Intersection hole boring cutting force measurement method and intelligent sensing system

Abstract

The application relates to the field of mechanical processing process mechanical quantity measurement and intelligent sensing technology, in particular to a method for measuring boring cutting force of an intersection hole and an intelligent sensing system. The method comprises the following steps: acquiring geometric data of the intersection hole, boring tool pose data and original response signals of a plurality of mechanical sensing channels and performing time correlation; determining a material contact state and an equivalent action position of cutting load according to the geometric data and the pose data; determining current force response parameters according to a corresponding relationship between the action position of the cutting load and the force response parameters; performing channel decoupling and dynamic response compensation on the original response signals according to the current force response parameters and the material contact state, obtaining multi-component cutting forces in a measurement coordinate system, and converting the multi-component cutting forces to a tool follow-up coordinate system. The intelligent sensing system comprises a force measurement structure, a mechanical sensor, a signal conditioning and data acquisition unit, a boring tool pose data acquisition unit and a data processing unit.

Description

Technical Field

[0001] This application relates to the field of mechanical quantity measurement and intelligent sensing technology in machining processes, specifically to a method for measuring cutting force in boring of intersection holes and an intelligent sensing system. Background Technology

[0002] Intersection holes typically refer to hole structures formed by the interconnection of a hole to be machined with transverse holes, oblique holes, or other hole systems. They are widely used in large structural components and precision assembly parts. When finishing intersection holes using boring, the boring bar feeds along the axial direction of the hole to be machined. Upon passing through the material-deficient area formed by the intersecting holes, the cutting state between the tool and the workpiece changes from a relatively stable continuous cutting state to an intermittent cutting state. After leaving the intersecting area, it re-enters a solid material cutting state, causing changes in the magnitude, direction, and rate of change of the cutting load on the tool. Cutting force is an important mechanical quantity reflecting the interaction state between the tool and the workpiece. Accurate measurement of this force provides fundamental data for intersection hole boring process analysis, machining parameter optimization, and machining quality control. Therefore, it is necessary to utilize mechanical sensors and corresponding intelligent sensing systems to measure the cutting force in real time during the intersection hole boring process.

[0003] Existing cutting force measurements typically utilize multi-channel force sensors to acquire response signals in different force directions and obtain the corresponding cutting force based on pre-calibrated sensitivity or channel switching relationships. However, during the boring of intersecting holes, a stable solid cutting phase alternates with an intermittent cutting phase when passing through the intersecting hole region, resulting in differences in the amplitude and dynamic variation characteristics of the cutting force at different stages. Furthermore, the dynamic response of the sensor mounting structure and force transmission path, the coupling between different force measurement channels, and zero-point changes during the measurement process can all be superimposed on the sensor output. When a fixed static calibration relationship is used to process the entire boring process, it is difficult to reflect the changes in force response characteristics caused by variations in the cutting load's position. Moreover, the coupling between different force measurement channels and the dynamic response of the force measurement structure itself can cause amplitude or phase deviations in each cutting force component. Therefore, how to adapt the measurement relationship of multi-component cutting forces to the changes in the cutting load's position and material contact state during the boring process of intersecting holes, and how to reduce the influence of channel coupling and the dynamic response of the force measurement structure on the measurement results, are problems that need further resolution in existing cutting force measurements for boring of intersecting holes. Summary of the Invention

[0004] In view of the aforementioned problems, the first aspect of this application provides a method for measuring the cutting force in boring intersecting holes, including: Acquire the geometric data of the intersection hole, the boring tool pose data, and the raw response signals collected by multiple mechanical sensing channels, and associate the geometric data of the intersection hole, the boring tool pose data, and the raw response signals with a unified time reference; Based on the geometric data of the intersection holes and the boring tool pose data, the material contact state of the boring tool cutting edge relative to the material missing area of ​​the intersection holes is determined, and the equivalent action position of the current cutting load is determined. Based on the equivalent action position, the current force response parameter is determined from the pre-established correspondence between the cutting load action position and the force response parameter. Based on the current force response parameters and material contact state, channel decoupling and dynamic response compensation are performed on the original response signals of multiple mechanical sensing channels to obtain multi-component cutting force in the measurement coordinate system. Based on the boring tool pose data, the multi-component cutting force is converted to the tool follower coordinate system to obtain the cutting force measurement results during the boring process of the intersection hole.

[0005] According to the method for measuring cutting force in boring intersecting holes provided in this application, the step of determining the material contact state of the boring tool cutting edge relative to the material-deficient area of ​​the intersecting hole based on the geometric data of the intersecting hole and the boring tool pose data, and determining the equivalent position of the current cutting load, includes: Based on the tool geometry parameters and the boring tool pose data at the current sampling time, determine the spatial position of the boring tool cutting edge in the workpiece coordinate system; Based on the geometric data of the intersecting holes, determine the spatial range of the material missing area of ​​the intersecting holes in the workpiece coordinate system; By geometrically comparing the spatial position of the boring tool cutting edge with the spatial range of the missing area of ​​the intersecting hole material, the solid contact section in the boring tool cutting edge corresponding to the solid material to be removed is determined; The current material contact state is determined based on the spatial distribution of the solid contact section on the boring tool cutting edge, and the equivalent position of the current cutting load is determined based on the solid contact section.

[0006] According to the method for measuring cutting force in boring intersecting holes provided in this application, determining the equivalent position of the current cutting load based on the solid contact section includes: The solid contact area is divided into multiple local cutting units, and the representative position of each local cutting unit on the boring tool cutting edge and the corresponding effective contact length are determined. The effective contact length of each local cutting unit is used as the corresponding load contribution weight. The equivalent position of the current cutting load is obtained by weighting the representative positions of each local cutting unit and the corresponding load contribution weights.

[0007] According to the method for measuring cutting force in boring at intersection points provided in this application, the correspondence between the location of the cutting load and the force response parameters is pre-established in the following manner: The effective calibration domain is determined based on the predetermined range of variation of the equivalent action position, and multiple calibration action positions are set within the effective calibration domain; A calibration load of known magnitude and direction is applied at each calibration position, and the response data of the multiple mechanical sensing channels under the corresponding calibration load is acquired simultaneously. Based on the calibration load corresponding to each calibration position and the response data of the multiple mechanical sensing channels, the force response parameters corresponding to each calibration position are determined. By associating each calibrated application position with the corresponding force response parameter, a correspondence between the application position of the cutting load and the force response parameter is established.

[0008] According to the method for measuring cutting force in boring intersecting holes provided in this application, the force response parameters include static force response parameters and dynamic force response parameters; The static force response parameters are determined by applying calibration loads along multiple independent force directions at the same calibration position and based on the response data corresponding to each calibration load and the multiple mechanical sensing channels. These parameters are used to characterize the static sensitivity and channel coupling relationship between multiple cutting force components and the multiple mechanical sensing channels. The dynamic force response parameters are determined by applying a known dynamic excitation load at the calibrated position and based on the dynamic response data corresponding to the dynamic excitation load and the plurality of mechanical sensing channels, and are used to characterize the dynamic transmission characteristics between the cutting load and the plurality of mechanical sensing channels.

[0009] According to the method for measuring cutting force in boring at intersections provided in this application, determining the current force response parameter based on the equivalent action position from a pre-established correspondence between the cutting load action position and the force response parameter includes: From the multiple calibration action positions set within the effective calibration domain, determine a plurality of calibration action positions adjacent to the equivalent action position; Based on the positional relationship between the equivalent action position and each adjacent calibration action position, the force response parameters corresponding to each adjacent calibration action position are interpolated to obtain the current force response parameters corresponding to the equivalent action position.

[0010] According to the method for measuring cutting force in boring at intersections provided in this application, the current force response parameters include static force response parameters used to characterize the static sensitivity and channel coupling relationship between multiple cutting force components and multiple mechanical sensing channels; the channel decoupling of the original response signals of the multiple mechanical sensing channels includes: The original response signals of the multiple mechanical sensing channels at the same sampling time are combined into a response vector; Construct a current force response matrix based on the static force response parameters, characterizing the response relationship between multiple cutting force components and the multiple mechanical sensing channels; Based on the measurement relationship between the current force response matrix and the response vector, the multiple cutting force components in the measurement coordinate system are solved.

[0011] According to the method for measuring cutting force in boring at intersections provided in this application, the current force response parameters include dynamic force response parameters used to characterize the dynamic transmission characteristics between multiple cutting force components and multiple mechanical sensing channels; the channel decoupling and dynamic response compensation include: Based on the dynamic force response parameters, a multi-channel frequency response matrix is ​​established between multiple mechanical sensing channels and multiple cutting force components within the effective frequency range corresponding to the dynamic force response parameters. The responses of multiple mechanical sensing channels at the same frequency position are combined to form a frequency domain response vector; Based on the multi-channel frequency response matrix and frequency domain response vector, the frequency domain results of each cutting force component at the corresponding frequency position are obtained; The frequency domain results of each cutting force component are transformed to the time domain to obtain the multi-component cutting force after channel decoupling and dynamic response compensation.

[0012] According to the method for measuring cutting force in boring of intersection holes provided in this application, the step of converting the multi-component cutting force to the tool follower coordinate system based on the boring tool pose data includes: Based on the boring tool pose data and the installation geometry between the measurement coordinate system and the boring tool, determine the coordinate transformation relationship between the measurement coordinate system and the tool follower coordinate system at the current sampling time; Based on the coordinate transformation relationship, the multi-component cutting force in the measurement coordinate system is converted into radial cutting force, tangential cutting force and axial cutting force in the tool follower coordinate system.

[0013] The second aspect of this application provides an intelligent sensing system for cutting force in boring of intersection holes, including a force measuring structure, a mechanical sensor, a signal conditioning and data acquisition unit, a boring tool posture data acquisition unit, and a data processing unit; The mechanical sensor is disposed on the force measuring structure and has multiple mechanical sensing channels. The signal conditioning and data acquisition unit is connected to the mechanical sensor. The signal conditioning and data acquisition unit and the boring tool posture data acquisition unit are respectively connected to the data processing unit. The data processing unit is configured as follows: Acquire the geometric data of the intersection hole, the boring tool pose data, and the raw response signals collected by multiple mechanical sensing channels, and associate the geometric data of the intersection hole, the boring tool pose data, and the raw response signals with a unified time reference; Based on the geometric data of the intersection holes and the boring tool pose data, the material contact state of the boring tool cutting edge relative to the material missing area of ​​the intersection holes is determined, and the equivalent action position of the current cutting load is determined. Based on the equivalent action position, the current force response parameter is determined from the pre-established correspondence between the cutting load action position and the force response parameter. Based on the current force response parameters and material contact state, channel decoupling and dynamic response compensation are performed on the original response signals of multiple mechanical sensing channels to obtain multi-component cutting force in the measurement coordinate system. Based on the boring tool pose data, the multi-component cutting force is converted to the tool follower coordinate system to obtain the cutting force measurement results during the boring process of the intersection hole.

[0014] The beneficial effects of this application are as follows: Compared with existing technologies, this application determines the material contact state of the boring tool cutting edge relative to the material-deficient area of ​​the intersecting hole based on the geometric data of the intersecting hole and the boring tool pose data. It further determines the equivalent position of the current cutting load and then determines the current force response parameters based on a pre-established correspondence between the cutting load position and the force response parameters. Therefore, the force response relationship used for cutting force measurement can be adjusted accordingly to changes in the cutting load position and material contact state during the boring of the intersecting hole, reducing measurement deviations caused by using a single fixed force response relationship to handle different cutting positions.

[0015] Based on the current force response parameters and material contact state, this application performs channel decoupling and dynamic response compensation on the original response signals of multiple mechanical sensing channels. This can reduce the cross-coupling between different mechanical sensing channels and the influence of the dynamic transmission characteristics of the force measuring structure on the cutting force measurement results, reduce the amplitude and phase distortion caused by the dynamic response of the force measuring structure, and thus obtain independent multi-component cutting forces in the measurement coordinate system.

[0016] Furthermore, this application correlates the geometric data of the intersection hole, the boring tool pose data, and the original response signal to a unified time reference, and transforms the multi-component cutting force in the measurement coordinate system to the tool follower coordinate system based on the boring tool pose data. This allows the cutting force obtained at different machining times to be characterized according to the radial, tangential, and axial directions corresponding to the actual cutting direction of the boring tool, which is beneficial for forming the measurement results of the cutting force of the intersection hole boring with a clear machining position and time correspondence. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0018] Figure 1 A flowchart of a method for measuring cutting force in boring intersecting holes according to some embodiments of this application is shown; Figure 2 A schematic diagram of the structure of the intelligent sensing system for cutting force in boring of intersection holes provided in some embodiments of this application is shown. Detailed Implementation

[0019] To make the technical solution, the technical problem solved, and the resulting technical effects of this application clearer, the technical solution of this application will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. Other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are all within the protection scope of this application.

[0020] It should be noted that, unless otherwise specified, the embodiments and technical features described in this application can be combined with each other. The terms "first" and "second" used in this application are only used to distinguish identical or similar technical features and are not intended to limit the number, order, or importance of the corresponding technical features.

[0021] This application provides a method for measuring the cutting force in the boring of intersecting holes using several embodiments. This method is implemented based on an intelligent sensing system for the cutting force in the boring of intersecting holes. The intelligent sensing system includes at least a mechanical sensor, a signal conditioning and data acquisition unit, a boring tool pose data acquisition unit, and a data processing unit. The mechanical sensor has multiple mechanical sensing channels. These multiple channels respond to different mechanical forces generated during the boring of the intersecting holes. The signal conditioning and data acquisition unit acquires the sensing signals generated by each mechanical sensing channel. The boring tool pose data acquisition unit acquires the pose data of the boring tool during the machining process. The data processing unit combines the geometric data of the intersecting hole and the boring tool pose data to process the raw response signals from the multiple mechanical sensing channels to obtain multi-component cutting force measurement results during the boring of the intersecting holes.

[0022] In this application, an intersecting hole refers to a hole system structure formed by the hole to be boring and at least one intersecting hole interconnecting each other. The material-deficient region of the intersecting hole refers to a non-solid material region formed at the corresponding position of the hole to be boring due to the interconnection between the intersecting hole and the hole to be boring. The material contact state is used to characterize the contact relationship between the boring tool cutting edge and the material-deficient region of the intersecting hole and its surrounding solid material. The equivalent action position refers to the spatial action position used to characterize the equivalent measurement response of the current cutting load on the force measuring structure.

[0023] In this application, the force response parameter refers to the parameter characterizing the measurement response characteristics of multiple mechanical sensing channels when the cutting load is applied to different positions; the measurement coordinate system is a coordinate system with a fixed spatial relationship with the force measurement structure corresponding to the mechanical sensing channel; the tool follower coordinate system is a coordinate system determined with the boring tool posture and used to characterize the force direction of the boring tool.

[0024] See Figure 1 This application provides a method for measuring cutting force in the boring of intersecting holes, which processes the multi-channel sensing response generated by the cutting load during the boring process to obtain multi-component cutting force measurement results during the boring process. The method includes: Step S100: Acquire the geometric data of the intersection hole, the boring tool pose data, and the raw response signals collected by multiple mechanical sensing channels, and associate the geometric data of the intersection hole, the boring tool pose data, and the raw response signals with a unified time reference.

[0025] Step S200: Based on the geometric data of the intersection hole and the boring tool pose data, determine the material contact state of the boring tool cutting edge relative to the material missing area of ​​the intersection hole, and determine the equivalent position of the current cutting load.

[0026] Step S300: Determine the current force response parameter from the pre-established correspondence between the cutting load application position and the force response parameter based on the equivalent application position.

[0027] Step S400: Based on the current force response parameters and material contact state, perform channel decoupling and dynamic response compensation on the original response signals of multiple mechanical sensing channels to obtain multi-component cutting force in the measurement coordinate system.

[0028] Step S500: Based on the boring tool pose data, the multi-component cutting force is converted to the tool follower coordinate system to obtain the cutting force measurement results during the boring process of the intersection hole.

[0029] In the above method, the equivalent position of the current cutting load is determined based on the contact relationship between the cutting edge and the workpiece material when the boring tool passes through the intersection hole area. Based on this, the force response parameters that match the current force transmission state are determined, so that the response processing of multiple mechanical sensing channels can adapt to the changes in the position of the cutting load and the material contact state during the boring of the intersection hole, providing a measurement basis corresponding to the current machining position for channel decoupling and dynamic response compensation.

[0030] The step numbers mentioned above are only used to distinguish the corresponding steps. Provided the data dependencies between steps are satisfied, they are not intended to require processes without technical logical dependencies to be executed in a strict chronological order. The implementation process of the above method will be further explained below with reference to specific embodiments.

[0031] Step S100 is used to acquire the basic data required for subsequent cutting force measurement and establish the time correspondence between data from different sources. The intersection hole geometry data describes the geometry of the current hole system to be machined, the boring tool pose data describes the pose changes of the boring tool during machining as it moves with the feed motion and spindle rotation, and the raw response signals collected by multiple mechanical sensing channels reflect the sensing response generated after the cutting load acts on the force measuring structure. Because the data sources and update methods of the above data are different, they need to be correlated to a unified time reference before proceeding to the subsequent material contact state determination and cutting force processing. This ensures that the raw response signals collected at each moment can determine the boring tool pose at the corresponding moment and be used in conjunction with the intersection hole geometry data corresponding to the current machining task.

[0032] Intersection hole geometry data is used at least to characterize the spatial geometric relationship between the hole to be bored and the intersecting holes, and may include the hole diameter, hole axis position, and hole axis direction of the intersecting holes. In some embodiments, the intersection hole geometry data may further include the intersection angle, intersection position, and relevant hole system structure parameters determined by the geometric connection between the intersecting holes and the hole to be bored. The intersection hole geometry data can be obtained from the workpiece design model, machining process data, hole system parameters pre-saved in the CNC machining program, or workpiece geometric measurement data obtained before machining. When there are multiple intersecting holes for the same hole to be bored, the geometry data corresponding to each intersecting hole can be recorded separately, enabling the determination of the corresponding material contact state for different intersection positions.

[0033] Boring tool pose data is used to characterize the position and rotational state of the boring tool during machining. In some embodiments, the boring tool pose data includes the axial position of the boring tool along the axis of the hole to be boring and the angular position corresponding to the spindle rotation. The axial position can be obtained from the feed axis position data or the corresponding position detection signal in the CNC system, and the angular position can be obtained from the spindle encoder, spindle position detection device, or spindle angular position information provided by the CNC system. For machining forms where the boring tool involves radial adjustment or tool posture changes, the boring tool pose data may further include the corresponding radial position or posture parameters. The data format of the boring tool pose data is not limited, as long as the position and state of the boring tool cutting edge at the corresponding machining moment can be determined in subsequent processing.

[0034] The raw response signal originates from multiple mechanical sensing channels of the mechanical sensor. These channels can be formed within the same multi-component mechanical sensor or separately within multiple cooperating mechanical sensing units. Each channel responds to the corresponding mechanical action generated by the cutting load in the force-measuring structure and generates a sensing signal. This sensing signal is then acquired by the signal conditioning and data acquisition unit to form the raw response signal. The raw response signal can undergo the signal conditioning, amplification, and analog-to-digital conversion required for normal sensor operation, but in step S100, subsequent channel decoupling and dynamic response compensation based on the current force-measuring response parameters have not yet been performed.

[0035] In one specific embodiment, a force-measuring structure is positioned between the workpiece fixture and the machine tool table. A force sensor is mounted on the force-measuring structure and fixed relative to the measurement coordinate system. The force sensor has multiple force-sensing channels. During boring, the cutting load is transmitted to the force-measuring structure via the workpiece and workpiece fixture. Each force-sensing channel responds to the corresponding mechanical action and generates a corresponding sensing signal. The force sensor is connected to a signal conditioning and data acquisition unit via a fixed data acquisition line. The signal conditioning and data acquisition unit acquires the sensing signals generated by each force-sensing channel and generates the original response signal. Therefore, the force sensor and its force-sensing channels do not rotate with the boring tool and spindle. With this configuration, changes in the position of the cutting load caused by the boring tool's axial feed along the hole to be bored and its passage through intersecting hole areas will manifest as changes in the position of the cutting load relative to the force-measuring structure and the force transmission state. This allows for the determination of the force response parameters corresponding to the current equivalent position in subsequent steps.

[0036] In some embodiments, the multiple mechanical sensing channels include an axial force measurement channel, a torque measurement channel, and bending moment measurement channels that characterize the bending action around the X-axis and Y-axis of the measurement coordinate system, respectively. Each channel acquires measurement data synchronously or continuously during the machining process according to a sampling method that establishes a time-correspondence, enabling the responses of multiple channels to be used together for subsequent calculation of multi-component cutting forces.

[0037] In one specific implementation, the signal conditioning and data acquisition unit acquires the sensing signals from multiple mechanical sensing channels at a sampling frequency of 2500 Hz to form corresponding raw response signals. The raw data acquisition frequency is not lower than 2 kHz. The 2500 Hz sampling frequency meets the raw data acquisition frequency requirements and can continuously record the sensing response generated by the boring tool as it passes through the intersection hole area with changes in cutting load. The effective frequency range for subsequent dynamic response compensation is determined based on the dynamic calibration results of the force measurement structure and is limited to the frequency range that the current sampling frequency can effectively characterize. When it is necessary to suppress frequency components higher than the effective sampling frequency range, anti-aliasing filtering can be performed at the data acquisition front end. Data acquisition can be performed using a triggered acquisition method or a non-triggered continuous acquisition method. When using a triggered acquisition method, the start time of data acquisition can be determined based on the machining program start signal, spindle running signal, or preset acquisition trigger signal. When using a non-triggered continuous acquisition method, the raw response signal can be continuously acquired, and data for subsequent processing can be selected according to the time interval corresponding to the current machining task.

[0038] When the above data is associated with a unified time reference, the unified time reference is used to establish a defined time mapping relationship between different dynamic data. It does not require the intersection hole geometry data, boring tool pose data, and original response signals to have the same data update frequency. For the original response signals and boring tool pose data, a unified clock, a synchronous trigger signal, or a timestamp generated based on a unified timing reference can be used to establish the time correspondence. Each original response signal sampling point records or can be converted to its corresponding sampling time, and the boring tool pose data similarly records or can be converted to its corresponding position update time. Therefore, the boring tool pose corresponding to each original response signal sampling point can be determined based on its time and position.

[0039] In some embodiments, when the update frequency of the boring tool pose data is lower than the sampling frequency of the original response signal, the original sampling times of both types of data can be retained, and adjacent boring tool pose data can be time-matched or interpolated based on timestamps to obtain the boring tool pose corresponding to each sampling time of the original response signal. This process is only used to establish the time correspondence between different data and does not require changing the sampling frequency and measurement value of the original response signal itself.

[0040] For intersection hole geometry data, since the hole system geometry corresponding to the same machining task remains fixed during machining, the intersection hole geometry data can be associated with the data acquisition time interval corresponding to the current machining task. This ensures that the boring tool pose data and the original response signal within that time interval both correspond to the current intersection hole geometry data. Therefore, it is unnecessary to repeatedly generate intersection hole geometry data according to the sampling frequency of the mechanical sensing channel.

[0041] In some embodiments, when there is a fixed transmission delay between different data acquisition links, the corresponding timestamps can be corrected according to the predetermined link delay during the time association process to reduce the timing deviation caused by data transmission delay.

[0042] In some embodiments, when the spindle angular position is used for tool follower coordinate transformation in step S500, the spindle angular position data and the original response signal can be synchronously verified using the reference angle mark or periodic index signal of the spindle encoder. The same synchronous trigger signal can be input to both the spindle angular position acquisition link and the mechanical sensing channel acquisition link, or the corresponding time position of the spindle encoder reference angle mark in the two types of data can be recorded. Based on this, a fixed time offset between the two data links can be determined, and the spindle angular position time series can be corrected. After correction, the spindle angular position corresponding to the sampling time of each original response signal reflects the boring tool rotation position at the same actual machining time, providing time-consistent angular position data for subsequent coordinate transformation of radial and tangential cutting forces.

[0043] After completing step S100, the geometric data of the intersection hole, the boring tool pose data and the original response signals of multiple mechanical sensing channels with clear time correspondence can be obtained, which provides a basis for step S200 to determine the material contact state and the equivalent position of the current cutting load based on the data corresponding to the same processing time.

[0044] Step S200 is used to determine the cutting edge part currently involved in material removal based on the actual geometric structure of the intersection hole and the boring tool pose at the current sampling time, and on this basis, obtain the material contact state and the equivalent position of the current cutting load.

[0045] During the boring of the intersecting hole, as the boring bar feeds along the hole to be bored and rotates with the spindle, the cutting edge periodically passes through the area where the material in the intersecting hole is missing, causing the area of ​​the cutting edge that actually bears the cutting load to change with the machining position. When the cutting load is transmitted to the force measuring structure and the mechanical sensor generates a multi-channel response, the change in the load application position will cause the measurement response relationship corresponding to each mechanical sensing channel to change. Therefore, step S200 is not used to determine whether the machining is normal or abnormal, but rather to form the geometric measurement conditions describing the current cutting load input position, providing a basis for step S300 to determine the force response parameters that match the current force transmission state.

[0046] In some embodiments, step S200 includes steps S210 to S230.

[0047] Step S210: Based on the geometric data of the intersection hole and the boring tool pose data at the current sampling time, determine the instantaneous spatial relationship between the boring tool cutting edge and the material missing area of ​​the intersection hole, and determine the solid contact segment currently involved in material removal.

[0048] During implementation, the tool geometry parameters corresponding to the current boring tool can be obtained in advance. These parameters describe the geometric relationship between the cutting edge and the boring tool's reference position, and can be derived from tool design data, tool configuration data, or tool parameters entered before machining. Based on the tool geometry parameters and the boring tool pose data obtained in step S100, the spatial position of the cutting edge in the workpiece coordinate system at the current sampling moment can be determined. The intersection hole geometry data already provides the spatial structure of the hole to be boring and the intersecting holes, which allows the determination of the spatial range of the material-deficient area of ​​the intersecting holes in the workpiece coordinate system.

[0049] By geometrically comparing the spatial position of the cutting edge at the current sampling moment with the material-deficient area of ​​the intersecting hole, it can be determined whether different parts of the cutting edge currently correspond to the solid material of the workpiece or the material-deficient area of ​​the intersecting hole. In this application, the solid contact section refers to the section of the cutting edge that corresponds to the solid material to be removed and can form a cutting load under the current boring tool posture. The part of the cutting edge corresponding to the material-deficient area of ​​the intersecting hole does not form the current solid contact section. Through this processing, the three-dimensional geometry of the intersecting hole can be converted into the spatial distribution of the cutting edges that actually participate in material removal at the current sampling moment.

[0050] In some embodiments, spatial intersection can be determined directly using the workpiece's three-dimensional geometric model and the cutting edge's geometric model. After converting the cutting edge's geometric model to the current spatial position based on the boring tool's pose, it is determined whether the material to be removed along the effective cutting range of the cutting edge is located outside the material missing area of ​​the intersecting hole. The continuous portion within the area of ​​the solid material to be removed is defined as the solid contact section, while the portion within the material missing area of ​​the intersecting hole is not included in the solid contact section.

[0051] In other embodiments, a discretization approach can be used to determine the solid contact sections. Specifically, geometric judgment positions are arranged sequentially along the effective cutting range of the cutting edge. The spatial coordinates of each geometric judgment position in the workpiece coordinate system are calculated based on the current pose of the boring tool, and it is determined whether the corresponding position falls within the material missing area of ​​the intersecting hole. For adjacent geometric judgment positions that both correspond to the solid material to be removed, they can be classified into the same solid contact section; when adjacent geometric judgment positions cross the material missing area of ​​the intersecting hole, they are divided into different solid contact sections. Increasing the density of the geometric judgment positions can improve the description accuracy of the solid contact sections near the boundary of the intersecting hole.

[0052] In one embodiment where the intersecting hole is cylindrical, the material deficiency area of ​​the intersecting hole can be determined based on the hole axis, hole diameter, and hole depth range along the hole axis. For any geometric judgment position on the cutting edge, the shortest distance from the geometric judgment position to the hole axis of the intersecting hole is calculated, and the projection position of the geometric judgment position in the direction of the hole axis of the intersecting hole is determined. When the shortest distance is not greater than the radius of the intersecting hole, and the corresponding projection position is within the actual hole depth range of the intersecting hole, the geometric judgment position is determined to be located in the material deficiency area of ​​the intersecting hole; otherwise, the geometric judgment position is determined to correspond to the solid material of the workpiece. For judgment positions near the geometric boundary of the intersecting hole, a boundary judgment tolerance can be set according to the allowable deviation of the workpiece geometric dimensions, and the start and end positions of the solid contact section can be determined using adjacent geometric judgment positions.

[0053] When the cutting edge is completely aligned with the material to be removed, a continuous solid contact segment can be formed. When the cutting edge partially passes through the area where the material of the intersecting hole is missing, a single solid contact segment with a reduced length can be formed, or multiple solid contact segments separated from each other can be formed according to the shape of the intersecting hole opening. When the cutting edge does not have actual material contact at the current position, there is no solid contact segment. The above judgment is directly based on the instantaneous geometric relationship between the current cutting edge and the material to be removed, and it is not necessary to pre-divide the entire boring process into fixed intersection hole entry, penetration, or exit stages.

[0054] Step S220: Determine the current material contact state based on the spatial distribution of the solid contact section on the boring tool cutting edge.

[0055] The material contact state reflects the contact relationship between the cutting edge and the missing material area of ​​the intersecting hole and the surrounding solid material at the current sampling moment. In this embodiment, the material contact state can be determined based on the existence, quantity, spatial location, and distribution range along the cutting edge of the solid contact segments. Therefore, the material contact state can not only distinguish whether solid material is currently involved in cutting, but also retain the spatial contact information needed to subsequently determine the equivalent position of the cutting load.

[0056] In some embodiments, when the effective cutting range of the cutting edge corresponds entirely to the material to be removed, the material contact state can be defined as a complete material contact state; when a portion of the effective cutting range corresponds to the missing area of ​​the intersecting hole material and another portion corresponds to the material to be removed, it can be defined as a partial material contact state; when the effective cutting range does not form contact with the material to be removed, it can be defined as a disconnected material contact state. For partial material contact states, the starting position, ending position, and corresponding spatial coordinates of each contact segment on the cutting edge can be further recorded, so that the material contact state can describe the migration of the area actually bearing the cutting load on the cutting edge.

[0057] In some embodiments, for a boring bar with two or more cutting edges, the physical contact section corresponding to each cutting edge can be determined separately, and the physical contact conditions of each cutting edge can be combined to form the current material contact state. Thus, when different cutting edges pass through the material-deficient area of ​​the intersecting hole at the same time and form different material contact relationships, they can still participate in the determination of the subsequent equivalent action position according to their respective spatial positions.

[0058] Step S230: Determine the equivalent position of the current cutting load based on the solid contact section in the current material contact state.

[0059] During the boring of the intersection hole, the cutting load actually acts on the cutting edge region currently involved in the cutting, and may be distributed along the solid contact section. To ensure that this distributed load, which varies with the geometry of the intersection hole, can be matched with the force response parameters corresponding to different cutting load application positions pre-established in step S300, this embodiment uses an equivalent application position to uniformly characterize the spatial input position of the current distributed cutting load. The equivalent application position is not required to be identical to the actual pressure center of the distributed load at any instant, but rather, according to predetermined spatial equivalence rules, the load application area corresponding to the current solid contact section is converted into a spatial position that can characterize the current force transmission position. When pre-establishing the correspondence between the cutting load application position and the force response parameters, the same equivalence rules as the actual measurement process are used, so that the currently determined equivalent application position can serve as a unified positional basis for matching the force response parameters.

[0060] In some embodiments, the equivalent application position can be determined based on the relative contribution of different local cutting regions in the solid contact section to the current cutting load. Specifically, the solid contact section can be divided into multiple local cutting units, and the corresponding representative positions can be determined based on the spatial positions of each local cutting unit on the cutting edge. The load contribution weight corresponding to each local cutting unit can also be determined, and then the equivalent application position of the current cutting load can be determined based on each representative position and its load contribution weight.

[0061] The representative position of each local cutting unit can be determined based on the spatial range of the local cutting unit on the boring tool cutting edge. In one specific embodiment, the geometric center position of the local cutting unit along the cutting edge direction can be used as the corresponding representative position. The effective contact length of each local cutting unit is the contact length of the local cutting unit along the cutting edge direction corresponding to the material to be removed.

[0062] In one specific implementation, the load contribution weight can be determined based on the effective contact length corresponding to each local cutting unit or each solid contact segment. Local cutting units or solid contact segments with larger effective contact lengths correspond to larger load contribution weights, and the equivalent application position of the current cutting load is determined based on the representative position of each local cutting unit and its load contribution weight. When the material contact state includes two or more separate solid contact segments, each solid contact segment is weighted according to its own effective contact length to obtain a unified equivalent application position corresponding to all current solid contact segments. For cases with only one continuous solid contact segment where the load contribution can be approximately considered uniformly distributed, the geometric center position of the solid contact segment along the cutting edge direction can be used as the equivalent application position.

[0063] In some further embodiments, when the undeformed chip cross-sectional area corresponding to different local cutting units can be obtained based on the tool geometry parameters, feed parameters, and solid contact sections, the local undeformed chip cross-sectional area can also be used to replace the effective contact length to determine the load contribution weight, so that the equivalent action position further reflects the load contribution difference of different local cutting regions.

[0064] The method for determining the equivalent action position remains consistent in the same force calibration configuration and actual cutting force measurement process. The calibration action position and the equivalent action position use the same spatial reference datum and position parameterization method so that the equivalent action position determined in step S200 can correspond to the position-related force response parameters in step S300.

[0065] Once the equivalent position of action is determined, it can be transformed from the workpiece coordinate system to a measurement coordinate system with a fixed spatial relationship to the force-measuring structure, thus characterizing the position of the current cutting load relative to the force-measuring structure. The coordinate transformation relationship can be predetermined based on the installation position of the force-measuring structure, the boring tool reference position, and the known geometric relationships between the coordinate systems. Therefore, even with continuous rotation and axial feed of the boring tool, the time-varying area of ​​the cutting load can be uniformly represented as its spatial position relative to the force-measuring structure.

[0066] For sampling moments where there is currently no physical contact zone, the material contact state can be recorded as a state of no material contact, and a flag indicating no effective cutting load can be set for the equivalent application location. This flag indicates that there is no cutting load input that needs to be matched according to the application location of a physical cutting load at the current moment, avoiding the incorrect mapping of the non-cutting contact state in the missing material area of ​​the intersecting hole to a certain physical cutting position. In some embodiments, the raw response signal at such sampling moments can also serve as a data source for subsequent sensing background baseline estimation or no-load response evaluation.

[0067] Step S200 allows for the acquisition of the material contact state and the equivalent application position of the current cutting load for each sampling moment with a time-corresponding relationship. Compared to stage division based solely on whether the boring bar enters the intersection hole region, the equivalent application position further characterizes the spatial variation of the actual solid contact segment involved in cutting, enabling the differentiation of load input position differences within the same intersection hole region due to variations in boring bar rotation angle, feed position, and intersection hole geometry. Step S300 then determines the current force response parameters based on the pre-established correspondence between the cutting load application position and the force response parameters, thereby ensuring that subsequent cutting force decoupling and dynamic response compensation match the current actual force transmission position.

[0068] Step S300 is used to determine the force response parameters that match the current force transmission state based on the equivalent position of the current cutting load obtained in step S200.

[0069] During the boring process of the intersection hole, the cutting load is transmitted to the force measuring structure via the workpiece side, and a multi-channel response is generated by the mechanical sensors installed on the force measuring structure. For a cutting load of the same magnitude and direction, when the position of the load changes, the lever arm and structural transmission path between the load and the force measuring structure may change accordingly, causing changes in the response amplitude, inter-channel coupling relationship, and dynamic response characteristics of different mechanical sensing channels. For example, when the mechanical sensing channels include an axial force measurement channel, a torque measurement channel, and bending moment measurement channels that respectively characterize the bending action around the X-axis and Y-axis of the measurement coordinate system, the same radial cutting force acting at different axial positions can generate different bending moment responses in the force measuring structure due to different lever arms. Therefore, this application does not use a single fixed force measurement response relationship to process all machining positions, but instead pre-establishes the correspondence between the cutting load position and the force measurement response parameters, and determines the current force measurement response parameters based on the current equivalent position.

[0070] The correspondence between the location of the cutting load and the force response parameters can be obtained through calibration before actual boring measurements. During calibration, the mechanical sensors, force-measuring structures, and mounting components related to force transmission are placed in an installation state that is the same as or equivalent to the actual force transmission characteristics, and multiple calibration locations are set within the spatial range where the cutting load may act. A calibration load of known magnitude and direction is applied to each calibration location, and response data from multiple mechanical sensing channels are simultaneously collected. The force response parameters for the corresponding calibration locations are determined based on the relationship between the calibration load and the responses of each mechanical sensing channel. The different calibration locations and their corresponding force response parameters together constitute the correspondence between the location of the cutting load and the force response parameters.

[0071] In some embodiments, the effective calibration domain is determined based on the boring tool structure, the effective cutting edge range, and the range of changes in the equivalent action position during the boring of the intersection hole, which is predetermined. The effective calibration domain refers to the spatial range within which the equivalent action position of the cutting load may be distributed during the actual boring process, and where a position-dependent force response relationship needs to be established. The calibration action position is set within the effective calibration domain, eliminating the need to calibrate spatial regions that are inaccessible to the equivalent action position.

[0072] The parameterization dimension of the effective calibration domain can be determined based on the degree of variation of the force response parameters with different spatial directions. When the force response mainly varies with the axial position of the boring tool, the equivalent position can be projected onto the boring tool axis, and multiple calibration positions can be set along the axis. When the radial position change has a non-negligible impact on the force response parameters, the radial position can be further incorporated into the calibration parameters to form a two-dimensional position-dependent force response relationship. Only when the position changes in all three independent spatial directions have a compensable impact on the force response can a three-dimensional position-dependent force response relationship be established. This ensures that the calibration dimension matches the position-dependent characteristics of the actual force response, reducing calibration data unrelated to the actual cutting load range.

[0073] The number and spacing of calibration points can be determined based on the degree of change in the force response parameters between adjacent points. When the change in force response parameters between adjacent calibration points cannot meet the predetermined parameter fitting or interpolation accuracy requirements, calibration points can be added in the corresponding position interval; when the force response parameters change gradually with position, the spacing between calibration points can be increased accordingly.

[0074] In some embodiments, calibration loads are applied along multiple independent force directions at each calibration location, and the outputs of each mechanical sensing channel are recorded simultaneously. This allows for the acquisition of not only the response of the sensing channel corresponding to the target force direction, but also the cross-response generated by the same calibration load in other mechanical sensing channels. Based on the calibration loads in multiple independent directions and their corresponding multi-channel responses, static force response parameters characterizing the response relationship between each cutting force component and multiple mechanical sensing channels can be obtained. These static force response parameters can be represented by sensitivity coefficients, channel coupling coefficients, or a parameter matrix composed of multiple sensitivity and coupling coefficients.

[0075] In some embodiments, the dynamic force response characteristics corresponding to different calibration positions are also calibrated. A known dynamic excitation load can be applied at the corresponding calibration position to obtain the synchronous response of the dynamic excitation load and multiple mechanical sensing channels, and the dynamic force response parameters at the corresponding position can be determined according to the amplitude and phase relationship between the input load and the sensing response.

[0076] In one specific implementation, a force hammer or excitation device with a reference force measurement function can be used to apply a dynamic excitation load at the calibration position, and the direction of the dynamic excitation should correspond to the direction of the cutting force to be calibrated. The frequency range of the dynamic excitation should at least cover the effective frequency range for which dynamic response compensation is to be performed. At the same time, the reference excitation load and the response signals of each mechanical sensing channel are acquired simultaneously, thereby obtaining the dynamic transmission relationship between the input load and the multi-channel response at the corresponding calibration position.

[0077] Dynamic force response parameters can be represented by frequency response data, transfer function parameters, impulse response parameters, or other parameter forms that can describe the dynamic transmission characteristics of cutting load to each mechanical sensing channel.

[0078] Therefore, the force response parameters in this application can include static force response parameters describing the static sensitivity and cross-coupling relationship of the multi-channel system, and dynamic force response parameters describing the dynamic transmission characteristics of the force-measuring structure. In actual implementation, the types of parameters to be saved can be determined according to the channel decoupling method and dynamic response compensation method adopted in step S400, as long as the response of the mechanical sensing channel can be restored to the corresponding cutting force component based on the corresponding parameters.

[0079] In some embodiments, the spatial coordinates of each calibrated action position are associated and stored with its corresponding force response parameter to form a set of force response parameters with a position index. The calibrated action position is represented using the same spatial reference datum as the equivalent action position in step S200, thereby enabling direct matching within the set of force response parameters based on the current equivalent action position. The set of force response parameters can be stored in the data processing unit of the intelligent sensing system or in a storage unit connected to the data processing unit, and can be retrieved when measuring the cutting force of the intersection hole boring.

[0080] When determining the current force response parameter, the equivalent action position obtained in step S200 is compared with each calibrated action position. When the current equivalent action position is consistent with a calibrated action position or the position difference between the two meets a preset position matching condition, the force response parameter corresponding to the calibrated action position can be determined as the current force response parameter.

[0081] When the current equivalent action position is located between adjacent calibration action positions, the current force response parameter can be determined based on the force response parameters corresponding to the adjacent calibration action positions. For a one-dimensional effective calibration domain, interpolation can be performed based on the positional relationship between the current equivalent action position and the adjacent calibration action positions on both sides; for a two-dimensional or three-dimensional effective calibration domain, multi-dimensional interpolation can be performed based on the adjacent calibration action positions surrounding the current equivalent action position and their spatial positional relationship, thereby obtaining the force response parameter corresponding to the current equivalent action position.

[0082] When establishing the position-dependent force response relationship, calibration data not involved in determining the corresponding interpolation parameters can be used to verify the interpolation results. When the difference between the interpolated force response parameters and the corresponding calibration results exceeds the predetermined allowable error, additional calibration locations are added within the corresponding position range, or a piecewise fitting method is used to re-establish the correspondence between the position and the force response parameters. This ensures that position interpolation is only applied to the range of positions that have been calibrated and verified to maintain the continuous variation characteristics of the force response, reducing the deviation in force response parameters caused by directly using spatial distance interpolation.

[0083] In some embodiments, for static force response parameters, position interpolation can be performed on each sensitivity parameter and channel coupling parameter separately. For dynamic force response parameters represented by frequency response data, interpolation can be performed on the frequency response parameters corresponding to adjacent calibration positions at the same frequency position, so that the obtained dynamic force response parameters correspond to the current equivalent position. For dynamic force response parameters represented by other parameter models, position matching or interpolation can also be performed on the parameters characterizing the dynamic response characteristics in the model.

[0084] In some embodiments, to avoid discontinuous changes during parameter switching between adjacent calibration positions, the current force response parameter can be determined by continuous interpolation of the force response parameters corresponding to adjacent positions. This ensures that as the equivalent position changes continuously with the boring tool feed and rotation, the current force response parameter is also continuously updated with the position. This reduces the introduction of unrealistic load changes into subsequent multi-component cutting force calculations due to abrupt changes in the force response parameter.

[0085] In some embodiments, the calibrated force response parameters can also be version-associated according to calibration time, sensor installation status, or force measurement structure configuration. When the force sensor, boring tool assembly, or force measurement structure with influence transmission relationship is reinstalled or replaced, the calibration at the corresponding location can be re-executed, and the correspondence between the cutting load application location and the force response parameters can be updated to ensure that the force response parameters are consistent with the actual force transmission state of the current intelligent sensing system.

[0086] The current equivalent action position is preferably located within a predetermined effective calibration domain. When the equivalent action position obtained in step S200 exceeds the effective calibration domain, in some embodiments, the corresponding sampling time can be marked as exceeding the effective range of the force response parameters to avoid reconstructing the cutting force using unverified extrapolated parameters. For boundary regions that have already passed extended calibration verification, the current force response parameters can also be obtained according to the corresponding boundary parameter determination rules.

[0087] In step S300, the equivalent action position obtained in step S200, which varies with the geometry of the intersection hole and the boring tool posture, can be converted into force response parameters corresponding to the actual force transmission position of the current cutting load. Thus, the same set of mechanical sensing channels no longer relies on a single force relationship applicable to a fixed load action position, but can update the response relationship used for cutting force measurement according to the current equivalent action position, providing a basis for measurement parameters in step S400 for channel decoupling and dynamic response compensation based on the current material contact state.

[0088] Step S400 is used to correct the measurement relationship of the original response signals of multiple mechanical sensing channels based on the current force response parameters and material contact state, and restore the sensing response affected by the channel cross response and the dynamic transmission characteristics of the force measuring structure to the corresponding cutting force component.

[0089] Since the contact range between the cutting edge and the solid material changes with the position of the boring tool and the rotation of the spindle during the boring process, the continuity and dynamic change characteristics of the cutting load differ under different material contact states. Therefore, while using the current force response parameters to eliminate the coupling effect between different mechanical sensing channels, a dynamic response compensation method adapted to the current measurement conditions is also determined based on the current material contact state. This ensures that the obtained multi-component cutting force maintains the independence between the force directions and minimizes the amplitude and phase distortion caused by the dynamic characteristics of the force measurement structure.

[0090] In some embodiments, step S400 includes steps S410 to S440.

[0091] Step S410: Determine the effective force measurement range and dynamic response compensation conditions corresponding to the original response signal based on the current material contact state.

[0092] Step S200 has already determined the material contact state for each sampling time. Therefore, the material contact state can be correlated point-by-point or segment-by-segment with the original response signal obtained in step S100 along a unified time reference. When the material contact state indicates that the boring tool cutting edge is in contact with the solid material, the corresponding original response signal is used as cutting load measurement data and enters the subsequent channel decoupling and dynamic response compensation. When the material contact state indicates that the boring tool cutting edge is detached from the solid material, the corresponding time period is not considered as the solid cutting load range and can be identified as the sensing background response under no-cutting contact conditions.

[0093] The dynamic response compensation conditions in this application refer to the processing conditions used when dynamically correcting the original response signal by combining the current material contact state and the effective dynamic range of the current force response parameters. Dynamic response compensation conditions may include one or more of the following: effective compensation frequency range, dynamic response parameter call status, and conditions for determining the validity of the compensation result. Dynamic response compensation conditions are not used to determine whether the boring process is normal, but rather to limit the current original response signal under what measurement conditions it is corrected according to the corresponding dynamic force response characteristics.

[0094] In some embodiments, for the complete material contact state, dynamic response compensation can be performed according to the effective dynamic measurement range corresponding to the continuous cutting conditions; for the partial material contact state, since rapid load changes may occur when the cutting edge enters or leaves the material-deficient area of ​​the intersecting hole, the corresponding transient load components can be retained within the effective frequency range of the current force response parameters after calibration and verification, avoiding the weakening of actual cutting force changes by using excessive smoothing processing. The frequency range used for dynamic response compensation does not exceed the effective range of the corresponding dynamic force response parameters after calibration and verification, so as to avoid excessive amplification of measurement noise in the force measurement structure resonance or low signal-to-noise ratio frequency band.

[0095] In some embodiments, when the material contact state is the de-contact state, the corresponding original response signal can be used as candidate data for sensing background baseline estimation, but the instantaneous response in the de-contact state is not directly taken as zero. First, the transient response interval corresponding to when the cutting edge has just de-contacted the solid material or is about to re-enter the solid material is excluded based on the material contact state, and the background response interval that satisfies the stability condition is determined from the remaining candidate data.

[0096] For the background response range, quasi-static components or low-frequency drift components can be extracted from each mechanical sensing channel, and the sensing background baseline of the corresponding channel can be updated based on these components. In cases where there is a periodic background response synchronized with the spindle rotation, the periodic background response can be identified by combining it with the spindle angular position obtained in step S100, and distinguished from the quasi-static or low-frequency drift components, so that the dynamic response synchronized with the spindle rotation is not directly subtracted as zero-point drift.

[0097] The original response signal with subsequent material contact can be baseline corrected based on the updated sensing background baseline before entering channel decoupling and dynamic response compensation. When the length of the material contact interval is insufficient or the background response does not meet the stability condition, the previous effective sensing background baseline can be maintained instead of being forcibly updated using the current interval. Through the above processing, the slowly changing sensing background can be estimated using the non-cutting contact interval naturally formed during the boring of the intersection hole, while reducing the possibility of rotationally correlated dynamic response being mistaken for zero-point drift and introducing additional measurement errors.

[0098] Step S420: Decouple the original response signals of multiple mechanical sensing channels according to the current force response parameters to obtain the preliminary multi-component cutting force in the measurement coordinate system.

[0099] The responses of multiple mechanical sensing channels to cutting loads are not necessarily independent one-to-one correspondences with the components of the cutting force being measured. For example, a radial cutting force may generate a response not only in its primary corresponding mechanical sensing channel, but also in other mechanical sensing channels due to the geometric transmission relationship of the force measuring structure, the arrangement of sensing elements, and structural deformation. Therefore, directly using the outputs of each mechanical sensing channel as the cutting force in the corresponding direction may introduce coupling errors between different cutting force components.

[0100] Channel decoupling refers to converting the coupled response formed by multiple mechanical sensing channels into independent cutting force components based on the force response relationship between multiple mechanical sensing channels and multiple independent cutting force components. The current force response parameters determined in step S300 correspond to the current equivalent action position. Therefore, the multi-channel force measurement relationship corresponding to the current sampling position can be established based on the static force response parameters, and the cutting force components that generate the current multi-channel response can be obtained using this force measurement relationship.

[0101] In some embodiments, the original response signals from multiple mechanical sensing channels at the same sampling time can be combined to form a response vector, and a current force response matrix can be constructed based on the static force response parameters in the current force response parameters. The current force response matrix characterizes the response relationship between multiple cutting force components and multiple mechanical sensing channels, with each parameter in the matrix describing the degree of response of a cutting force component to its corresponding mechanical sensing channel. By solving for the measurement relationship between the current force response matrix and the response vector, the preliminary cutting force components corresponding to each direction in the measurement coordinate system can be obtained.

[0102] Each mechanical sensing channel can use the electrical signal output of the corresponding sensing element, or it can use the force or torque response after primary calibration of the channel as the response quantity. The parameters in the force response matrix are determined by the correspondence between the known calibration load and the response of each mechanical sensing channel. The corresponding parameters include the channel sensitivity, the load lever arm, and the unit conversion relationship. Therefore, the response quantities of different mechanical sensing channels are not required to have the same physical dimensions.

[0103] When the number of mechanical sensing channels equals the number of cutting force components to be measured, and the current force response matrix satisfies the invertibility condition, each cutting force component can be obtained through matrix inversion or equivalent linear solution. When the number of mechanical sensing channels exceeds the number of cutting force components to be measured, a minimum error solution method based on redundant measurement information can be used to determine each cutting force component, allowing multiple mechanical sensing channels to participate in cutting force reconstruction.

[0104] In some embodiments, when the force response matrix exhibits strong coupling near a specific equivalent action location, making direct solution prone to amplifying measurement disturbances, a constrained stable solution method can be used to obtain the initial multi-component cutting force. The corresponding constraints are used to suppress abnormal amplification caused by ill-conditioned force response relationships or measurement noise, without altering the actual force direction corresponding to each cutting force component.

[0105] Step S430: Perform dynamic response compensation on the initial multi-component cutting force based on the dynamic force response parameters in the current force response parameters and the dynamic response compensation conditions determined in step S410.

[0106] When the boring cutting load is transmitted from the workpiece side to the force measuring structure and responded to by the mechanical sensor, the force measuring structure itself has dynamic characteristics such as mass, stiffness, and damping. Therefore, the responses formed by each mechanical sensing channel do not maintain the same amplitude and phase relationship with the actual cutting load across all frequency ranges. Especially when the boring tool passes through the boundary position of the material-deficient area of ​​the intersecting hole, the cutting load may change in a short period of time, and the dynamic response of the force measuring structure may be superimposed on the actual load response. Dynamic response compensation is used to correct the measurement distortion caused by the dynamic transmission of the structure based on the dynamic force measurement response parameters corresponding to the current position determined in step S300.

[0107] In some embodiments, when the dynamic force response parameters are represented by frequency response data, the initial multi-component cutting force can be converted to the frequency domain. Within the effective frequency range that has been calibrated and verified, the amplitude attenuation, amplitude amplification, and phase shift of each frequency component are corrected according to the amplitude-frequency characteristics and phase-frequency characteristics corresponding to the current equivalent action position. The corrected frequency domain result is then converted back to the time domain to obtain the multi-component cutting force after dynamic response compensation.

[0108] In some embodiments, when the dynamic force response parameters are represented in the form of a transfer function or impulse response, an inverse dynamic compensation model corresponding to the current equivalent action position can be established, and this dynamic compensation model can be used to process the initial multi-component cutting force. The inverse dynamic compensation model is limited to the effective dynamic range confirmed by calibration to avoid noise amplification caused by directly inverting the dynamic characteristics of the force measuring structure near resonance or in the low-frequency range of the response amplitude.

[0109] In implementations requiring online output of cutting force measurement results during boring, a stable causal digital compensation filter can be constructed within a calibrated and confirmed effective dynamic range based on the current dynamic force response parameters. Continuous data can then be recursively compensated according to the sampling order of the original response signals. For dynamic response compensation implemented in the frequency domain, the continuously sampled data can be divided into sequentially arriving data blocks. Frequency domain conversion, dynamic response correction, and time domain recovery can be performed on the acquired data blocks, and the compensation result can be output after processing the corresponding data blocks. Thus, the data acquisition process can continue continuously, and dynamic response compensation allows for limited processing delays caused by data buffering and computation, without waiting for the entire boring process of the intersection hole to finish before performing cutting force measurement.

[0110] In some embodiments, channel decoupling and dynamic response compensation can be jointly processed using a multi-input multi-output dynamic force measurement relationship. Specifically, based on the dynamic force response parameters in the current force response parameters, a multi-channel frequency response matrix is ​​established for each discrete frequency position within the effective frequency range corresponding to the dynamic force response parameters, relating multiple mechanical sensing channels to multiple cutting force components. Different rows in the frequency response matrix correspond to different mechanical sensing channels, and different columns correspond to different cutting force components to be determined. Matrix elements characterize the dynamic response of the corresponding cutting force component to the corresponding mechanical sensing channel at the corresponding frequency position. For measurement conditions where channel cross-coupling varies with frequency, the aforementioned multi-input multi-output dynamic force measurement relationship can be used to simultaneously perform channel decoupling and dynamic response compensation.

[0111] In actual measurement, the responses of multiple mechanical sensing channels at the same frequency position are combined into a frequency domain response vector, and the frequency domain results of each cutting force component are jointly obtained based on the frequency response matrix corresponding to the current equivalent action position. When the frequency response matrix satisfies the stability solution condition, a pseudo-inverse method can be used for solution; when there is strong dynamic coupling at some frequency positions or when direct inverse solution of the frequency response matrix easily amplifies measurement noise, an inverse solution method with regularization constraints can be used to limit abnormal amplification. After completing the joint solution of each frequency component within the effective frequency range, the obtained cutting force components are converted back to the time domain, forming a multi-component cutting force that has undergone channel decoupling and dynamic response compensation.

[0112] When using the above combined processing method, the channel decoupling in step S420 and the dynamic response compensation in step S430 can be completed in the same multi-input multi-output dynamic solution process, without requiring the static channel decoupling to be completed first and then the dynamic inverse compensation to be performed independently. For measurement conditions where the impact of dynamic channel coupling is small, the corresponding processing can still be performed separately according to steps S420 and S430.

[0113] In some embodiments, dynamic response compensation can be performed using a sliding processing window on continuously sampled data. The processing window moves along the processing process with a unified time reference, and the use of the same set of dynamic response compensation conditions is determined based on the corresponding material contact states within the window. When a processing window spans different material contact states, the processing window can be shortened, or dynamic response compensation can be performed separately on the data segments corresponding to different states and then continuously connected to reduce boundary errors caused by directly mixing different measurement conditions.

[0114] When the current force response parameters are continuously updated with the equivalent application position, the dynamic force response parameters used in the dynamic response compensation process can be updated synchronously. To avoid the introduction of artificial jumps due to excessively rapid parameter changes between adjacent sampling times, the continuous position force response parameters output in step S300 can be directly smoothed out, or continuous interpolation can be performed between adjacent force response parameters according to the equivalent application position, so that the changes in compensation parameters are consistent with the migration of the actual cutting load application position.

[0115] Step S440: Perform time-correspondence processing on each cutting force component after channel decoupling and dynamic response compensation to obtain the multi-component cutting force in the measurement coordinate system.

[0116] After dynamic response compensation is completed, each cutting force component retains the unified time reference established in step S100, thus maintaining correspondence with the boring tool pose data and material contact state at the corresponding sampling time. The multi-component cutting force in the measurement coordinate system may include two or more independent force components along different coordinate axes of the measurement coordinate system, and the specific number of components is determined according to the configuration of the mechanical sensing channel and the actual measurement requirements.

[0117] In some embodiments, for three-component cutting force measurement, the cutting force components in three mutually orthogonal directions of the measurement coordinate system can be obtained. If the mechanical sensing channel also includes torque or bending moment response, the torque and bending moment channels can be used as sensing inputs in the multi-component cutting force solution process to improve the distinguishability of different force directions. The final output measurement result can still be represented as three linear cutting force components in the measurement coordinate system as needed.

[0118] In some embodiments, a measurement validity indicator can be added to the multi-component cutting force after dynamic response compensation. Measurement validity can be determined based on conditions such as whether the current equivalent action position is within the valid range of the force response parameters, whether the current dynamic frequency component is within the calibrated and verified compensation range, and whether each mechanical sensing channel is saturated. When any condition does not meet the pre-defined measurement validity conditions, the corresponding sampling interval can be marked, instead of using unverified compensation results to replace the actual cutting force measurement value.

[0119] In step S400, the raw response signals from multiple mechanical sensing channels are processed according to the force response relationship corresponding to the current equivalent action position, and the dynamic response compensation conditions are adapted in conjunction with the current material contact state, thereby obtaining the multi-component cutting force in the measurement coordinate system. This process not only decouples the cross-response between different force directions, but also corrects the dynamic amplitude and phase distortion caused by the cutting load transmitted through the force measurement structure, so that the multi-component cutting force output in step S400 can serve as the measurement basis for the tool follow-up coordinate transformation in step S500.

[0120] Step S500 is used to convert the multi-component cutting force in the measurement coordinate system obtained in step S400 into the tool follower coordinate system corresponding to the motion state of the boring tool itself.

[0121] The measurement coordinate system maintains a fixed spatial relationship with the force measuring structure, and the force components in each direction facilitate sensor calibration, channel decoupling, and dynamic response compensation. However, as the boring bar rotates around its own axis, the direction of the same cutting direction in the measurement coordinate system changes with the spindle angle position. Therefore, it is necessary to combine the boring bar pose data obtained in step S100 to determine the real-time transformation relationship between the two coordinate systems, converting the force components in the fixed measurement coordinate system into cutting force components that move with the boring bar, so that the final measurement result can directly characterize the radial, tangential, and axial cutting loads experienced by the boring bar at the current machining moment.

[0122] In some embodiments, step S500 includes steps S510 to S530.

[0123] Step S510: Based on the boring tool pose data and the installation geometry between the measurement coordinate system and the boring tool, determine the coordinate transformation relationship between the measurement coordinate system and the tool follower coordinate system at the current sampling moment.

[0124] The tool follower coordinate system changes with the boring tool's position and is used to represent the cutting force in a direction related to the boring tool's own structure and cutting direction. In some embodiments, a predetermined tool reference point on the boring tool can be used as the reference position of the tool follower coordinate system. The direction along the boring tool axis is determined as the axial direction, and the direction perpendicular to the boring tool axis and along a predetermined radial reference direction of the tool is determined as the radial direction. The tangential direction is then determined based on the radial and axial directions. For a single-edge boring tool, the radial reference direction can be determined based on the mounting direction of the cutting edge relative to the boring tool axis. For a boring tool with multiple cutting edges, a predetermined reference direction in the tool structure can be selected as the radial reference direction, and represented according to the fixed angular relationship between each cutting edge and this reference direction.

[0125] The initial installation relationship between the measurement coordinate system and the tool follower coordinate system can be determined during the installation or calibration of the intelligent sensing system. Specifically, the relative orientation relationship between the two coordinate systems in the reference pose can be determined based on the installation direction of the force measuring structure, the boring tool axis direction, and the tool reference direction, and the corresponding initial coordinate transformation parameters can be saved. During the machining process, the initial coordinate transformation parameters are updated based on the current boring tool pose data, thereby obtaining the real-time coordinate transformation relationship corresponding to each sampling moment.

[0126] In some embodiments, when the boring tool axis remains fixed relative to the measurement coordinate system and rotates only around the boring tool axis, the rotation angle between the radial plane of the measurement coordinate system and the radial plane of the tool follower coordinate system can be determined based on the spindle angular position. The zero position of the spindle angular position can be determined before machining using the spindle encoder zero position, the tool mounting reference, or a preset tool reference direction, so that different machining processes use a consistent angular position reference. Step S510 uses the spindle angular position data after time correlation and synchronization verification completed in step S100 to determine the real-time coordinate transformation relationship.

[0127] When the boring tool experiences changes in tool axis direction, angle head posture, or other spatial postures in addition to rotation and axial feed, the orientation of each coordinate axis of the tool follower coordinate system in the measurement coordinate system can be determined based on the boring tool posture data, and a three-dimensional coordinate transformation relationship can be established accordingly. In this case, the coordinate transformation simultaneously considers the spatial posture of the boring tool and the spindle rotation state, and is not limited to planar rotation around a single axis.

[0128] Step S520: According to the coordinate transformation relationship corresponding to the current sampling time, convert the multi-component cutting force in the measurement coordinate system into the cutting force component in the tool follower coordinate system.

[0129] The multi-component cutting forces obtained in step S400 can be combined into a force vector based on the cutting forces in each direction at the same sampling time. According to the coordinate transformation relationship determined in step S510, the components of this force vector in the measurement coordinate system are projected onto the coordinate axes of the tool follower coordinate system, thus obtaining the cutting force components corresponding to the radial, tangential, and axial directions of the tool. The coordinate transformation only changes the coordinate system in which the cutting force vector is expressed; it does not change the actual mechanical vector obtained after decoupling and dynamic response compensation in step S400.

[0130] In some embodiments, when one axis of the measurement coordinate system coincides with or is parallel to the boring tool axis, the axial cutting force can be directly determined by the cutting force component in the corresponding direction of the measurement coordinate system. The other two cutting force components located in the radial plane of the boring tool are rotated according to the current spindle angle position to obtain the radial cutting force and the tangential cutting force, respectively.

[0131] When there is a fixed angular deviation between the measurement coordinate system and the boring tool axis, the installation posture of the multi-component cutting forces in the measurement coordinate system can be corrected first based on the fixed posture relationship obtained from the installation calibration. Then, the transformation to the tool follower coordinate system can be completed by combining the current boring tool posture. Alternatively, the installation posture relationship and the current boring tool posture relationship can be merged to form a unified coordinate transformation relationship, and the coordinate transformation of the multi-component cutting forces can be completed in one step.

[0132] The positive direction in the tangential direction can be determined according to the predetermined rotation direction of the boring tool. The positive direction in the radial direction can be defined as pointing from the boring tool axis to the predetermined tool reference direction. The positive direction in the axial direction can be determined according to the predetermined direction of the boring tool axis. The above-mentioned directions should be kept consistent in the same machining task and the corresponding force measurement calibration process to avoid changes in the sign of the cutting force measurement results due to changes in the positive direction of the coordinates.

[0133] Step S530: Organize the cutting force components under the tool follower coordinate system according to a unified time reference to form the cutting force measurement results during the boring process of the intersection hole.

[0134] In some embodiments, the cutting force measurement results include radial cutting force, tangential cutting force, and axial cutting force that vary with time, and each cutting force component maintains the same time correspondence with the boring tool pose data in step S100. Therefore, the machining position, material contact state, and corresponding multi-component cutting force of the boring tool can be determined simultaneously based on any sampling time.

[0135] For the sampling interval with a measurement validity indicator attached in step S400, the corresponding measurement validity indicator can be retained when forming the cutting force measurement result, so that when the cutting force data is displayed, stored or analyzed in the future, it can be distinguished between normal valid measurement data and data that exceeds the effective range of the force response parameter, the sensor channel is saturated or other data that does not meet the measurement validity conditions.

[0136] In some embodiments, cutting force measurement results can be continuously generated in a time sequence and stored in association with the current machining task, the hole to be boring, and the corresponding information of intersecting holes. This allows for the acquisition of a complete multi-component cutting force variation process covering the boring bar entering the intersecting hole region, passing through the material-deficient region of the intersecting hole, and re-entering the solid material region. This provides cutting force measurement data with clear spatial and temporal locations for subsequent machining process analysis and cutting parameter evaluation.

[0137] In step S500, the multi-component cutting force obtained under the fixed coordinate direction of the force measuring structure is converted into cutting force components corresponding to the actual cutting direction of the boring tool. This allows the cutting force at different sampling moments during the continuous rotation of the boring tool to be compared according to a unified tool force direction. Thus, steps S100 to S500 form a complete cutting force measurement process, from acquiring the geometric data of the intersection hole, the boring tool pose data, and the multi-channel original response signal, to determining the material contact state and equivalent action position, matching the force response parameters at the current position, channel decoupling and dynamic response compensation, and finally to the tool follow-up coordinate transformation, ultimately obtaining the multi-component cutting force measurement results during the boring process of the intersection hole.

[0138] This application also provides an intelligent sensing system for the cutting force of boring intersecting holes. This intelligent sensing system is used to implement the aforementioned method for measuring the cutting force of boring intersecting holes, see reference [link to relevant documentation]. Figure 2 The system includes a force measuring structure, a mechanical sensor, a signal conditioning and data acquisition unit, a boring tool position data acquisition unit, and a data processing unit.

[0139] The mechanical sensor is disposed on the force measuring structure to respond to the cutting load transmitted to the force measuring structure, and has multiple mechanical sensing channels for characterizing different mechanical actions.

[0140] The force-measuring structure is used to withstand the cutting load transmitted through the workpiece side during the boring of the intersection hole. Each mechanical sensing channel generates a sensing signal related to the corresponding mechanical action.

[0141] The signal conditioning and data acquisition unit is connected to the mechanical sensor and is used to acquire the sensing signals formed by each mechanical sensing channel to obtain the original response signals corresponding to multiple mechanical sensing channels.

[0142] The boring tool pose data acquisition unit is used to acquire the boring tool pose data during the boring process of the intersection hole.

[0143] The signal conditioning and data acquisition unit and the boring tool pose data acquisition unit are respectively connected to the data processing unit, and the data processing unit can acquire the geometric data of the intersection hole corresponding to the current machining task.

[0144] The data processing unit is configured to: acquire the geometric data of the intersection hole, the boring tool pose data, and the raw response signals collected by multiple mechanical sensing channels; and associate the geometric data of the intersection hole, the boring tool pose data, and the raw response signals to a unified time reference; determine the material contact state of the boring tool cutting edge relative to the material missing area of ​​the intersection hole based on the geometric data of the intersection hole and the boring tool pose data, and determine the equivalent action position of the current cutting load; determine the current force response parameters based on the equivalent action position from the pre-established correspondence between the action position of the cutting load and the force response parameters; perform channel decoupling and dynamic response compensation on the raw response signals of multiple mechanical sensing channels based on the current force response parameters and the material contact state to obtain multi-component cutting forces in the measurement coordinate system; and convert the multi-component cutting forces to the tool follower coordinate system based on the boring tool pose data to obtain the cutting force measurement results during the boring process of the intersection hole.

[0145] Therefore, the force measuring structure and mechanical sensor constitute the sensing part of the cutting load, the signal conditioning and data acquisition unit completes the acquisition of multi-channel raw response signals, the boring tool posture data acquisition unit provides tool motion data corresponding to the cutting load measurement process, and the data processing unit combines the intersection hole geometry data to determine the material contact state, equivalent action position, current force response parameters and multi-component cutting force, and completes the conversion of cutting force from the measurement coordinate system to the tool follow-up coordinate system, so that the intelligent sensing system can realize the measurement of multi-component cutting force in the intersection hole boring process.

[0146] In some embodiments, a force-measuring structure is disposed between the workpiece fixture and the machine tool table. One side of the force-measuring structure is connected to the workpiece fixture, and the other side is connected to the machine tool table. The workpiece is mounted on the workpiece fixture. During boring, the cutting load generated by the boring bar acting on the workpiece is sequentially transmitted to the force-measuring structure via the workpiece and the workpiece fixture. A force sensor is disposed on the force-measuring structure and kept fixed relative to the measurement coordinate system. The force sensor has multiple force sensing channels, enabling different force sensing channels to respond accordingly to axial loads, torsional loads, and bending loads transmitted to the force-measuring structure.

[0147] In some embodiments, the multiple mechanical sensing channels include an axial force measurement channel, a torque measurement channel, and bending moment measurement channels that characterize bending forces about the X and Y axes of the measurement coordinate system, respectively. The mechanical sensors are connected to a signal conditioning and data acquisition unit via fixed data acquisition lines. The signal conditioning and data acquisition unit acquires the sensing signals generated by each mechanical sensing channel. The signal conditioning and data acquisition unit can perform one or more of the following processing on the sensing signals output from each mechanical sensing channel: signal conditioning, amplification, anti-aliasing filtering, and analog-to-digital conversion. It then generates the original response signals for each mechanical sensing channel according to a unified sampling clock or a sampling method that establishes a time correspondence.

[0148] In some embodiments, the boring tool pose data acquisition unit includes an axial position acquisition interface and a spindle angular position acquisition interface. The axial position acquisition interface can be connected to the machine tool CNC system, a feed axis position detection device, or a corresponding position data interface to obtain the axial position of the boring tool along the axis of the hole to be boring. The spindle angular position acquisition interface can be connected to a spindle encoder, a spindle position detection device, or a corresponding data interface of the CNC system to obtain the angular position of the boring tool as the spindle rotates. For machining processes involving radial adjustment or other tool posture changes, the boring tool pose data acquisition unit may also have corresponding position or posture data acquisition interfaces.

[0149] Both the signal conditioning and data acquisition unit and the boring tool posture data acquisition unit establish data connections with the data processing unit. This data connection can utilize an internal data bus, an industrial communication interface, or other connection methods capable of transmitting the acquired data. The data processing unit establishes a time correspondence between the original response signal and the boring tool posture data based on the timestamps corresponding to each data point, a common trigger signal, or a unified clock. When the spindle angular position data and the original response signal are obtained from different acquisition links, the data processing unit can also perform synchronous verification based on the spindle encoder's reference angle mark, periodic index signal, or a predetermined link delay.

[0150] In some embodiments, the data processing unit has a data storage area or is connected to a storage unit. The geometric data of the intersection holes and the pre-calibrated correspondence between the cutting load application positions and the force response parameters can be stored in the data processing unit or a storage unit connected to it. When performing cutting force measurement, the data processing unit reads the corresponding intersection hole geometric data according to the current machining task, and calls or calculates the corresponding current force response parameters based on the currently determined equivalent application position.

[0151] In some embodiments, to facilitate the implementation of data processing logic, the data processing unit may include a synchronization processing module, a contact and application position determination module, a force response parameter determination module, a cutting force processing module, and a coordinate transformation module. These modules are functional modules within the data processing unit, divided according to their processing functions, and do not require separate implementation using independent hardware devices.

[0152] The synchronization processing module receives the geometric data of the intersection hole, the boring tool pose data, and the raw response signal output by the signal conditioning and data acquisition unit, respectively. It is used to associate the above data with a unified time reference and send the time-associated data to the contact and action position determination module and subsequent functional modules that require the corresponding data.

[0153] The contact and application position determination module is connected to the synchronization processing module. It determines the material contact state of the boring tool cutting edge relative to the material-deficient area of ​​the intersecting hole based on the intersection hole geometry data and the current boring tool pose data. It also determines the equivalent application position of the cutting load based on the current solid contact section. The output of the contact and application position determination module is connected to the force response parameter determination module, and sends the equivalent application position to the force response parameter determination module.

[0154] The force response parameter determination module reads the pre-established correspondence between the cutting load application position and the force response parameters, and determines the current force response parameters based on the current equivalent application position. The output of the force response parameter determination module is connected to the cutting force processing module, providing the current force response parameters to the cutting force processing module.

[0155] The cutting force processing module receives the original response signals, current force response parameters, and material contact state corresponding to multiple mechanical sensing channels, and performs channel decoupling and dynamic response compensation according to the processing method described in step S400 above, outputting multi-component cutting forces in the measurement coordinate system. For implementations using multi-input multi-output dynamic joint processing, channel decoupling and dynamic response compensation can be completed by the cutting force processing module in the same dynamic solution process.

[0156] The coordinate transformation module is connected to the cutting force processing module and the synchronization processing module respectively. It is used to receive the multi-component cutting force in the measurement coordinate system and the boring tool posture data at the corresponding time. According to the coordinate transformation relationship between the measurement coordinate system and the tool follower coordinate system, the multi-component cutting force is converted into the cutting force component in the tool follower coordinate system, forming the cutting force measurement result in the boring process of the intersection hole.

[0157] In some embodiments, the intelligent sensing system may further include an output and storage unit connected to a data processing unit for receiving, storing, displaying, or transmitting cutting force measurement results to external machining monitoring equipment. The cutting force measurement results may include radial cutting force, tangential cutting force, and axial cutting force, and may be associated with and stored in conjunction with corresponding machining time, boring tool position, material contact state, and measurement validity indicators.

[0158] In the aforementioned intelligent sensing system, the force-measuring structure, mechanical sensor, and signal conditioning and data acquisition unit form a physical sensing and data acquisition link for the cutting load, while the boring tool posture data acquisition unit forms a tool motion data acquisition link. Both data links are connected to the data processing unit. The data processing unit organizes the corresponding data according to a unified time reference and sequentially completes the determination of material contact state and equivalent action position, determination of current force response parameters, channel decoupling and dynamic response compensation, and tool follow-up coordinate transformation. This ensures that the system's structural composition and data transmission relationship correspond to the aforementioned method for measuring the cutting force in intersection hole boring.

[0159] It should be noted that, in order to simplify the description of this application and thus aid in the understanding of one or more embodiments of the invention, the foregoing description of the embodiments of this application sometimes combines multiple features into one embodiment, drawing, or description thereof. However, this does not mean that the technical solution claimed in this application must simultaneously possess all the described features. For those skilled in the art, the technical features in the above embodiments can be combined, substituted, or adjusted without departing from the concept of this application, and such combinations, substitutions, or adjustments should all fall within the protection scope of this application.

Claims

1. A method for measuring the cutting force in boring intersecting holes, characterized in that, include: Acquire the geometric data of the intersection hole, the boring tool pose data, and the raw response signals collected by multiple mechanical sensing channels, and associate the geometric data of the intersection hole, the boring tool pose data, and the raw response signals with a unified time reference; Based on the geometric data of the intersection holes and the boring tool pose data, the material contact state of the boring tool cutting edge relative to the material missing area of ​​the intersection holes is determined, and the equivalent action position of the current cutting load is determined. Based on the equivalent action position, the current force response parameter is determined from the pre-established correspondence between the cutting load action position and the force response parameter. Based on the current force response parameters and material contact state, channel decoupling and dynamic response compensation are performed on the original response signals of multiple mechanical sensing channels to obtain multi-component cutting force in the measurement coordinate system. Based on the boring tool pose data, the multi-component cutting force is converted to the tool follower coordinate system to obtain the cutting force measurement results during the boring process of the intersection hole.

2. The method for measuring cutting force in boring intersecting holes according to claim 1, characterized in that, The step of determining the material contact state of the boring tool cutting edge relative to the material-deficient area of ​​the intersecting hole based on the geometric data of the intersecting hole and the boring tool pose data, and determining the equivalent position of the current cutting load, includes: Based on the tool geometry parameters and the boring tool pose data at the current sampling time, determine the spatial position of the boring tool cutting edge in the workpiece coordinate system; Based on the geometric data of the intersecting holes, determine the spatial range of the material missing area of ​​the intersecting holes in the workpiece coordinate system; By geometrically comparing the spatial position of the boring tool cutting edge with the spatial range of the missing area of ​​the intersecting hole material, the solid contact section in the boring tool cutting edge corresponding to the solid material to be removed is determined; The current material contact state is determined based on the spatial distribution of the solid contact section on the boring tool cutting edge, and the equivalent position of the current cutting load is determined based on the solid contact section.

3. The method for measuring cutting force in boring intersecting holes according to claim 2, characterized in that, Determining the equivalent position of the current cutting load based on the physical contact section includes: The solid contact area is divided into multiple local cutting units, and the representative position of each local cutting unit on the boring tool cutting edge and the corresponding effective contact length are determined. The effective contact length of each local cutting unit is used as the corresponding load contribution weight. The equivalent position of the current cutting load is obtained by weighting the representative positions of each local cutting unit and the corresponding load contribution weights.

4. The method for measuring cutting force in boring intersecting holes according to claim 1, characterized in that, The correspondence between the location of the cutting load and the force response parameters is established in advance in the following way: The effective calibration domain is determined based on the predetermined range of variation of the equivalent action position, and multiple calibration action positions are set within the effective calibration domain; A calibration load of known magnitude and direction is applied at each calibration position, and the response data of the multiple mechanical sensing channels under the corresponding calibration load is acquired simultaneously. Based on the calibration load corresponding to each calibration position and the response data of the multiple mechanical sensing channels, the force response parameters corresponding to each calibration position are determined. By associating each calibrated application position with the corresponding force response parameter, a correspondence between the application position of the cutting load and the force response parameter is established.

5. The method for measuring cutting force in boring intersecting holes according to claim 4, characterized in that, The force response parameters include static force response parameters and dynamic force response parameters; The static force response parameters are determined by applying calibration loads along multiple independent force directions at the same calibration position and based on the response data corresponding to each calibration load and the multiple mechanical sensing channels. These parameters are used to characterize the static sensitivity and channel coupling relationship between multiple cutting force components and the multiple mechanical sensing channels. The dynamic force response parameters are determined by applying a known dynamic excitation load at the calibrated position and based on the dynamic response data corresponding to the dynamic excitation load and the plurality of mechanical sensing channels, and are used to characterize the dynamic transmission characteristics between the cutting load and the plurality of mechanical sensing channels.

6. The method for measuring cutting force in boring intersecting holes according to claim 4, characterized in that, The step of determining the current force response parameters based on the equivalent application position from the pre-established correspondence between the cutting load application position and the force response parameters includes: From the multiple calibration action positions set within the effective calibration domain, determine a plurality of calibration action positions adjacent to the equivalent action position; Based on the positional relationship between the equivalent action position and each adjacent calibration action position, the force response parameters corresponding to each adjacent calibration action position are interpolated to obtain the current force response parameters corresponding to the equivalent action position.

7. The method for measuring cutting force in boring intersecting holes according to claim 1, characterized in that, The current force response parameters include static force response parameters used to characterize the static sensitivity and channel coupling relationship between multiple cutting force components and multiple mechanical sensing channels; The channel decoupling of the raw response signals from multiple mechanical sensing channels includes: The original response signals of the multiple mechanical sensing channels at the same sampling time are combined into a response vector; Construct a current force response matrix based on the static force response parameters, characterizing the response relationship between multiple cutting force components and the multiple mechanical sensing channels; Based on the measurement relationship between the current force response matrix and the response vector, the multiple cutting force components in the measurement coordinate system are solved.

8. The method for measuring cutting force in boring intersecting holes according to claim 1, characterized in that, The current force response parameters include dynamic force response parameters used to characterize the dynamic transmission characteristics between multiple cutting force components and multiple mechanical sensing channels; The channel decoupling and dynamic response compensation include: Based on the dynamic force response parameters, a multi-channel frequency response matrix is ​​established between multiple mechanical sensing channels and multiple cutting force components within the effective frequency range corresponding to the dynamic force response parameters. The responses of multiple mechanical sensing channels at the same frequency position are combined to form a frequency domain response vector; Based on the multi-channel frequency response matrix and frequency domain response vector, the frequency domain results of each cutting force component at the corresponding frequency position are obtained; The frequency domain results of each cutting force component are transformed to the time domain to obtain the multi-component cutting force after channel decoupling and dynamic response compensation.

9. The method for measuring cutting force in boring intersecting holes according to claim 1, characterized in that, The step of converting the multi-component cutting force to the tool follower coordinate system based on the boring tool pose data includes: Based on the boring tool pose data and the installation geometry between the measurement coordinate system and the boring tool, determine the coordinate transformation relationship between the measurement coordinate system and the tool follower coordinate system at the current sampling time; Based on the coordinate transformation relationship, the multi-component cutting force in the measurement coordinate system is converted into radial cutting force, tangential cutting force and axial cutting force in the tool follower coordinate system.

10. A smart sensing system for cutting force in boring intersecting holes, characterized in that, It includes a force measurement structure, a mechanical sensor, a signal conditioning and data acquisition unit, a boring tool position data acquisition unit, and a data processing unit; The mechanical sensor is disposed on the force measuring structure and has multiple mechanical sensing channels. The signal conditioning and data acquisition unit is connected to the mechanical sensor. The signal conditioning and data acquisition unit and the boring tool posture data acquisition unit are respectively connected to the data processing unit. The data processing unit is configured as follows: Acquire the geometric data of the intersection hole, the boring tool pose data, and the raw response signals collected by multiple mechanical sensing channels, and associate the geometric data of the intersection hole, the boring tool pose data, and the raw response signals with a unified time reference; Based on the geometric data of the intersection holes and the boring tool pose data, the material contact state of the boring tool cutting edge relative to the material missing area of ​​the intersection holes is determined, and the equivalent action position of the current cutting load is determined. Based on the equivalent action position, the current force response parameter is determined from the pre-established correspondence between the cutting load action position and the force response parameter. Based on the current force response parameters and material contact state, channel decoupling and dynamic response compensation are performed on the original response signals of multiple mechanical sensing channels to obtain multi-component cutting force in the measurement coordinate system. Based on the boring tool pose data, the multi-component cutting force is converted to the tool follower coordinate system to obtain the cutting force measurement results during the boring process of the intersection hole.

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