model under the current load based on the material's elastic modulus and structural geometry. After solving, it extracts the support reaction force data of the main pressure point loading point under 10 load steps, forming a pressure reading sequence [24, 48, 72, 82, 101, 124, 139, 168, 199, 240], in kN. At the same time, it extracts the displacement data of that point along the pressure direction, forming a displacement reading sequence [0.15, 0.31, 0.48, 0.56, 0.73, 0.88, 1.02, 1.22, 1.36, 1.52], in mm. These two sequences strictly correspond to each other at each load step index, together forming a pressure deformation data sequence. For example, the second data pair represents the expected displacement of the flange at that point when the main pressure is applied to the force value corresponding to the second load step.

[0102] Step S1042: Extract the first stiffness value of the high neck flange end face by differential calculation of the pressure deformation data sequence, identify the starting point of the elastic-plastic transition, and use the pressure value and deformation value of the starting point as the yield threshold group.

[0103] In this embodiment, the instantaneous stiffness is calculated based on the pressure deformation data sequence. Specifically, starting from the second data point, for each data point, the ratio of the pressure increment to the displacement increment between it and the previous point is calculated, i.e., the instantaneous stiffness, thus obtaining an instantaneous stiffness sequence corresponding to the data points. The changing trend of the instantaneous stiffness sequence is observed. In the initial stage of loading, the instantaneous stiffness fluctuates within a small range, and its average value is recorded as the first stiffness value, reflecting the macroscopic stiffness of the flange in the elastic stage. As the load increases, when the instantaneous stiffness value satisfies a decreasing trend, the instantaneous stiffness value satisfies the decreasing trend. The decrease is greater than the decrease threshold; the decrease trend is specifically reflected by the decrease threshold, which indicates the direction of decrease and does not represent specific parameters or values. The decrease magnitude represents the difference between the instantaneous stiffness before and after the decrease. The decrease threshold is set according to the yield strength. For example, when the yield strength is less than or equal to 345MPa, the decrease threshold is 30%; when 345MPa < yield strength ≤ 460MPa, the decrease threshold is 20%. This decrease starting point is marked as the starting point of the elastic-plastic transition. The pressure value and displacement value corresponding to this starting point in the original pressure deformation data sequence are extracted as the yield threshold group.

[0104] Step S1043: Obtain the statistical distribution of yield threshold groups for flanges of the same specification from the straightening database, correct the yield threshold groups, and generate a yield threshold interval that includes the center expected value and tolerance range. The straightening database is set according to the successful straightening data of flanges of the same specification.

[0105] In this embodiment, the yield threshold set of the high-neck flange is used as the input value to be corrected. Based on the specification information of the high-neck flange, all matching historical yield pressure and yield displacement values ​​are retrieved from the straightening database. The corresponding statistical characteristics are calculated, and the average and standard deviation of the historical yield pressure and historical yield displacement values ​​are calculated to correct the yield threshold set. The pressure values ​​in the original pressure deformation data sequence are added to the average of the historical yield pressure values, and then divided by two to obtain the corrected yield pressure center value. Using the same calculation method, the simulated yield displacement value is combined with the average of the historical displacement values ​​to obtain the corrected yield displacement center value. Based on the historical yield... The standard deviations of pressure values ​​and historical yield displacement values ​​are used to generate tolerance ranges. For example, using the corrected yield pressure center value as a benchmark, twice the historical pressure standard deviation is subtracted downwards and twice the historical pressure standard deviation is added upwards to determine the allowable upper and lower limits of yield pressure. Using the same calculation method, using the corrected yield displacement center value as a benchmark and combining it with the historical displacement standard deviation, the allowable upper and lower limits of yield displacement are determined, generating a yield threshold interval containing a set of corrected center expected values ​​and tolerance ranges. The nominal diameter, thickness, and material grade of the flange are used as indexes to store a set of yield threshold data for flanges of the same specification that have been successfully straightened in the past, resulting in a straightening database.

[0106] Step S1044: Integrate the first stiffness value, yield threshold range and deformation target, and encapsulate them into a pressure deformation curve feature, wherein the deformation target is set according to the indentation depth target value.

[0107] In this embodiment, the first stiffness value, yield threshold range, and deformation target are integrated and encapsulated into a structured data object, namely the pressure deformation curve feature. This object defines the key stages and parameters of the ideal straightening process. The elastic stage uses the first stiffness value as the slope guide for this stage. The elastic-plastic transition zone defines the target window using the yield threshold range. The pressure deformation curve feature should enter the plastic platform within the target window. The plastic forming segment uses the indentation depth target value of the main pressure point as the deformation target, which represents the main displacement criterion for process termination. The first stiffness value guides the initial pressurization rate, the yield threshold range provides a threshold window for monitoring material state changes, and the deformation target provides a quantitative target for the final forming, thereby improving the accuracy and stability of the entire straightening process.

[0108] Step S2: Drive the end control unit of the servo straightening press to apply pressure to the high neck flange according to the initial controlled pressure field, and apply auxiliary support force at the corresponding point on the back of the high neck flange, and collect the corresponding pressure value and displacement value to construct the pressure deformation curve.

[0109] The specific steps of step S2 are as follows:

[0110] Step S201: Based on the position of the main pressure point, control the main pressure head of the servo straightening press to move directly above the main pressure point, and control the corresponding auxiliary device to move to the corresponding auxiliary support point on the back of the high neck flange.

[0111] In this embodiment, the three-dimensional coordinates of the main pressure point in the initial controlled pressure field under the coordinate system of the high-neck flange end face are extracted and mapped to the global machine tool coordinate system of the servo straightening press to obtain the target horizontal positioning coordinates of the main pressure head under the global machine tool coordinate system. The horizontal and vertical servo drive motors of the main pressure head are controlled to move the pressure sensor and the main pressure head assembly to the target horizontal positioning coordinate position. The vertical servo drive motor of the main pressure head is controlled to drive it down to a safe height position above the theoretical end face of the flange, for example, 50 to 100 mm, to complete the pre-positioning of the main pressure head. For each determined auxiliary support point, its coordinates under the coordinate system of the flange back are read. After the same coordinate system transformation, the target positioning coordinates of the cooperative auxiliary device on the global machine tool coordinate system are obtained. The horizontal two-dimensional servo slides of each cooperative auxiliary device installed under the worktable are controlled. The platform aligns the center of its support rod with the respective target coordinates (including the target horizontal positioning coordinates and the target positioning coordinates). The vertical servo electric cylinder of the auxiliary device is controlled to drive its support rod to rise at a speed of 0.1 mm / s. When the pressure sensor of the support rod detects a contact force greater than or equal to 50 N, it determines that it has reached the pre-contact position on the back of the flange and stops rising, completing the pre-positioning of the auxiliary device. In the machining scenario of high neck flange straightening, the precise spatial positioning of the force application tool is achieved through coordinate system mapping and independent control of multi-axis servo drive. This avoids the distortion of the theoretical optimal pressure field caused by positioning errors during actual construction. By decomposing the positioning process into two stages, horizontal movement and vertical pre-positioning, and setting a safety height and pre-contact sensing, the risk of collision between the instrument and the flange is reduced, improving the safety and reliability of the system operation.

[0112] Step S202: Apply pressure to the high neck flange through the main pressure fitting head, and increase the output force of the auxiliary device according to the pressure rise amplitude and the preset nonlinear gain coefficient to build an axial pressure gradient field on the high neck flange.

[0113] The specific steps of step S202 are as follows:

[0114] Step S2021: Based on the target pressure value and pressure application rate in the initial controlled pressure field, control the main pressure fitting head to move along the flange axis and read the pressure sensor data to obtain the main pressure that increases over time.

[0115] In this embodiment, based on the target pressure value of the main pressure point in the initial controlled pressure field and the preset constant pressure application rate, the vertical servo motor of the main pressure fitting head is controlled to drive the main pressure fitting head to press down uniformly onto the flange end face at a constant pressure application rate. At the instant the main pressure fitting head contacts the flange end face and begins to apply pressure, the measured value of the pressure sensor inside the main pressure fitting head is read using a fixed synchronous frequency, such as 500Hz. As the main pressure fitting head continues to press down, the main pressure increases monotonically from zero with time. Timestamps and corresponding main pressures are continuously recorded to form a main pressure data stream that increases with time. The constant pressure application rate is determined comprehensively based on the flange thickness and the dynamic response capability and control process of the servo system. For example, it is 1 to 2 mm / s for a thickness less than or equal to 80 mm and 0.5 to 1 mm / s for a thickness less than or equal to 150 mm.

[0116] Step S2022: Calculate the target output force corresponding to the cooperative auxiliary device based on the main pressure and the preset nonlinear gain coefficient.

[0117] In this embodiment, the main pressure is used as input to obtain the corresponding nonlinear gain coefficient for each auxiliary device. The nonlinear gain coefficient is calculated through finite element simulation based on the flange warping mode, structural stiffness distribution, and straightening process stage. The nonlinear gain coefficient is tied to the layout of the application points, defining the dynamic proportional relationship between the target output force of each auxiliary device and the main pressure when the main pressure is in different pressure ranges. Multiplying the nonlinear gain coefficient by the main pressure yields the target output force that each auxiliary device should output. For example, in an initial controlled pressure field containing two symmetrical auxiliary support points, when the main pressure is in the range of 0 to 200 kN, the nonlinear gain coefficients of both auxiliary devices are 0.4, meaning their respective target output forces are 0.4. When the main pressure enters the range of 200kN to 400kN, the nonlinear gain coefficient is adjusted to 0.6, and the target output force becomes 0.6. When the main pressure exceeds 400kN, the nonlinear gain coefficient drops to 0.3, and the target output force becomes 0.3. The main pressure is set by a nonlinear gain coefficient so that the target output force can be matched with the main pressure. In the elastic stage, a moderate target output force is used to stabilize the workpiece. In the main plastic stage, a higher target output force is used to provide sufficient constraint and guide the effective flow of material. In the finishing stage, the target output force is reduced to avoid over-hardening or reverse warping.

[0118] Step S2023: Feedback control is performed on the pressure controller of the auxiliary device according to the target output force, driving it to output real-time auxiliary support force to form an axial pressure gradient field in the local pressure area of ​​the high neck flange.

[0119] In this embodiment, the auxiliary support force of each cooperating auxiliary is sent as a setpoint to the independent pressure controller of the corresponding cooperating auxiliary. Each cooperating auxiliary's pressure controller uses a fixed synchronization frequency to read the measured value from its built-in pressure sensor. The pressure controller continuously compares the deviation between the auxiliary support force and the measured value. Based on this deviation, the pressure controller runs a PID control algorithm to calculate and output a control signal, adjusting the current or valve position of the cooperating auxiliary's servo electric cylinder, thereby dynamically adjusting its output force and driving the measured value to track changes in the auxiliary support force. Through the closed-loop force control of all cooperating auxiliary devices and the main pressure fitting head, a stable spatial force distribution, i.e., an axial pressure gradient field, is constructed in the local pressure area of ​​the flange. It should be noted that the controller operates at a standard position... The fixed-mode digital PID control algorithm uses PID gain parameters such as proportional gain of 5-10, integral gain of 0.1-0.5, and derivative gain of 0.05-0.1. It calculates the real-time deviation between the target output force and the measured force, and generates a control signal by linearly combining the proportional, integral, and derivative operations on this deviation. The proportional term provides a fast response proportional to the deviation, ensuring timely tracking. The integral term accumulates historical deviations to eliminate steady-state errors, ensuring long-term accuracy of the force value. The derivative term predicts the trend of deviation changes, suppresses overshoot and oscillation, and enhances system stability. In pressure servo control, it can handle complex disturbances such as system friction, material creep, and load stiffness changes. By adjusting the three gain parameters, it achieves an optimal balance between response speed, control accuracy, and stability.

[0120] exist Figure 3 In the diagram, the rectangle represents the cross-section of the high neck flange, with the top and bottom edges representing the end faces of the high neck flange. The downward thick arrow indicates the main pressure, the upward thick arrow indicates the auxiliary support force, and the double-headed arrow indicates the thickness of the high neck flange.

[0121] Step S203: Collect the main pressure sequence, main displacement sequence, and auxiliary support force sequence of the main press head and the auxiliary device at a preset synchronization frequency.

[0122] In this embodiment, during the process of the main pressure fitting head applying pressure to the high neck flange and each cooperating auxiliary device synchronously providing auxiliary support force, data acquisition of all relevant sensors is triggered at a fixed synchronization frequency, such as 1000 Hz. The following three sets of data are read and recorded through an analog-to-digital converter: the measured value of the main pressure is obtained from the pressure sensor integrated in the main pressure fitting head; the measured value of the main displacement is obtained from the magnetic scale displacement sensor integrated in the main pressure fitting head; and the measured value of the auxiliary support force is obtained from the pressure sensor integrated in each cooperating auxiliary device. Among them, all sensor readings obtained by each synchronous trigger are assigned the same timestamp. The measured values ​​of the main pressure, the main displacement, and each auxiliary support force with the same timestamp are arranged to form a time-aligned main pressure sequence, main displacement sequence, and multiple auxiliary support force sequences.

[0123] Step S204: Generate a time series index in the axial pressure gradient field by calculating the ratio of the auxiliary support force sequence to the main pressure sequence, and generate a pressure deformation curve representing the flange response characteristics under the axial pressure gradient field.

[0124] In this embodiment, the sum of all auxiliary support forces at each sampling time point is calculated to obtain the total auxiliary support force at that time. The total auxiliary support force at that time is then divided by the measured value of the main pressure at that time to obtain the instantaneous pressure ratio. This calculation is repeated for all sampling time points to generate a pressure ratio time series index sequence corresponding to the time series. This sequence represents the dynamic relationship between the relative strength of the support force field formed by the auxiliary devices and the main pressure applied by the main pressure head during the straightening process, reflecting the internal equilibrium state of the axial pressure gradient field. The measured value sequence of the main displacement is used as the abscissa, and the... Using the measured sequence of main pressure values ​​as the vertical axis, a pressure deformation curve is generated that includes force deformation relationship and real-time pressure field distribution information, and is represented as the flange response characteristics under the axial pressure gradient field. The pressure ratio time series index sequence is embedded into the corresponding data points of the pressure deformation curve. The pressure deformation curve generated in this way contains not only the correspondence between main pressure and main displacement at each data point, but also the instantaneous pressure ratio index that represents the overall equilibrium state of the current axial pressure gradient field. This allows the pressure deformation curve to reflect the mechanical response characteristics of the flange under the pressure field jointly constructed by the main pressure and the auxiliary support force.

[0125] For example, during a straightening process, the input main pressure sequence shows that the pressure rises steadily from 0 kN to 300 kN, and the input two auxiliary support force sequences rise from 0 kN to 90 kN respectively. The calculated pressure ratio time series index sequence fluctuates stably around 0.6 = (90 + 90) / 300, indicating that the pressure gradient field is in a stable equilibrium state. The corresponding pressure deformation curve rises smoothly and is considered a normal response. If the pressure ratio time series index drops from 0.6 to 0.4 in a certain stage, even if the main pressure curve is still rising, it indicates that an auxiliary support force has unexpectedly decreased, causing the pressure gradient field to become unbalanced. At this time, the pressure deformation curve warning process is abnormal.

[0126] Step S3: During the pressure application process, by comparing the characteristics of the pressure deformation curve with the pressure deformation curve, the pressure field superposition, pressure holding time truncation, and pressure parameter adjustment operations are dynamically executed.

[0127] The specific steps of step S3 are as follows:

[0128] Step S301: Calculate the instantaneous stiffness and cumulative deformation of the pressure deformation curve based on the auxiliary support force, main pressure sequence, and main displacement sequence of each auxiliary device.

[0129] In this embodiment, a sliding data window containing multiple sampling points is set, such as the most recent 5 points. Based on the main pressure sequence and the main displacement sequence, the sum of all measured auxiliary support forces within the sliding data window is calculated to obtain the instantaneous total auxiliary support force. This is then added to the main pressure at the same moment to obtain the comprehensive force value characterizing the total applied force state. Based on the ratio of this value to the increment of the main displacement, it is used as the instantaneous stiffness value at the current moment. This ratio calculation is repeated when each new sampling point arrives, thereby generating an instantaneous stiffness value sequence that is updated synchronously with the time series, providing a basis for calculating the cumulative stiffness. The variable, taking the moment when a stable contact force is established as the reference point, uses the principal displacement at that moment as the initial reference value. The difference between the latest principal displacement and this initial reference value is used as an approximate index of the amount of plastic deformation generated since the start of pressurization, namely the cumulative deformation. The instantaneous stiffness value reflects the flange material's ability to resist further deformation under the current stress state. Its changing trend is a key signal for identifying the material's transition from the elastic stage to the plastic yielding stage. The cumulative deformation quantifies the amount of plastic straightening work completed, realizing the digital real-time perception of the core physical state of the straightening process.

[0130] Step S302: Compare the instantaneous stiffness and cumulative deformation with the corresponding pressure deformation curve characteristics in the initial controlled pressure field to determine the type of deviation.

[0131] In this embodiment, the pressure deformation curve feature is used as a reference benchmark. The instantaneous stiffness is compared with the first stiffness value in the pressure deformation curve feature to determine whether the deviation exceeds the allowable range of elastic stiffness. The current principal pressure and principal displacement are used as a set of coordinates and compared with the yield threshold range in the pressure deformation curve feature to determine whether the coordinate point has entered or exceeded the range. The cumulative deformation is compared with the deformation target. Based on the comparison result, a comprehensive logic is executed to determine the deviation type, including stiffness deviation and deformation endpoint offset. In stiffness deviation, if the instantaneous stiffness value is significantly lower than the first stiffness value and the current force-displacement coordinate has not yet entered the yield threshold range, it is determined to be a stiffness weakening deviation, indicating that the material may soften prematurely or have local defects. If the current force-displacement coordinate has significantly exceeded the yield threshold range, it is determined to be a stiffness weakening deviation. If the cumulative deformation is still much smaller than the target at the upper boundary, it is judged as a strengthening deviation, indicating that the material resistance is higher than expected. In the deformation endpoint offset, if the measured value of the main pressure has reached the expected level but the cumulative deformation has not reached the target, it is judged as a deformation lag deviation. If the cumulative deformation has reached the target but the pressure is still at a very low level, it is judged as a deformation overspeed deviation. The allowable range of elastic stiffness is obtained based on the statistical data of the historical straightening process of flanges of the same specification in the straightening database. By analyzing the average value and standard deviation of the stiffness in the elastic stage in the historical data, combined with the safety factor determined by experience, the allowable range of elastic stiffness is adjusted, such as tightening or widening. Stiffness weakening deviation indicates that there are original microcracks or loose structure in this area, and more careful loading is required. Strengthening deviation indicates that the strength of the material batch is too high, and the loading strategy needs to be adjusted.

[0132] Step S303: If the deviation type is stiffness deviation, calculate and adjust the force distribution ratio between the main pressure point and the auxiliary support point according to the magnitude and direction of the stiffness deviation.

[0133] The specific steps of step S303 are as follows:

[0134] Step S3031: Based on the stiffness deviation and its direction, and combined with the real-time pressure of the main pressure point and the auxiliary device, calculate the pressure ratio between each point of action in the initial controlled pressure field, compare it with the preset pressure ratio, and identify the auxiliary device with the greatest influence of stiffness deviation.

[0135] The specific steps of step S3031 are as follows:

[0136] Step S30311: Calculate the pressure ratio based on the current force values ​​of the main pressure point and the auxiliary support point to obtain a pressure ratio set representing the pressure distribution state inside the initial controlled pressure field.

[0137] In this embodiment, the pressure sensor reading of the main pressure head at the current moment is obtained as the current main pressure, and the readings of the pressure sensors of all auxiliary auxiliary devices are obtained as the current auxiliary support force of the auxiliary support point. The current auxiliary support force is divided by the current main pressure to calculate the pressure ratio value of the auxiliary support point, that is, the ratio of the auxiliary support force to the main pressure. The pressure ratio values ​​calculated for all auxiliary support points are summarized to form a pressure ratio set, which represents the relative force distribution state of each support point inside the controlled pressure field at the current moment.

[0138] For example, in a system with two auxiliary support devices, assuming the measured value of the main pressure is 300 kN, the measured value of the auxiliary support force of the first auxiliary support device is 90 kN, and the second is 60 kN, the pressure ratio of the first auxiliary support point is calculated as 90 divided by 300, which equals 0.3, and the pressure ratio of the second auxiliary support point is calculated as 60 divided by 300, which equals 0.2. The resulting current pressure ratio set is {0.3, 0.2}. The pressure ratio set reflects the share of the support force provided by the two auxiliary support points in the pressure field at this moment relative to the main pressure. The difference between 0.3 and 0.2 indicates that the distribution of support force is uneven.

[0139] Step S30312: Compare the ratio in the pressure ratio set with the pressure ratio target value of the corresponding auxiliary device preset at the main pressure point, and calculate the pressure ratio deviation value of the auxiliary device.

[0140] In this embodiment, a preset pressure ratio target value set is defined, which defines the ideal proportional relationship between the auxiliary support force and the main pressure of each auxiliary device. Each value in the pressure ratio set is compared sequentially with the target value at the corresponding position in the pressure ratio target value set. For each auxiliary device, its pressure ratio value is calculated by subtracting the corresponding pressure ratio target value. The difference is the pressure ratio deviation value of that auxiliary device. A positive value indicates that the actual auxiliary support force share at that point exceeds the preset share, while a negative value indicates insufficient support. For example, assuming the pressure ratio target value set is {0.3, 0.3}, meaning that both auxiliary support points are expected to provide support force equivalent to 30% of the main pressure, the pressure ratio set {0.3, 0.2} is compared with the target set {0.3, 0.3}. For the first auxiliary device, the deviation value is 0. 0.3 minus 0.3 equals 0. For the second auxiliary device, the deviation value is 0.2 minus 0.3 equals -0.1. The calculated pressure ratio deviation value set is {0, -0.1}. The deviation of -0.1 indicates that the support contribution of this point is 10 percentage points weaker than expected. It should be noted that in the process of straightening high neck flanges, the absolute force value of a single point is not enough to determine whether the overall pressure field is balanced and in line with the design intent. The absolute force value is converted into a relative ratio relationship, thereby extracting the key feature information reflecting the internal balance state of the pressure field. The real-time ratio is subtracted from the preset target ratio to generate the pressure ratio deviation value, which realizes the accurate quantification of the pressure field imbalance state and identifies one or several auxiliary support points that deviate from the ideal working condition. For example, excessive support at one point may cause local pressure concentration, or insufficient support may cause flange twisting.

[0141] Step S30313: Multiply the pressure ratio deviation value by the preset influence coefficient that reflects the corresponding spatial location on the deformation stiffness at the main pressure point to obtain the influence index.

[0142] In this embodiment, a positive influence coefficient is set. This influence coefficient is determined by measuring and recording the precise spatial distance and relative angle between each auxiliary support point and the main pressure point. Using a standard test flange and standard applied pressure, under the condition that only a single auxiliary support point is working while the other points are unloaded, the change in stiffness at the main pressure point is measured and recorded. The changes measured at all auxiliary support points are normalized, and all changes are compared. The largest change is selected as the benchmark value. The change measured at each auxiliary support point is divided by this benchmark value, and the quotient is the normalized influence coefficient of that auxiliary support point. Its physical meaning lies in quantifying the influence of the auxiliary support force change on the overall equivalent deformation stiffness at the main pressure point. Generally speaking, the distance from the main pressure point... Coordinating auxiliary devices that are closer to the pressure point or located on the main force transmission path will be assigned a larger influence coefficient. The product of the pressure ratio deviation value of each coordinating auxiliary device and its corresponding influence coefficient value is the influence index of that coordinating auxiliary device on the stiffness deviation at the current main pressure point. For example, suppose there are three coordinating auxiliary devices with pressure ratio deviation values ​​of +0.05, -0.10 and +0.02, and corresponding influence coefficients of 1.2, 0.8 and 1.0, respectively. The influence index of the first coordinating auxiliary device is calculated as 0.05 multiplied by 1.2 equals 0.06, the second is -0.10 multiplied by 0.8 equals -0.08, and the third is 0.02 multiplied by 1.0 equals 0.02. The resulting three influence index values ​​are 0.06, -0.08 and 0.02, respectively.

[0143] Step S30314: Select the coordinating assistant with the largest absolute value of the influence index and use it as the coordinating assistant with the greatest impact on stiffness deviation.

[0144] In this embodiment, the influence index values ​​of all cooperating aids are collected, the influence index value with the largest absolute value is selected, and the corresponding cooperating aid is determined. This cooperating aid is judged as the cooperating aid with the greatest impact on the stiffness deviation at the main pressure point at the current moment, indicating that its current support force state is the primary adjustable factor causing the actual stiffness to deviate from the expected characteristics. Assuming that the absolute values ​​of the three influence index values ​​0.06, -0.08, and 0.02 are 0.06, 0.08, and 0.02, respectively, the absolute value of 0.08 is the largest, corresponding to the second cooperating aid. Therefore, the second cooperating aid is judged as the cooperating aid with the greatest impact on the stiffness deviation.

[0145] Step S3032: For the most affected auxiliary device, adjust the target pressure setting without interrupting the application of the main pressure.

[0146] In this embodiment, the pressure proportional deviation value of the coordinating auxiliary device, which has the greatest impact from stiffness deviation, is multiplied by the adjustment sensitivity coefficient, and the result is inverted to obtain the adjustment amount for the target pressure setting value of the coordinating auxiliary device. The adjustment sensitivity coefficient is a positive number, for example, 50 kN / unit deviation, meaning each unit of proportional deviation corresponds to a force adjustment of 50 kN. This coefficient is used to convert the unitless proportional deviation value into a specific force adjustment amount. If the pressure proportional deviation value is negative, it indicates that the support force provided by the coordinating auxiliary device is lower than the target relative to the main pressure, i.e., the support force share is insufficient. In this case, the calculated adjustment amount is the negative pressure proportional deviation value multiplied by the adjustment sensitivity coefficient, which is then inverted to a positive number, avoiding the need to increase the size of the coordinating auxiliary device. If the target pressure setpoint has a positive pressure ratio deviation, it indicates that the support force share is too high. The adjustment amount is the pressure ratio deviation multiplied by the adjustment sensitivity coefficient. If the result is negative (inverted), the target pressure setpoint needs to be reduced. After calculating the adjustment amount, a command is sent to the pressure controller of the auxiliary device without interrupting the main pressure applied by the main pressure head. This updates the target output force setpoint maintained internally to the original setpoint plus the calculated adjustment amount. For example, assuming the auxiliary device has a pressure ratio deviation of -0.1 and an adjustment sensitivity coefficient of 100kN / unit deviation (meaning each unit of ratio deviation corresponds to a 100kN force adjustment), the calculated adjustment amount is -0.1. The value of 100 is -10kN. Since the negative deviation indicates insufficient support, the adjustment is reversed to +10kN to positively compensate for the target pressure of the auxiliary device. If the original target pressure setting of the auxiliary device was 90kN, the updated target pressure setting becomes 100kN.

[0147] Step S3033: Monitor the change trend of instantaneous stiffness of pressure deformation curve at main pressure point during adjustment. If it corrects in the expected direction, maintain the adjustment. If it is opposite to the expectation or overshoots, restore to the state before adjustment until it is corrected to the preset range.

[0148] In this embodiment, the main pressure sequence and the main displacement sequence are acquired, and the instantaneous stiffness value at each subsequent sampling moment is calculated. A fixed monitoring time window is set, for example, the window length is 100 sampling cycles of the synchronization frequency. If the synchronization frequency is 1000Hz, the window length is 100ms. All newly calculated instantaneous stiffness values ​​within the monitoring time time are observed and analyzed. The average value of the instantaneous stiffness values ​​within the monitoring time window is calculated and compared with the instantaneous stiffness value at the moment before the adjustment operation. At the same time, the closeness of the average instantaneous stiffness value to the first stiffness value in the pressure deformation curve characteristics is evaluated. If the average instantaneous stiffness value within the monitoring window is closer to the first stiffness value than the instantaneous stiffness value before the adjustment, and its trend is closer to the first stiffness value, then the adjustment operation is determined to have a positive effect. If the instantaneous stiffness is correcting in the expected direction, then the target pressure setting value change made to the auxiliary device is maintained. If the average instantaneous stiffness value in the monitoring window is further away from the first stiffness value than before the adjustment, or is close to but exceeds the first stiffness value and continues to deviate, then the adjustment is determined to be invalid or overcorrected. When it is determined to be invalid or overcorrected, the target pressure setting value of the auxiliary device is restored to the state before the adjustment. After the setting is restored, the adjustment process is repeated until the instantaneous stiffness falls within the preset allowable error range centered on the expected first stiffness value. The allowable error range is set according to the standard deviation of the statistical distribution of the yield threshold group in the historical straightening data. For example, the expected value of the yield pressure center is set to ±30kN and the expected value of the yield displacement center is set to ±0.12mm.

[0149] Step S304: If the deviation type is deformation endpoint offset, the duration of the initial controlled pressure field is dynamically truncated or extended. When the cumulative deformation reaches the target, the main pressure head is stopped and the pressure holding state is entered. When the pressure reaches the target but the cumulative deformation is insufficient, the current pressure is maintained and the holding time is extended until the cumulative deformation reaches the target.

[0150] In this embodiment, if the current deviation type is determined to be deformation endpoint offset, based on the comparison results of the current real-time monitored cumulative deformation and deformation target, and the comparison results of the main pressure and expected pressure target, two cases are handled. In the first case, when the cumulative deformation reaches or exceeds the deformation target value for the first time, regardless of whether the measured value of the main pressure has reached the expected pressure target, the servo controller of the main pressure fitting head is used to control the main pressure fitting head to stop increasing the output force, that is, to terminate the pressurization process, and control the main pressure fitting head to enter the pressure holding state. In the pressure holding state, the main pressure at that moment is... The pressure serves as the holding pressure reference value. The output force of the main pressure fitting head is maintained at the holding pressure reference value for a fixed holding time, such as five seconds, to ensure sufficient stabilization of plastic deformation. After the holding pressure is completed, the main pressure fitting head is depressurized and lifted, ending the pressurization process. In the second case, when the main pressure reaches the expected pressure target value, but the real-time cumulative deformation is still less than the deformation target value, it is determined to be deformation hysteresis. The main pressure fitting head is then controlled to stop pressurizing to avoid overload and enters the pressure holding state. The currently reached expected pressure target value is used as the holding pressure reference value for force maintenance. This is achieved by setting dynamic... A pressure holding timer is used to continuously monitor the growth of cumulative deformation. If the cumulative deformation continues to grow slowly during the pressure holding period and does not exceed the safe time limit, the pressure holding state is maintained until the cumulative deformation reaches the target value. At this point, the pressure holding ends and the pressure is released. If the pressure holding time exceeds a preset maximum safe pressure holding time limit and the cumulative deformation still does not meet the target, it is considered abnormal. The pressure holding is terminated, and the material abnormality is checked or the process parameters are adjusted. The maximum safe pressure holding time limit is, for example, 30 seconds. The growth of cumulative deformation is continuously monitored at 0.5-second intervals. If the cumulative deformation reaches the target, the pressure holding is immediately terminated. If the pressure reaches the target within 30 seconds, it is considered a process abnormality. During the straightening of high-neck flanges, due to the fluctuation of material rheological properties and the uncertainty of internal residual stress, a single pressure or displacement endpoint criterion usually cannot guarantee the accuracy and safety of the results. Deformation or pressure is used as the dominant criterion for process termination, supplemented by a pressure holding process to promote deformation stability or full development. This can prevent equipment overload when the material resistance is high, improve the adaptability to the performance fluctuations of different batches of materials, and avoid the risk of under-straightening caused by relying solely on the pressure endpoint or overload caused by relying solely on the displacement endpoint.

[0151] For example, in one straightening cycle, assuming a deformation target of 5.0 mm and an expected pressure target of 320 kN, monitoring shows that when the cumulative deformation reaches 5.0 mm, the main pressure is 300 kN. This is the first case, so pressurization is stopped, and a five-second pressure holding period is initiated with 300 kN as the baseline, after which the cycle ends. In another cycle, when the measured main pressure reaches 320 kN, the cumulative deformation is only 4.6 mm. This is the second case, so a pressure holding period is initiated with 320 kN as the baseline, and monitoring continues. When the pressure holding period reaches eight seconds, the cumulative deformation slowly increases to 5.0 mm, and the pressure holding period ends and the pressure is released.

[0152] Step S4: Obtain the morphological data of the high-neck flange after pressure is applied, and reprogram the initial controlled pressure field by evaluating the straightening effect until the flange flatness reaches the preset qualified threshold.

[0153] The specific steps of step S4 are as follows:

[0154] Step S401: Obtain the morphological data of the high neck flange end face after the initial controlled pressure field is applied, quantify its actual straightening effect, and identify the residual error exceeding the standard area and the newly formed deformation area in combination with the preset qualified threshold.

[0155] In this embodiment, after the initial controlled pressure field is applied and the main pressure head is fully lifted, the online scanning module is driven to perform the same three-dimensional topographic scan on the high-neck flange end face to obtain the actual topographic data of the flange end face after pressure application. This data is then registered and aligned with the original topographic data in the same coordinate system. After alignment, the corresponding sampling points on the flange end face are calculated. The height value of the sampling point in the topographic data after pressure application is subtracted from its height value in the original topographic data to obtain the deformation of that point. A positive value indicates that the point is compressed, and a negative value indicates relative elevation. This process is repeated by traversing all points. A deformation distribution map describing the height change caused by this round of pressure is generated. To quantify the actual straightening effect, this map is compared and analyzed with the original flatness error distribution map. For regions with positive deviation values ​​in the original flatness error distribution map, it is expected that the deformation of the corresponding point in that region should be positive after this round of pressure, and the absolute value of the deformation should be close to the original bulge height. For regions with negative deviation values ​​in the original map, it is expected that the deformation should be negative or zero. The ratio of the actual average deformation in each region to its original average deviation value is calculated and used as the straightening efficiency coefficient for that region to quantify the controlled pressure in this round. The actual effect of the force field at this location is determined by calculating a new ideal reference plane using least-squares plane fitting based on the morphological data after pressure application. This generates a new flatness error distribution map after pressure application. The absolute value of the error at each point in the new flatness error distribution map is compared with a preset acceptable threshold. The continuous spatial region formed by all points whose absolute error values ​​are still greater than the acceptable threshold is marked as a region with excessive residual error. By comparing and analyzing the deformation distribution map with the original flatness error distribution map, areas with smaller deviations in the original flatness error distribution map but significant deformations in the deformation distribution map (i.e., areas with larger absolute deformations) are identified. Areas with values ​​greater than the preset deformation anomaly threshold are identified as new deformation areas that may be induced by the current pressure application. The acceptable threshold varies with the increase of flange diameter and accuracy level, and is set using a piecewise linear mapping relationship. For example, for high-neck flanges with diameters of 1-3 meters, it is set between 0.1 mm and 0.5 mm. For every 100 mm increase in the diameter of the high-neck flange, the acceptable threshold increases by 0.01 mm. The deformation anomaly threshold is set to 20% to 50% of the acceptable threshold. If the acceptable threshold is 0.2 mm, then the deformation anomaly threshold is usually set to 0.04 mm to 0.1 mm.

[0156] Step S402: Based on the quantization results, perform reprogramming on the initial controlled pressure field of the region with excessive residual error and the region with newly formed deformation to obtain the updated controlled pressure field.

[0157] The specific steps of step S402 are as follows:

[0158] Step S4021: Analyze the error pattern of the area where the residual error exceeds the standard, increase the pressure parameter of the original point of action or add a new point of action according to the amount of error, and generate the updated point of action and pressure parameters.

[0159] In this embodiment, error morphology analysis is performed on the residual error exceeding the standard area. Based on the data in the new flatness error distribution map of the residual error exceeding the standard area after pressure application, the spatial distribution characteristics of its error values ​​are analyzed. If the error values ​​in the residual error exceeding the standard area have consistent signs, such as all positive or all negative, and the changes are gradual, presenting a regular saucer or arch shape, then it is determined to be a uniform warping shape. For this shape, the original application point is strengthened. The original main pressure point that was previously pressured in the residual error exceeding the standard area or its adjacent area is located, and the pressure parameters used in the previous round are obtained. Based on the ratio of the current average residual error of the residual error exceeding the standard area to the original average error of the area, a strengthening coefficient greater than one is calculated. This strengthening coefficient is multiplied by the pressure parameters of the previous round to obtain the updated pressure parameters for the original main pressure point in this round. The coordinates of the application point remain unchanged. If the error values ​​in the region where the residual error exceeds the standard have inconsistent signs or change drastically, exhibiting irregular waves or local abrupt changes, it is determined to be a complex distortion pattern. For this pattern, a new application point layout is adopted. The point with the largest error gradient in the region where the residual error exceeds the standard is selected as the candidate position of the new main pressure point. By analyzing the geometric center and boundary of the region where the residual error exceeds the standard, and combining the principle of avoiding being too close to the existing application points, the coordinates of one or more new main pressure points are determined. For each new main pressure point, its initial pressure parameters are calculated based on the residual error value, thickness, and yield strength at its location. New auxiliary support points are planned at the corresponding positions on the back of the flange to obtain the updated application point and pressure parameters. By first analyzing the morphological characteristics of the residual error, it is determined whether it is uniform warping or complex distortion, thus avoiding ineffective global loading and energy waste, and improving the efficiency and accuracy of iterative straightening.

[0160] Step S4022: By analyzing the deformation characteristics and spatial correlation of the newly formed deformation region, plan the combination of action points at symmetrical positions, generate a controlled pressure field for reverse compensation, and adjust the pressure parameters of adjacent action points.

[0161] In this embodiment, deformation characteristics and spatial correlation analysis are performed on each newly deformed region to obtain its deformation direction and spatial distribution pattern in the deformation distribution map. The geometric center of the newly deformed region is calculated, and one or more application points closest to this geometric center are found among all the application points in the previous round of pressure. Their spatial correlation is analyzed. If it is found that the deformation direction of the newly deformed region, such as local concavity, is opposite to the deformation direction that the nearest application point attempted to produce in the previous round of pressure, and the distance is very close, then the newly deformed region is determined to be an over-correction side effect caused by excessive pressure from adjacent application points. In this case, the pressure parameters of adjacent application points are reduced to decrease the pressure parameters of the application points determined to cause over-correction in this round, thereby reducing their impact. If the analysis finds that the newly deformed region is far away from any application point in the previous round or its deformation pattern cannot be explained by the influence of neighboring points, then it is determined that it may be a secondary torsion caused by stress redistribution. In this case, a controlled pressure field for reverse compensation is planned at the symmetrical position of the newly deformed area. That is, on the other side of the newly deformed area symmetrical about the center of the high-neck flange, a new set of main pressure points and auxiliary support points are planned. The design goal is to generate a straightening amount opposite to the current direction of the newly deformed area. By fixing the already pressurized area, reverse pressure is applied to it to offset the newly deformed area. The initial pressure parameters and target deformation are calculated for the controlled pressure field. The target deformation is usually smaller than the absolute value of the newly deformed area. The newly deformed area is determined according to the deformation distribution map and is specifically set as the height change within the newly deformed area. By analyzing the characteristics and causes of the newly deformed area, the overpressure at the adjacent point and the secondary torsion at the far end are distinguished. The source is weakened or symmetrically offset, respectively, to enhance the stability and controllability of the iterative process, ensure that the flatness can steadily converge to the qualified standard, and avoid oscillation or divergence. The direction of the deformation can be positive or negative.

[0162] Step S403: Repeatedly apply pressure to the high neck flange end face according to the controlled pressure field until the flatness error value of the high neck flange end face is less than the qualified threshold.

[0163] In this embodiment, the controlled pressure field is used as a new initial input to repeatedly position, pressurize, monitor, and adaptively adjust the high-neck flange. After each cycle, the flatness error distribution map of the high-neck flange end face is checked. The absolute error values ​​of all sampling points in the flatness error distribution map are traversed and compared with the qualified threshold one by one. If and only if the absolute error values ​​of all sampling points are less than the qualified threshold, it is determined that the flatness of the entire high-neck flange end face has met the process requirements. The replanning and pressurization cycle is stopped, the main pressing head of the servo straightening press and all auxiliary devices are controlled to return to the safe position, and a straightening completion signal is sent to the upper control system or operator, and the process is terminated. Due to the nonlinearity of the plastic deformation of the high-neck flange material and the complexity of residual stress release, it is difficult to achieve the flatness requirements with a single pressurization. Through continuous optimization of cyclic pressurization, the dependence on the operator's experience and real-time judgment is reduced, ensuring that the high-neck flange can finally meet the flatness tolerance requirements.

[0164] In addition, the parts of the technical solutions provided in the embodiments of this application that are consistent with the implementation principles of the corresponding technical solutions in the prior art have not been described in detail, so as to avoid excessive elaboration.

[0165] The embodiments of the present invention have been described above with reference to the accompanying drawings. However, the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of the present invention without departing from the spirit and scope of the claims. All of these forms are within the protection scope of the present invention.

Claims

1. An adaptive pressure system for a servo-driven straightening press used in high-neck flange machining, characterized in that, The system includes: The online scanning module is used to collect structural features and material data of high-neck flanges, analyze the warping distribution pattern by combining the morphological data obtained by visual measurement, construct an initial controlled pressure field, and generate the corresponding pressure deformation curve features. The collaborative pressing module is used to drive the end control unit of the servo straightening press to apply pressure to the high neck flange according to the initial controlled pressure field, and apply auxiliary support force at the corresponding point on the back of the high neck flange, and collect the corresponding pressure value and displacement value to construct the pressure deformation curve. The pressure regulating module is used to dynamically perform pressure field superposition, pressure holding time truncation, and pressure parameter adjustment operations by comparing the characteristics of the pressure deformation curve and the pressure deformation curve during the pressure application process. The evaluation module is used to acquire the morphological data of the high-neck flange after pressure is applied, and to reprogram the initial controlled pressure field by evaluating the straightening effect until the flange flatness reaches the preset qualified threshold.

2. The adaptive pressure system for a servo straightening press used in high-neck flange processing according to claim 1, characterized in that, The online scanning module includes a topography scanning unit, a warpage analysis unit, a planning unit, and a feature analysis unit, comprising: The topography scanning unit is used to acquire the material data of the high neck flange and to measure the end face of the high neck flange point by point to acquire the spatial coordinate data of each point to form topography data. The warpage analysis unit is used to calculate the ideal reference plane based on the morphology data by least squares plane fitting, and to calculate the flatness error distribution map by point-by-point deviation, and to identify the warpage distribution pattern based on its spatial gradient change. The planning unit is used to select the action point of the high neck flange according to the warping distribution pattern, determine the main pressure point and auxiliary support point required to construct the initial controlled pressure field, and calculate the pressure parameters, the target value of the indentation depth and the direction of action of each point in combination with the material data. The feature analysis unit is used to predict the pressure and deformation relationship of the flange end face when an initial controlled pressure field is applied, based on pressure parameters, target value of indentation depth and direction of action, and to generate pressure deformation curve features. The points of action include main pressure points and auxiliary support points.

3. The adaptive pressure system for a servo straightening press used in high-neck flange processing according to claim 2, characterized in that, The feature analysis unit is configured with feature prediction logic, which includes: Based on the pressure parameters, the target value of the indentation depth and the direction of action, the mechanical response of the entire high-neck flange end face under the action of the initial controlled pressure field is simulated to obtain the pressure reading sequence and the displacement reading sequence, and to construct the pressure deformation data sequence. The first stiffness value of the high neck flange end face is extracted by differential calculation of the pressure deformation data sequence, and the starting point of the elastic-plastic transition is identified. The pressure value and deformation value at the starting point are used as the yield threshold group. The yield threshold group statistical distribution of flanges of the same specification is obtained from the straightening database. The yield threshold group is corrected to generate a yield threshold interval that includes the center expected value and tolerance range. The straightening database is set according to the successful straightening data of flanges of the same specification. The first stiffness value, yield threshold range, and deformation target are integrated and encapsulated into a pressure deformation curve feature, wherein the deformation target is set according to the indentation depth target value.

4. The adaptive pressure system for a servo straightening press used in high-neck flange processing according to claim 3, characterized in that, The collaborative pressing module includes an end-effector manipulation unit, a constraint unit, an acquisition unit, and a curve construction unit, comprising: The end control unit is used to control the main pressure head of the servo straightening press to move directly above the main pressure point according to the position of the main pressure point, and to control the corresponding auxiliary device to move to the corresponding auxiliary support point on the back of the high neck flange. The constraint unit is used to apply pressure to the high neck flange through the main pressure fitting head, and increase the output force of the cooperative auxiliary device according to the pressure rise amplitude by a preset nonlinear gain coefficient to construct an axial pressure gradient field on the high neck flange. The acquisition unit is used to acquire the main pressure sequence, main displacement sequence and auxiliary support force sequence of the main pressing head and the auxiliary device at a preset synchronization frequency. The curve construction unit is used to generate a time-series index within the axial pressure gradient field by calculating the ratio of the auxiliary support force sequence to the main pressure sequence, and to generate a pressure deformation curve representing the flange response characteristics under the axial pressure gradient field.

5. The adaptive pressure system for a servo straightening press used in high-neck flange processing according to claim 4, characterized in that, The constraint unit is configured with constraint logic, which includes: Based on the target pressure value and pressure application rate in the initial controlled pressure field, the main pressure fitting head is controlled to move along the flange axis and the pressure sensor data is read to obtain the main pressure that increases with time. Calculate the target output force corresponding to the cooperative auxiliary device based on the main pressure and the preset nonlinear gain coefficient; Feedback control is applied to the pressure controller of the auxiliary device based on the target output force, driving it to output real-time auxiliary support force, thereby forming an axial pressure gradient field in the local pressure area of ​​the high-neck flange.

6. The adaptive pressure application system for a servo straightening press used in high-neck flange processing according to claim 5, characterized in that, The voltage regulation module includes a feature calculation unit, a deviation identification unit, a field adjustment unit, and a deformation control unit, including: The feature calculation unit is used to calculate the instantaneous stiffness and cumulative deformation of the pressure deformation curve based on the auxiliary support force, main pressure sequence and main displacement sequence of each cooperating auxiliary device. The deviation identification unit is used to compare the instantaneous stiffness and cumulative deformation with the corresponding pressure deformation curve characteristics in the initial controlled pressure field to determine the deviation type. The field adjustment unit is used to calculate and adjust the force distribution ratio between the main pressure point and the auxiliary support point according to the magnitude and direction of the stiffness deviation if the deviation type is stiffness deviation. The deformation control unit is used to dynamically truncate or extend the duration of the initial controlled pressure field if the deviation type is deformation endpoint offset. When the cumulative deformation reaches the target, the main pressure head is stopped and the pressure holding state is entered. When the pressure reaches the target but the cumulative deformation is insufficient, the current pressure is maintained and the holding time is extended until the cumulative deformation reaches the target.

7. The adaptive pressure system for a servo straightening press used in high-neck flange processing according to claim 6, characterized in that, The field adjustment unit further includes field adjustment logic, which includes: Based on the stiffness deviation and its direction, and combined with the real-time pressure of the main pressure point and the cooperating auxiliary device, the pressure ratio relationship between each point of action in the initial controlled pressure field is calculated, and compared with the preset pressure ratio to identify the cooperating auxiliary device with the greatest influence of stiffness deviation. For the most affected auxiliary device, adjust the target pressure setting without interrupting the application of the main pressure; The system monitors the change trend of instantaneous stiffness of the pressure deformation curve at the main pressure point during adjustment. If the adjustment is corrected in the expected direction, the adjustment is maintained. If the adjustment is contrary to the expectation or overshoots, the system is restored to the state before adjustment until it is corrected to the preset range.

8. The adaptive pressure system for a servo straightening press used in high-neck flange processing according to claim 7, characterized in that, The field adjustment logic further includes field state analysis sub-logic, which includes: Based on the current force values ​​of the main pressure point and the auxiliary support point, the pressure ratio is calculated to obtain a set of pressure ratios representing the pressure distribution state inside the initial controlled pressure field. The pressure ratio in the pressure ratio set is compared with the pressure ratio target value of the corresponding coordinating auxiliary device preset at the main pressure point in the initial controlled pressure field, and the pressure ratio deviation value of the coordinating auxiliary device is calculated. Multiply the pressure ratio deviation value by a preset influence coefficient that reflects the corresponding spatial location on the deformation stiffness at the main pressure point to obtain the influence index. The coordinating assistant with the largest absolute value of the influence index is selected as the coordinating assistant with the greatest impact on stiffness deviation.

9. The adaptive pressure system for a servo straightening press used in high-neck flange processing according to claim 8, characterized in that, The evaluation module includes a retesting unit, a planning and updating unit, and an iteration unit, including: The retesting unit is used to acquire the morphological data of the high-neck flange end face after the initial controlled pressure field is applied, quantify its actual straightening effect, and identify the residual error exceeding the standard area and the newly deformed area in combination with the preset qualified threshold. The planning update unit is used to perform replanning on the initial controlled pressure field of the residual error exceeding the standard region and the newly deformed region based on the quantification results, so as to obtain the updated controlled pressure field. The iterative unit is used to repeatedly apply pressure to the high neck flange end face according to the controlled pressure field until the flatness error value of the high neck flange end face is less than the qualified threshold.

10. The adaptive pressure system for a servo straightening press used in high-neck flange processing according to claim 9, characterized in that, The planning update unit further includes planning update logic, which includes: Analyze the error pattern of the area where the residual error exceeds the standard, increase the pressure parameter of the original point of action or add a new point of action according to the amount of error, and generate the updated point of action and pressure parameter. By analyzing the deformation characteristics and spatial correlation of the newly formed deformation region, a combination of action points is planned at symmetrical locations to generate a controlled pressure field for reverse compensation and adjust the pressure parameters of adjacent action points.

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