An integrated drilling and tapping device for heavy-duty cast iron parts

Abstract

The application discloses an integrated drilling and tapping processing device for heavy cast iron parts, and relates to the technical field of drilling and tapping processing tools, comprising a processing table, a three-axis linear motor and two mounting outer frames mounted on the moving end of the three-axis linear motor, wherein drilling and tapping assemblies and cleaning mechanisms are respectively mounted in the two mounting outer frames, a tool changer is mounted on the processing table, and the device is further provided with a controller which is integrated with a fuzzy self-adaptive PID control module, a tool life estimation module and a cleaning parameter multi-target optimization and self-learning module; the application can realize one-time clamping continuous processing of drilling, tapping and cleaning, and has the advantages of high processing efficiency, good position consistency, stable sealing, complete chip removal, stable processing quality and self-learning capability.

Description

Technical Field

[0001] This invention relates to the field of drilling and tapping tools, specifically to an integrated drilling and tapping device for heavy-duty truck cast iron parts. Background Technology

[0002] Sinotruk cast iron parts typically include engine housings, gearbox housings, and other load-bearing housings. These parts require multiple mounting holes and threaded holes for connection with other components. Because cast iron machining easily generates granular debris, the drilling, tapping, and hole cleaning processes directly affect thread machining accuracy and subsequent assembly quality.

[0003] Currently, some existing drilling and tapping devices typically include a machining table, a three-axis moving mechanism, a drilling and tapping assembly, and a tool changing mechanism. In use, the cast iron part is fixed on the machining table, and the three-axis moving mechanism drives the drilling and tapping assembly to complete drilling and tapping sequentially. Then, compressed air is blown into the hole using an air gun or cleaning rod to remove residual cast iron debris from the bottom of the hole and the thread groove. While these devices structurally achieve the basic functions of drilling and tapping, they still have many shortcomings in practical applications: (1) When compressed air is used alone for purging, the debris in the bottom of the hole and the thread groove is not easy to be completely discharged. The blown debris is easy to fly around the processing area or fall back into the processing hole, resulting in an unsatisfactory cleaning effect. At the same time, the existing cleaning structure is difficult to adapt to the local height error of the surface of the cast iron parts, and it is also not easy to judge the contact pressure between the cleaning structure and the hole opening, which is prone to negative pressure leakage and unstable chip suction. (2) The drilling and tapping parameters of the existing equipment mostly rely on manual setting. After the operator selects the spindle speed and feed rate based on experience, the parameters remain unchanged throughout the entire processing. However, there are differences in hardness between batches of Sinotruk cast iron parts, and the casting structure at different positions of the same workpiece is not completely uniform. Fixed parameters cannot adapt to the real-time changes in the processing state, which can easily lead to quality problems such as increased drill wear, unstable thread accuracy, or even tool breakage. (3) The existing equipment lacks systematic parameter optimization in its cleaning process. The blowing pressure of compressed air and the suction intensity of negative pressure are often fixed values ​​preset by humans, and there is no coordinated matching relationship between the two. When the blowing pressure is too high and the negative pressure is insufficient, the debris is easily blown out of the hole and scattered around; when the blowing pressure is too low and the negative pressure is too high, the debris cannot be effectively loosened and remains at the bottom of the thread groove. Due to the lack of a closed-loop cleaning effect verification mechanism, operators cannot judge whether the cleaning meets the process requirements and can only rely on visual inspection or increase the number of cleaning times to make up for it, which reduces production efficiency and causes energy waste. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the existing technology and to propose an integrated drilling and tapping device for heavy-duty truck cast iron parts.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: an integrated drilling and tapping machining device for heavy-duty truck cast iron parts, comprising a machining table and a three-axis linear motor mounted on the machining table, characterized in that: two mounting frames are installed at intervals along the moving direction at the moving end of the three-axis linear motor, one mounting frame housing a drilling and tapping assembly, and the other mounting frame housing a cleaning mechanism; a tool changer is mounted on the machining table, the tool changer being located within the moving path range of the drilling and tapping assembly; the three-axis linear motor, the drilling and tapping assembly, the tool changer, and the cleaning mechanism are each electrically connected to a controller, the controller integrating multiple functional modules for controlling the coordinated operation of the drilling, tapping, and cleaning processes and for adaptive parameter adjustment.

[0006] Preferably, the cleaning mechanism includes an electric actuator, a lifting plate, a mounting plate, a negative pressure ring, a cleaning rod, and a sleeve; the electric actuator is vertically installed in a corresponding mounting frame, the lifting plate is connected to the piston rod of the electric actuator, and the mounting plate is positioned below the lifting plate via an elastic guide assembly; the negative pressure ring is installed on the bottom surface of the mounting plate, the sleeve is installed at the center of the mounting plate, and the cleaning rod is coaxially arranged with the sleeve and slides through the sleeve.

[0007] Preferably, the piston rod of the electric actuator is fixed with a cross-shaped limiting bracket embedded in the lifting plate, the lower end of the piston rod is provided with an external thread and is threadedly connected to an installation collar; an air intake ring is fixed at the bottom end of the installation collar, the top end of the cleaning rod is fixedly connected to and communicates with the air intake ring, and a compressed air input pipe is connected to one side of the air intake ring.

[0008] Preferably, the elastic guide assembly includes four guide rods and four springs. The four guide rods are respectively fixed to the four corners of the top surface of the mounting plate, and the upper ends of the guide rods slide through the lifting plate. The four springs are respectively sleeved on the outside of the corresponding guide rods, and the two ends of the springs abut against the lifting plate and the mounting plate respectively. A laser rangefinder is installed on the lifting plate, and the detection end of the laser rangefinder faces the mounting plate.

[0009] Preferably, the negative pressure ring is an annular structure with an internal negative pressure cavity, and a negative pressure interface communicating with the negative pressure cavity is provided on one side of the negative pressure ring; an annular mounting groove is provided on the bottom surface of the negative pressure ring, and an annular rubber pad is inserted into the annular mounting groove, and at least one pressure sensor is installed in the annular rubber pad.

[0010] Preferably, the sleeve is fixed at the center of the bottom surface of the mounting plate and extends into the negative pressure ring. The bottom end of the sleeve is equipped with an annular cleaning scraper made of wear-resistant elastic material, and the inner edge of the cleaning scraper slides against the outer circumferential surface of the cleaning rod. The cleaning rod is a hollow rod with an internal air intake channel. Multiple exhaust holes are equidistantly opened along the lower outer circumference of the cleaning rod. All exhaust holes are connected to the air intake channel, and the axis of the exhaust holes is inclined towards the lower outer side of the cleaning rod. An annular dust suction channel is formed between the inner wall of the negative pressure ring and the outer wall of the sleeve. The bottom end of the cleaning rod extends downward from the sleeve and the annular rubber pad.

[0011] Preferably, the multiple functional modules include a fuzzy adaptive PID control module and a tool life online prediction module. The fuzzy adaptive PID control module adjusts the spindle speed and feed rate of the drilling and tapping assembly in real time based on the machining status signals collected during the machining process. The controller also has a built-in tool life online prediction module, which calculates the remaining tool life in real time based on the cumulative cutting time, cumulative machining times, and the hardness and tensile strength of the current machining material, and executes corresponding warnings or tool change actions based on the threshold range of the remaining tool life. The optimal insertion depth of the cleaning rod is determined by the controller in real time based on the machining hole depth and thread profile height obtained during the drilling and tapping stage. The controller automatically identifies the thread profile height based on the specifications of the current tap in the tool changer.

[0012] Preferably, the machining status signal includes a spindle current signal, a vibration acceleration signal, and a feed motor torque signal; the input of the fuzzy adaptive PID control module is the deviation signal and its rate of change, which are divided into five fuzzy subsets; the deviation signal is obtained by weighted summation of the spindle current deviation, vibration acceleration deviation, and feed torque deviation, and the three weighting coefficients are adjusted online according to the hardness grade and tensile strength of the cast iron part; the output of the fuzzy adaptive PID control module is a proportional coefficient correction, an integral coefficient correction, and a derivative coefficient correction, each correction being determined online through fuzzy inference rules and superimposed on the initial PID parameters to form the final control quantity.

[0013] Preferably, the plurality of functional modules further includes a multi-objective optimization module for cleaning parameters. The output of the controller is also connected to the servo driver of the electric actuator of the cleaning mechanism, the frequency converter of the external negative pressure device, and the electronically controlled proportional pressure valve of the compressed air source. The pressure sensor, the laser rangefinder, and the debris mass flow meter installed at the negative pressure interface are respectively connected to the input of the controller. The controller integrates a multi-objective optimization module for cleaning parameters. The multi-objective optimization module for cleaning parameters takes maximizing cleaning efficiency, minimizing energy consumption, and minimizing cleaning time as comprehensive optimization objectives. It uses a particle swarm optimization algorithm to search for and output the optimized negative pressure intensity and the optimized blowing pressure. The search boundary of the particle swarm optimization algorithm is limited by the sealing force of the negative pressure ring and the rated pressure of the compressed air source.

[0014] Preferably, the plurality of functional modules further include a real-time cleaning effect verification module and a historical data self-learning module; the real-time cleaning effect verification module compares the cumulative debris mass measured by the debris mass flow meter within the cleaning cycle with the theoretical total debris mass to determine whether the cleaning meets the standard, and automatically triggers a secondary cleaning process if it does not meet the standard; the historical data self-learning module stores the working condition parameters of each successful cleaning and the corresponding optimized cleaning parameters in a database, performs cluster analysis according to hole depth and thread specification and updates the recommended initial population position of the particle swarm optimization algorithm under each working condition, and dynamically adjusts the weight allocation of each sub-objective in the multi-objective optimization according to the recent cleaning pass rate trend; the cleaning pass rate statistics are periodically fed back to the process database of the controller to adjust the weighting coefficient of the deviation signal in the drilling and tapping stage.

[0015] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention uses a single three-axis linear motor shared by two mounting frames to achieve continuous completion of drilling, tapping, and cleaning processes in a single clamping operation, ensuring positional consistency. The cleaning mechanism uses an elastic guide component in conjunction with a laser rangefinder and a pressure sensor to achieve adaptive fitting and precise pressure control of the negative pressure ring. The cleaning rod's central air blowing and the negative pressure ring's periphery's dust suction form a coordinated blowing and suction cleaning path. Combined with a cleaning scraper, it prevents debris from being carried into the sleeve, improving the orifice sealing stability, debris removal effect, and operational reliability of the cleaning mechanism. 2. The fuzzy adaptive PID control module adjusts the drilling and tapping parameters in real time based on the spindle current, vibration acceleration, and feed torque, making the machining process adaptable to material hardness fluctuations; the tool life online prediction module calculates the remaining tool life in real time and performs graded warnings and automatic tool changing to avoid tool breakage and thread damage, ensuring the stability of thread machining quality. 3. The particle swarm optimization algorithm is used to optimize the negative pressure intensity and blowing pressure in a coordinated manner, taking into account cleaning efficiency, energy consumption and time. The real-time cleaning effect verification module determines whether the cleaning meets the standard and automatically triggers secondary cleaning. The historical data self-learning module clusters and analyzes successful cases to optimize the initial population position of the algorithm, so that the control strategy has the ability to continuously evolve, improving the reliability and consistency of the cleaning process. 4. Data collaboration between processes is achieved through the internal data bus of the controller. The hole depth and thread specifications obtained in the drilling and tapping stage are directly used to calculate the optimal insertion depth of the cleaning rod. The cleaning qualification rate is periodically fed back to the weighting coefficient adjustment in the drilling and tapping stage, forming a two-way optimization closed loop between the front and rear processes, realizing intelligent adaptive control of the entire process. Attached Figure Description

[0016] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and, together with their description, serve to explain the invention and do not constitute an undue limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the overall appearance of the device proposed in this invention; Figure 2 This is a top view of the overall appearance and structure of the device proposed in this invention; Figure 3 This is a schematic diagram of the cleaning mechanism structure proposed in this invention; Figure 4 This is a schematic diagram of the lifting plate and mounting plate structure proposed in this invention; Figure 5 This is a partial structural diagram of the cleaning mechanism proposed in this invention; Figure 6 This is a schematic diagram of the mounting collar and intake ring structure proposed in this invention; Figure 7 This is a schematic cross-sectional view of the cleaning mechanism proposed in this invention; Figure 8 This is a diagram of the overall system architecture of the present invention; Figure 9 This is a flowchart illustrating the control execution process of the present invention. Attached reference numerals: 1. Machining table; 2. Three-axis linear motor; 3. Mounting frame; 4. Tool changer; 5. Electric actuator; 6. Lifting plate; 7. Mounting plate; 8. Negative pressure ring; 9. Mounting collar; 10. Air intake ring; 11. Cleaning rod; 12. Sleeve; 13. Pressure sensor; 14. Laser rangefinder; 15. Guide rod; 16. Cross limit frame. Detailed Implementation

[0017] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0018] Example 1: See Figure 1 and Figure 2 This invention provides an integrated drilling and tapping device for heavy-duty truck cast iron parts, comprising a machining table 1 and a three-axis linear motor 2 mounted on the machining table 1. Two mounting frames 3 are fixedly installed at intervals along the moving direction of the three-axis linear motor 2. One mounting frame 3 houses the drilling and tapping assembly, and the other mounting frame 3 houses the cleaning mechanism. The three-axis linear motor 2 is a gantry-type three-axis linear motor module, and its moving end can move precisely along the X, Y, and Z axes, thereby driving the two mounting frames 3 to move synchronously. The interval between the two mounting frames 3 is preset according to the distribution of the machining holes to ensure that the cleaning mechanism can be accurately positioned after the drilling and tapping assembly completes machining.

[0019] A tool changer 4 is installed on the machining table 1. The tool changer 4 is located within the movement path of the drilling and tapping assembly. The tool changer 4 has multiple tool positions for holding drill bits and taps of different specifications. The drilling and tapping assembly includes a spindle motor and a tool clamping mechanism. The spindle motor drives the tool to rotate to achieve cutting. An automatic tool changer arm is installed on one side of the tool changer 4. After receiving a tool change command, the tool changer arm unloads the current tool from the drilling and tapping assembly and places it in the corresponding tool position. Then, it retrieves the target tool from the tool changer 4 and clamps it into the drilling and tapping assembly.

[0020] The moving end of the three-axis linear motor 2 drives the two mounting frames 3 to move horizontally, longitudinally, and vertically, so that the drilling and tapping assembly is sequentially aligned with each hole to be machined. The drilling and tapping assembly first loads a drill bit from the tool changer 4 to complete the drilling, then returns to the tool changer 4 to change the tap to complete the tapping. Subsequently, the three-axis linear motor 2 moves to align the cleaning mechanism with the same machined hole for cleaning. By sharing the three-axis linear motor 2 with the two mounting frames 3, drilling, tapping, and hole cleaning can be completed sequentially without re-clamping the cast iron part, which improves processing efficiency and ensures the consistency of hole positioning between each process.

[0021] Example 2: Based on Example 1, this example further defines the specific structure of the cleaning mechanism. See [link / reference] Figure 3 and Figure 4 The cleaning mechanism includes an electric push rod 5, a lifting plate 6, a mounting plate 7, a negative pressure ring 8, a cleaning rod 11, and a sleeve 12.

[0022] The electric actuator 5 is vertically installed within the corresponding mounting frame 3, with its piston rod extending vertically downwards. The lifting plate 6 has a horizontal plate-like structure and is fixedly connected to the end of the piston rod of the electric actuator 5. A cross-shaped limiting bracket 16 is fixed to the outer periphery of the piston rod of the electric actuator 5. The cross-shaped limiting bracket 16 is embedded inside the lifting plate 6 and is used to transmit the vertical movement of the piston rod to the lifting plate 6, while restricting the rotation of the lifting plate 6 relative to the piston rod. The lower end of the piston rod has an external thread, and a mounting collar 9 is threadedly connected to it. An air inlet ring 10 is fixed to the bottom end of the mounting collar 9. The air inlet ring 10 has an annular air passage inside, and a compressed air input pipe is connected to one side of it for introducing external compressed air.

[0023] The mounting plate 7 has a horizontal plate-like structure and is positioned below the lifting plate 6 via an elastic guide assembly. The elastic guide assembly includes four guide rods 15 and four springs. The four guide rods 15 are vertically fixed at the four corners of the top surface of the mounting plate 7, and the upper end of each guide rod 15 slides through the corresponding corner of the lifting plate 6. The four springs are respectively sleeved on the outside of the corresponding guide rod 15, with the upper end of each spring abutting against the bottom surface of the lifting plate 6 and the lower end abutting against the top surface of the mounting plate 7. In its natural state, the springs support the mounting plate 7, maintaining a certain distance between it and the lifting plate 6.

[0024] The negative pressure ring 8 is fixedly installed on the bottom surface of the mounting plate 7, forming a ring structure. The cleaning rod 11 is vertically positioned at the center of the mounting plate 7, with its top end fixedly connected to and communicating with the air intake ring 10. The sleeve 12 is fixed at the center of the bottom surface of the mounting plate 7, and its upper end passes through the mounting plate 7 and is fixedly connected to it. The cleaning rod 11 passes through the sleeve 12 and is coaxially arranged with the sleeve 12. A gap is left between the outer circumferential surface of the cleaning rod 11 and the inner wall of the sleeve 12, allowing the cleaning rod 11 to slide freely along the axial direction of the sleeve 12.

[0025] A laser rangefinder 14 is installed on the lifting plate 6. The detection end of the laser rangefinder 14 is vertically downward and facing the top surface of the mounting plate 7, and is used to detect the change in the distance between the lifting plate 6 and the mounting plate 7 in real time.

[0026] When the cleaning mechanism is working, the piston rod of the electric actuator 5 extends, pushing the lifting plate 6 downward through the cross limit bracket 16. The lifting plate 6 drives the mounting plate 7 to descend synchronously via a spring, and the negative pressure ring 8 descends with the mounting plate 7 and first contacts the surface of the cast iron part. After the negative pressure ring 8 contacts the workpiece, the mounting plate 7 stops descending, while the lifting plate 6 continues to move downward and compress the spring. At the same time, the piston rod drives the cleaning rod 11 downward through the mounting collar 9 and the air intake ring 10. The cleaning rod 11 extends from the sleeve 12 and gradually inserts into the machining hole. The laser rangefinder 14 monitors the change in the distance between the lifting plate 6 and the mounting plate 7 in real time. When the distance compression reaches a preset value, the extension of the electric actuator 5 stops to prevent the negative pressure ring 8 from being over-compressed. Through the above-mentioned elastic guide components, the negative pressure ring 8 can adapt to the local height error of the cast iron part surface, while the insertion depth of the cleaning rod 11 is precisely controlled.

[0027] Example 3: Based on Examples 1 and 2, this example further defines the specific structure of the negative pressure ring 8, the cleaning rod 11, and the sleeve 12. See [link to example 1]. Figures 5 to 7 The negative pressure ring 8 is a hollow ring structure with an internal annular negative pressure cavity. A negative pressure interface communicating with the negative pressure cavity is provided on one side of the negative pressure ring 8. The negative pressure interface is connected to an external negative pressure device through a negative pressure air pipe.

[0028] The bottom surface of the negative pressure ring 8 has an annular mounting groove, into which an annular rubber pad is inserted. The lower surface of the annular rubber pad is lower than the bottom surface of the negative pressure ring 8. When the negative pressure ring 8 presses against the surface of the cast iron part, the annular rubber pad contacts the workpiece first and undergoes elastic deformation, forming an elastic seal between the negative pressure ring 8 and the cast iron part. At least one pressure sensor 13 is embedded inside the annular rubber pad to detect the contact pressure between the annular rubber pad and the surface of the cast iron part in real time. The signal output terminal of the pressure sensor 13 is connected to the controller. The controller determines whether the negative pressure ring 8 has effectively adhered to the workpiece surface based on the contact pressure value, and only starts the negative pressure equipment and compressed air source after the pressure reaches a set threshold to avoid negative pressure leakage.

[0029] The cleaning rod 11 is a hollow rod with an internal air intake channel. An air intake ring 10 is connected to the top of the cleaning rod 11, allowing compressed air to enter the air intake channel inside the cleaning rod 11 through the air intake ring 10. Multiple exhaust holes are equidistantly spaced along the lower outer circumference of the cleaning rod 11. Each exhaust hole communicates with the air intake channel, and the axis of each exhaust hole is inclined downwards and outwards towards the cleaning rod 11, i.e., the exhaust direction is downwards and outwards. When compressed air is ejected from the exhaust holes, the airflow obliquely impacts the bottom of the machined hole and the wall of the threaded groove, effectively loosening cast iron debris adhering to the hole wall and the threaded groove.

[0030] The sleeve 12 is fixed to the center of the bottom surface of the mounting plate 7 and extends downward into the internal space of the negative pressure ring 8. An annular cleaning scraper is installed at the bottom end of the sleeve 12. The cleaning scraper is made of a wear-resistant elastic material, and its inner edge slides against the outer circumferential surface of the cleaning rod 11. That is, the inner diameter of the cleaning scraper is slightly smaller than the outer diameter of the cleaning rod 11, creating an interference fit between them. During the extension and retraction of the cleaning rod 11, the cleaning scraper remains in contact with the outer circumferential surface of the cleaning rod 11. When the cleaning rod 11 retracts, the cleaning scraper removes debris adhering to the outer circumferential surface of the cleaning rod 11, preventing debris from being carried into the interior of the sleeve 12 along with the cleaning rod 11.

[0031] The negative pressure ring 8, sleeve 12, and cleaning rod 11 are coaxially arranged. An annular chip suction channel is formed between the inner wall of the negative pressure ring 8 and the outer wall of the sleeve 12. The upper end of the annular chip suction channel communicates with the negative pressure chamber inside the negative pressure ring 8, and the lower end opens towards the machining hole. The bottom end of the cleaning rod 11 extends downward beyond the lower end of the sleeve 12 and further extends beyond the lower surface of the annular rubber pad, ensuring that the cleaning rod 11 can reach into the machining hole for cleaning.

[0032] During the cleaning process, the cleaning rod 11 extends into the machining hole, and compressed air is ejected obliquely from the exhaust port at the bottom of the cleaning rod 11 to loosen and blow away debris at the bottom of the machining hole and in the thread groove. Simultaneously, an external negative pressure device creates negative pressure in the negative pressure chamber of the negative pressure ring 8 through a negative pressure interface. The lower opening of the annular chip suction channel faces the machining hole opening, and the loosened debris, along with the returning air, enters the negative pressure chamber through the annular chip suction channel and is finally discharged through the negative pressure interface. This coordinated cleaning method of central air blowing and peripheral chip suction ensures that debris is immediately drawn away by negative pressure after being loosened from the hole wall, effectively preventing debris from scattering to the outside.

[0033] After cleaning, the electric push rod 5 drives the cleaning rod 11 to retract upwards, and the cleaning scraper at the bottom of the sleeve 12 scrapes off the debris attached to the outer circumference of the cleaning rod 11. The scraped debris falls into the negative pressure chamber of the negative pressure ring 8 and is then discharged through the negative pressure interface, ensuring the cleanliness of the surface of the cleaning rod 11 and the cleanliness of the inside of the sleeve 12.

[0034] It should be noted that the pressure sensor 13 and the laser rangefinder 14 are used to output contact pressure signals and displacement signals, respectively. The electric actuator 5, the external negative pressure device and the compressed air source have interfaces that can accept external electrical control signals, providing a hardware foundation for the automated control of subsequent cleaning processes.

[0035] Example 4: See Figures 1 to 8This embodiment further provides an intelligent control system for controlling the operation of the above-mentioned device. As described in embodiments one to three, the control terminals of the X-axis, Y-axis, and Z-axis drivers of the three-axis linear motor 2, the spindle motor driver and feed motor driver of the drilling and tapping assembly, and the tool changer actuator of the tool changer 4) are electrically connected to an industrial-grade programmable logic controller. The controller integrates a fuzzy adaptive PID control module and a tool life online prediction module.

[0036] The controller has a built-in process database for various cast iron materials commonly used in Sinotruk, including but not limited to HT250, HT300, QT400-18, and QT500-7. After the operator selects the material grade of the cast iron part to be processed through the human-machine interface, the controller automatically retrieves the corresponding basic processing parameters: reference spindle speed. Reference feed rate Reference spindle current Reference vibration acceleration Reference feed torque For materials not covered in the database, operators can manually enter the material's hardness grade (H) and tensile strength. The controller automatically calculates the above reference parameters using a linear interpolation algorithm.

[0037] The input to the fuzzy adaptive PID control module is the deviation signal. and its rate of change The output is the proportional coefficient correction amount. Integral coefficient correction amount and differential coefficient correction amount .

[0038] Among them, the deviation signal Defined as:

[0039] In the formula, For real-time acquisition of spindle current. For real-time acquisition of vibration acceleration, For the real-time feed torque, the three real-time values ​​mentioned above are obtained by a current sensor mounted on the spindle motor, a vibration sensor mounted on the spindle bearing housing, and a torque sensor mounted on the feed motor, respectively; the values ​​of each weighting coefficient are related to the hardness grade H and tensile strength of the cast iron part. The mapping relationship is as follows:

[0040]

[0041]

[0042] in =170, =241, the above hardness upper and lower limits correspond to the lowest hardness (QT500-7) and the highest hardness (HT300) of commonly used materials for Sinotruk cast iron parts, respectively.

[0043] Current weighting The weighting decreases with increasing hardness, based on the fact that spindle current is the most direct electrical representation of cutting force and has the fastest response speed. However, current fluctuations become more drastic with increasing hardness, necessitating a reduction in its weighting to prevent over-adjustment; torque weighting. The weighting increases with increasing hardness. The criterion for this is that the feed torque directly reflects the cutting edge load. In the machining of hard cast iron, a sudden increase in torque is a precursor to tool breakage, and the feed mechanism must be prioritized for protection. Vibration acceleration weighting... The value is fixed at 0.25. The basis for this determination is that vibration signals are easily affected by the inherent vibrations of machine tools, so they should not be given too high a weight. They can be used as an auxiliary reference.

[0044] The input variables of the fuzzy controller and The dataset is divided into five fuzzy subsets: negative large, negative small, zero, positive small, and positive large. The membership functions are all trigonometric functions. The output variable... , , It is also divided into 5 fuzzy subsets; the fuzzy inference rules adopt the Mamdani type, with a total of 25 rules in the rule base. Initial PID parameters. , , According to tensile strength Perform initialization:

[0045]

[0046]

[0047] in =250MPa, =500MPa, which correspond to the lower limit of tensile strength of the lowest and highest grade of Sinotruk cast iron parts, respectively; =2.5、 =0.8、 =0.3.

[0048] The above-mentioned reference coefficients are determined by simplifying the feed system into a second-order mass-spring-damped model. The feed mechanism has an equivalent mass of approximately 50 kg, the optimal damping ratio for engineering is taken as 0.7, and the system's natural frequency is taken as 100 rad / s. From this, the reference value for the proportional coefficient is calculated to be 2.5, and the reference value for the differential coefficient is 0.3. The principle for selecting the integral coefficient is to make the integral time constant... Approximately 3.1 seconds, ensuring the system can eliminate steady-state error within 3 to 5 seconds. The controller calculates and outputs the final PID control input in real time based on the above formula:

[0049] Control quantity After D / A conversion, the outputs are sent to the spindle motor inverter and the feed motor servo driver respectively, enabling millisecond-level real-time adjustment of spindle speed and feed rate.

[0050] The online tool life prediction module monitors the cumulative cutting time since the current tool clamping in real time. and cumulative number of drilling or tapping operations This module incorporates a tool wear evolution model:

[0051] In the formula: This is the reference service life of the tool under rated operating conditions. =2500 times; The wear attenuation coefficient is set to 0.0025. =1.2、 =0.8 are the wear contribution indices of rotational speed and feed rate, respectively. The values ​​are based on the cutting theory that cutting speed has the greatest impact on tool durability, followed by feed rate. The hardness compensation coefficient is set to 0.15. Its value is determined based on the fact that tool life decreases by approximately 5% to 8% for every 10 HBW increase in hardness; the median value is used for linear compensation. In the formula... The measured value of the spindle speed at time τ. Let τ be the measured feed rate at time τ, and H be the actual hardness of the material being processed. =200 is the base hardness.

[0052] The controller is equipped with a three-level tool change early warning mechanism: Normal state: When > At this time, the system maintains the current processing parameters unchanged; Warning status: When < ≤ When this happens, the controller will automatically reduce the feed rate to 85% of the current value and prompt the operator through the human-machine interface to prepare to change the tool. Forced tool change: When ≤ When the current hole is completed and the tool retraction phase is completed, the controller automatically sends a tool change command to the tool changer 4, and the tool change actuator completes the tool change and resets the life count.

[0053] The 30% warning line is determined by the starting point of the accelerated tool wear period, and the 15% forced tool change line is determined by the axial force increase of more than 40% when the flank wear reaches 0.3mm, which sharply increases the risk of tool breakage during continued machining.

[0054] Example 5: See Figures 3 to 7 ,as well as Figure 9 Based on embodiments one to four above, this embodiment provides an intelligent control system for the cleaning process of an integrated drilling and tapping device for heavy-duty cast iron parts. The servo driver of the electric actuator 5 of the cleaning mechanism, the frequency converter of the external negative pressure equipment, and the electrically controlled proportional pressure valve of the compressed air source are electrically connected to the output of the controller. The pressure signal from the pressure sensor 13, the displacement signal from the laser rangefinder 14, and the signal from the debris mass flow meter installed at the negative pressure interface are connected to the input of the controller. The controller integrates a multi-objective optimization module for cleaning parameters, a real-time verification module for cleaning effects, and a self-learning module for historical data. (See [link to relevant documentation]). Figures 1 to 7 Based on embodiments one to four above, this embodiment further provides an intelligent control system for the cleaning process to control the operation of the aforementioned cleaning mechanism. As described in embodiments two and three, the electric actuator 5, external negative pressure equipment, and compressed air source of the cleaning mechanism are all electrically controllable components, and the pressure sensor 13, laser rangefinder 14, and debris mass flow meter that can be added to the negative pressure interface are all sensing components capable of outputting electrical signals. Based on this, this embodiment, based on the controller of embodiment four above, connects the relevant execution components and sensing components of the aforementioned cleaning mechanism to the same controller to form an intelligent control system for the cleaning process.

[0055] Specifically, the servo driver of the electric actuator 5 of the cleaning mechanism, the frequency converter of the external negative pressure equipment, and the electrically controlled proportional pressure valve of the compressed air source are electrically connected to the output of the controller; the pressure signal of the pressure sensor 13, the displacement signal of the laser rangefinder 14, and the signal of the debris mass flow meter installed at the negative pressure interface are connected to the input of the controller. The controller integrates a multi-objective optimization module for cleaning parameters, a real-time verification module for cleaning effect, and a self-learning module for historical data.

[0056] The optimal insertion depth of the cleaning rod 11 The depth of the machined hole obtained from the drilling and tapping stage in Example 4 and the corresponding thread height for the current thread specification Jointly determined:

[0057] In the formula The safety margin factor is set between 0.88 and 0.92. To account for the compensation amount of the surface flatness error of the cast iron parts, the local height deviation measured by the laser rangefinder 14 at the moment of contact with the negative pressure ring is determined in real time, with a value range of 0 to 0.5 mm. The value of this coefficient is based on the following: if the coefficient is 1.0, the vent hole is directly opposite the tooth root and cannot effectively clean the thread groove wall; if it is less than 0.85, the insertion is insufficient and there is a cleaning dead angle; and if it is 0.88 to 0.92, the vent hole is located in the middle of the tooth and the airflow can obliquely impact the tooth root to form a vortex.

[0058] Air pressure during cleaning With negative pressure intensity The dynamic balance constraints between them are:

[0059] And must satisfy ≥1.2 That is, the negative pressure suction capacity is at least 1.2 times the blowing air volume; when the measured contact pressure Below the effective sealing threshold When =10N, the constraint is automatically adjusted to ≥1.5 Flow coefficient Take 0.62 as the standard value for the flow coefficient of thin-walled orifices. Take 0.75 as the standard value for the flow coefficient of the annular channel, and the air density... Taking 1.225 kg / m³ as the standard state value, the criterion for the 1.2 times margin is to ensure that the suction velocity at the annular gap inlet is not lower than the radial component velocity after the blowing jet diffuses. Numerical simulation shows that this value is the critical safety margin.

[0060] The multi-objective optimization module uses maximizing cleaning efficiency, minimizing energy consumption, and minimizing cleaning time as comprehensive optimization objectives, and establishes a fitness function:

[0061] In the formula, the weighting coefficient =0.5、 =0.3、 =0.2, which is preset and stored in the controller according to the cleaning process requirements.

[0062] Cleaning efficiency The mathematical model is as follows:

[0063] In the formula =15L / s =8L / s =30N; The value is based on the flow rate when the flow velocity in the annular channel reaches 10 m / s. The value is based on the theoretical flow rate of the vent at 0.4 MPa. The value is determined by the contact pressure when the rubber seal's compression ratio reaches the median of the design compression ratio.

[0064] Energy consumption function The model is as follows:

[0065] In the formula =0.002 , =0.05 , =0.15 , =0.10 The above energy consumption coefficients are calibrated by fitting the power-load characteristic curves of the selected vacuum pump and air compressor; and The negative pressure and air blowing operation times are recorded by the controller's internal timer.

[0066] The search space boundary of the particle swarm optimization algorithm is kPa MPa, particle swarm size of 30, maximum number of iterations of 50, inertia weight Adopting a linear decreasing strategy Learning factor = =2.0; Criteria for determining the search boundary: The lower limit of negative pressure is 10 kPa, which is determined by the inability to overcome pipeline resistance and the gravity of debris below this value, and can be calculated from the mass flow constraint; The upper limit of negative pressure is 80 kPa, which is determined by the fact that the suction force generated by the rubber pad under this pressure difference exceeds the friction force between it and the mounting groove, and there is a risk of it being sucked into the negative pressure chamber; The lower limit of blowing air is 0.2 MPa, which is determined by the fact that the airflow velocity below this value cannot loosen the compacted debris in the thread groove; The upper limit of blowing air is 1.0 MPa, which is the rated working pressure of the compressed air source pipeline and the seal; The values ​​of inertia weight and learning factor are the standard recommended values ​​of the PSO algorithm.

[0067] After the cleaning process is completed, the controller calculates the cumulative debris mass through the debris mass flow meter at the negative pressure interface. The criteria for determining whether cleanliness meets standards are: ≥

[0068] in This is the theoretical total mass of chips estimated from the volume of the machined hole and the density of the cast iron chips. To allow for a 5% residue rate, the controller automatically triggers a secondary cleaning process if the result is deemed unqualified: the air pressure is increased to 1.1 times the optimal value (not exceeding the upper limit), the negative pressure intensity is increased to 1.1 times the optimal value (not exceeding the upper limit), the cleaning is performed again and verified once more. If the secondary cleaning still fails, the system issues an audible and visual alarm. The criteria for the 1.1 times gain coefficient are as follows: when it is below 1.1 times, the improvement effect on minor non-compliance is not obvious; when it is above 1.1 times, energy consumption and noise increase significantly but the improvement in cleaning effect is limited. 1.1 times is the optimal gain coefficient verified by experiments.

[0069] The historical data self-learning module performs offline optimization and updates of the initial particle positions of the PSO algorithm every 100 holes processed. It uses K-means clustering to divide historical successful cases into clusters based on hole depth and thread specifications. The mean parameter value within each cluster serves as the recommended initial population center for subsequent processing under the same conditions. The period for 100 holes is determined as follows: the processing time for a single hole is approximately 8–15 seconds, and 100 holes correspond to approximately 15–25 minutes, which is basically consistent with the thermal equilibrium cycle of the three-axis linear motor and transmission components. Data collected within this period is stable and representative, avoiding interference from random fluctuations in single holes on the self-learning results. Simultaneously, the module dynamically adjusts the weight coefficients based on recent cleaning pass rate trends: appropriately reducing the weight coefficient when the pass rate consistently remains above 98%. and increase Prioritize energy conservation, and increase capacity again when the pass rate declines. Prioritize efficiency.

[0070] Examples 4 and 5 achieve data collaboration through the controller's internal data bus: Example 4 records the machining depth of each hole in real time. and tap specifications (corresponding tooth height) In Example 5, the cleaning parameter optimization module directly reads the above parameters and substitutes them into the module. Calculation formula; if a tool change action is triggered after drilling and tapping, the controller delays the cleaning process until the tool change is completed to avoid mechanical interference; the cleaning pass rate statistics are periodically fed back to the process database of Example 4. When a certain material continuously fails to meet cleaning standards, the weighting coefficient is appropriately adjusted to reduce the feed rate and reduce hole wall burrs, thereby reducing the cleaning difficulty from the source.

[0071] Working principle: When using this device, the operator first connects the compressed air input pipe on the intake ring 10 to an external compressed air source, and connects the negative pressure interface on the negative pressure ring 8 to an external negative pressure device; then, the heavy-duty truck cast iron part to be processed is fixed on the processing table 1; the operator selects the material grade of the cast iron part to be processed through the human-machine interface of the controller, the controller automatically retrieves the reference processing parameters corresponding to the material, and calculates the weighting coefficient of the deviation signal and initializes the PID parameters according to the material hardness.

[0072] The three-axis linear motor 2 is started, driving the two mounting brackets 3 to move and align the drilling and tapping assembly with the position to be machined on the cast iron part. During the drilling and tapping process, the current sensor mounted on the spindle motor, the vibration sensor mounted on the spindle bearing housing, and the torque sensor mounted on the feed motor collect machining status signals in real time and transmit them to the controller. The fuzzy adaptive PID control module in the controller calculates the correction amount of the PID parameters online based on the deviation and rate of change between the measured signal and the reference value, and superimposes it on the initial parameters to form the final control quantity, which is output to the spindle motor frequency converter and the feed motor servo drive to achieve millisecond-level real-time adjustment of the spindle speed and feed rate. At the same time, the tool life online prediction module continuously monitors the cumulative cutting time and cumulative machining number since the tool is clamped, and calculates the remaining tool life in real time based on the hardness and tensile strength of the current material. When the remaining lifespan drops below 30% of the initial lifespan, the controller automatically reduces the speed and prompts the human-machine interface to prepare for tool change; when the remaining lifespan drops below 15%, the controller automatically sends a tool change command to the tool changer 4 during the tool retraction stage after the current hole is machined, and the tool change actuator completes the tool change and resets the lifespan count.

[0073] After drilling and tapping are completed, the three-axis linear motor 2 drives the mounting bracket 3, which is equipped with the cleaning mechanism, to move, so that the cleaning rod 11 is coaxially aligned with the machined hole. The controller retrieves the machining depth of the hole and the thread profile height corresponding to the tap specification recorded during the drilling and tapping stage, and automatically calculates the optimal insertion depth of the cleaning rod 11. The electric actuator 5 starts and pushes the piston rod downward. The piston rod drives the lifting plate 6 downward through the cross limit bracket 16. The lifting plate 6 drives the mounting plate 7, the negative pressure ring 8, and the sleeve 12 to descend synchronously through the spring. At the same time, the piston rod drives the cleaning rod 11 to move towards the machined hole through the mounting sleeve 9 and the air intake ring 10. The four guide rods 15 slide along the lifting plate 6, keeping the mounting plate 7 and the negative pressure ring 8 descending horizontally.

[0074] When the annular rubber pad abuts against the surface of the cast iron part, the pressure sensor 13 detects the contact pressure between the negative pressure ring 8 and the cast iron part and transmits the signal to the controller. The mounting plate 7 stops descending, and the lifting plate 6 continues to move downward with the electric push rod 5, compressing the four springs and causing the cleaning rod 11 to continue extending into the machining hole. The laser rangefinder 14 detects the change in the distance between the lifting plate 6 and the mounting plate 7 in real time and transmits the signal to the controller. When the cleaning rod 11 reaches the calculated optimal insertion depth, the controller controls the electric push rod 5 to stop extending. The pressure sensor 13 provides real-time feedback on the contact pressure to ensure that the sealing pressure is within the effective range.

[0075] The multi-objective optimization module for cleaning parameters within the controller initiates a particle swarm optimization algorithm. With the comprehensive optimization objectives of maximizing cleaning efficiency, minimizing energy consumption, and minimizing cleaning time, it iteratively optimizes within the search space of negative pressure intensity and blowing pressure, outputting the optimized combination of negative pressure intensity and blowing pressure. The external negative pressure equipment activates according to the optimized negative pressure intensity, creating negative pressure inside the negative pressure ring 8. The electronically controlled proportional pressure valve of the compressed air source opens according to the optimized blowing pressure. Compressed air enters the intake ring 10 through the compressed air input pipe, then enters the intake channel inside the cleaning rod 11, and is ejected from multiple oblique exhaust holes at the bottom of the cleaning rod 11, blowing away cast iron debris from the bottom of the machining hole and the thread groove. Loose debris moves towards the orifice with the returning gas, enters the negative pressure chamber through the annular debris suction channel between the inner wall of the negative pressure ring 8 and the outer wall of the sleeve 12, and is discharged through the negative pressure interface, forming a coordinated cleaning process of central blowing and peripheral debris suction.

[0076] During the cleaning process, a debris mass flow meter installed at the negative pressure interface measures the mass flow rate of the sucked-up debris in real time and transmits the signal to the controller. After cleaning, the real-time cleaning effect verification module in the controller performs an integral calculation on the cumulative debris mass during the cleaning cycle and compares it with the theoretical total debris mass. If the cumulative debris mass reaches more than 95% of the theoretical total debris mass, the cleaning is deemed qualified; if it is lower than this threshold, it is deemed unqualified, and the controller automatically triggers a secondary cleaning process, increasing the blowing pressure and negative pressure intensity to 1.1 times the original value and cleaning again. If the secondary cleaning is still unqualified, an audible and visual alarm is issued.

[0077] After cleaning, the compressed air supply is stopped first, and the negative pressure equipment continues to run for a period of time to expel residual debris from the negative pressure chamber. Then, the negative pressure equipment is turned off and the electric push rod 5 is retracted. The cleaning rod 11 moves upward along the sleeve 12, and the cleaning scraper at the bottom of the sleeve 12 scrapes off the debris attached to the outer circumference of the cleaning rod 11. The scraped debris falls into the negative pressure chamber and is then discharged. As the lifting plate 6 rises, the spring returns to its original state and drives the mounting plate 7 and the negative pressure ring 8 away from the surface of the cast iron part.

[0078] The historical data self-learning module performs offline optimization and updates of the initial particle positions of the particle swarm optimization algorithm every 100 holes processed. The K-means clustering algorithm is used to divide historical successful cases into several clusters according to hole depth and thread specifications. The mean of parameters within each cluster is used as the recommended initial population center for subsequent working conditions. At the same time, the module dynamically adjusts the weight coefficients according to the recent cleaning pass rate trend.

[0079] The cleaning pass rate statistics are periodically fed back to the process database of the controller. When a certain type of cast iron part fails to pass cleaning continuously, the controller appropriately adjusts the weighting coefficient of the deviation signal in the drilling and tapping stage to reduce the feed rate and reduce burrs on the hole wall, thereby reducing the difficulty of subsequent cleaning from the source and forming a two-way optimization closed loop from drilling and tapping to hole cleaning.

[0080] The three-axis linear motor 2 then moves the two mounting brackets 3 to the next processing position, allowing drilling, tapping, and hole cleaning to continue.

[0081] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An integrated drilling and tapping device for heavy-duty truck cast iron parts, comprising a machining table (1) and a three-axis linear motor (2) mounted on the machining table (1), characterized in that: The moving end of the three-axis linear motor (2) is equipped with two mounting frames (3) at intervals along the moving direction. One mounting frame (3) is equipped with a drilling and tapping assembly, and the other mounting frame (3) is equipped with a cleaning mechanism. A tool changer (4) is installed on the processing table (1), and the tool changer (4) is located within the moving path of the drilling and tapping assembly. The three-axis linear motor (2), the drilling and tapping assembly, the tool changer (4) and the cleaning mechanism are electrically connected to a controller. The controller integrates multiple functional modules for controlling the coordinated operation of the drilling, tapping and cleaning processes and for adaptive parameter adjustment.

2. The integrated drilling and tapping device for heavy-duty truck cast iron parts according to claim 1, characterized in that: The cleaning mechanism includes an electric push rod (5), a lifting plate (6), a mounting plate (7), a negative pressure ring (8), a cleaning rod (11), and a sleeve (12); the electric push rod (5) is vertically installed in the corresponding mounting frame (3), the lifting plate (6) is connected to the piston rod of the electric push rod (5), and the mounting plate (7) is set below the lifting plate (6) through an elastic guide component; the negative pressure ring (8) is installed on the bottom surface of the mounting plate (7), the sleeve (12) is installed at the center of the mounting plate (7), and the cleaning rod (11) is coaxially arranged with the sleeve (12) and slides through the sleeve (12).

3. The integrated drilling and tapping device for heavy-duty truck cast iron parts according to claim 2, characterized in that: The piston rod of the electric actuator (5) is fixed with a cross-shaped limiting bracket (16) embedded in the lifting plate (6). The lower end of the piston rod is provided with an external thread and is threadedly connected to an installation collar (9). An air intake ring (10) is fixed at the bottom end of the installation collar (9). The top end of the cleaning rod (11) is fixedly connected to the air intake ring (10) and communicates with it. A compressed air input pipe is connected to one side of the air intake ring (10).

4. The integrated drilling and tapping device for heavy-duty truck cast iron parts according to claim 2, characterized in that: The elastic guide assembly includes four guide rods (15) and four springs. The four guide rods (15) are fixed to the four corners of the top surface of the mounting plate (7). The upper end of the guide rod (15) slides through the lifting plate (6). The four springs are respectively sleeved on the outside of the corresponding guide rod (15). The two ends of the springs abut against the lifting plate (6) and the mounting plate (7) respectively. A laser rangefinder (14) is installed on the lifting plate (6). The detection end of the laser rangefinder (14) faces the mounting plate (7).

5. The integrated drilling and tapping device for heavy-duty truck cast iron parts according to claim 2, characterized in that: The negative pressure ring (8) is an annular structure with a negative pressure cavity inside. A negative pressure interface communicating with the negative pressure cavity is provided on one side of the negative pressure ring (8). An annular mounting groove is provided on the bottom surface of the negative pressure ring (8). An annular rubber pad is inserted into the annular mounting groove. At least one pressure sensor (13) is installed in the annular rubber pad.

6. The integrated drilling and tapping device for heavy-duty truck cast iron parts according to claim 2, characterized in that: The sleeve (12) is fixed at the center of the bottom surface of the mounting plate (7) and extends into the negative pressure ring (8). The bottom end of the sleeve (12) is equipped with an annular cleaning scraper made of wear-resistant elastic material. The inner edge of the cleaning scraper slides against the outer circumferential surface of the cleaning rod (11). The cleaning rod (11) is a hollow rod with an internal air intake channel. Multiple exhaust holes are equidistantly opened along the lower outer circumference of the cleaning rod (11). All the exhaust holes are connected to the air intake channel, and the axis of the exhaust holes is inclined towards the lower outer side of the cleaning rod (11). An annular dust suction channel is formed between the inner wall of the negative pressure ring (8) and the outer wall of the sleeve (12). The bottom end of the cleaning rod (11) extends downward outward from the sleeve (12) and the annular rubber pad.

7. The integrated drilling and tapping device for heavy-duty truck cast iron parts according to claim 1, characterized in that: The multiple functional modules include a fuzzy adaptive PID control module and a tool life online prediction module. The fuzzy adaptive PID control module adjusts the spindle speed and feed rate of the drilling and tapping assembly in real time according to the processing status signal collected during the processing. The controller also has a built-in tool life online prediction module. The tool life online prediction module calculates the remaining tool life in real time based on the cumulative cutting time, cumulative processing times, and the hardness and tensile strength of the current processing material, and performs corresponding warning or tool change actions according to the threshold range of the remaining life. The optimal insertion depth of the cleaning rod (11) is determined by the controller in real time based on the processing hole depth and thread profile height obtained during the drilling and tapping stage. The controller automatically identifies the thread profile height according to the specifications of the current tap in the tool changer (4).

8. The integrated drilling and tapping device for heavy-duty truck cast iron parts according to claim 7, characterized in that: The machining status signals include spindle current signal, vibration acceleration signal, and feed motor torque signal; the input of the fuzzy adaptive PID control module is the deviation signal and its rate of change, which are divided into five fuzzy subsets; the deviation signal is obtained by weighted summation of spindle current deviation, vibration acceleration deviation, and feed torque deviation, and the three weighting coefficients are adjusted online according to the hardness grade and tensile strength of the cast iron part; the output of the fuzzy adaptive PID control module is the proportional coefficient correction, integral coefficient correction, and derivative coefficient correction, each correction is determined online by fuzzy inference rules and superimposed on the initial PID parameters to form the final control quantity.

9. The integrated drilling and tapping device for heavy-duty truck cast iron parts according to claim 7, characterized in that: The multiple functional modules also include a multi-objective optimization module for cleaning parameters. The output of the controller is also connected to the servo driver of the electric push rod (5) of the cleaning mechanism, the frequency converter of the external negative pressure equipment, and the electronically controlled proportional pressure valve of the compressed air source. The pressure sensor (13), the laser rangefinder (14), and the debris mass flow meter installed at the negative pressure interface are respectively connected to the input of the controller. The controller integrates a multi-objective optimization module for cleaning parameters. The multi-objective optimization module for cleaning parameters takes maximizing cleaning efficiency, minimizing energy consumption, and minimizing cleaning time as comprehensive optimization objectives. It uses a particle swarm optimization algorithm to search and output the optimized negative pressure intensity and the optimized blowing pressure. The search boundary of the particle swarm optimization algorithm is limited by the sealing and holding force of the negative pressure ring (8) and the rated pressure of the compressed air source.

10. An integrated drilling and tapping device for heavy-duty truck cast iron parts according to claim 9, characterized in that: The multiple functional modules also include a real-time cleaning effect verification module and a historical data self-learning module. The real-time cleaning effect verification module compares the cumulative debris mass measured by the debris mass flow meter within the cleaning cycle with the theoretical total debris mass to determine whether the cleaning meets the standard, and automatically triggers a secondary cleaning process if the standard is not met. The historical data self-learning module stores the working condition parameters of each successful cleaning and the corresponding optimized cleaning parameters in the database, performs cluster analysis according to hole depth and thread specifications, and updates the recommended initial population position of the particle swarm optimization algorithm under each working condition. At the same time, it dynamically adjusts the weight allocation of each sub-objective in the multi-objective optimization based on the recent cleaning pass rate trend. The cleaning pass rate statistics are periodically fed back to the process database of the controller to adjust the weighting coefficient of the deviation signal in the drilling and tapping stage.

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