Profiling edge milling machining equipment for long and straight structural parts

Abstract

The utility model relates to profiling edge milling equipment for a long and straight structural member, which adopts a displacement sensor to monitor the displacement between a workpiece and a milling power head in real time, and inputs the displacement into a PLC (Programmable Logic Controller) control system in an analog quantity form; according to the product drawing size requirement, the displacement median is calculated, a control program is programmed, the Y-direction displacement of the workpiece is judged through the PLC, a forward and reverse rotation instruction is sent to the servo motor, the Y-direction position of the edge milling machine walking trolley is controlled, the machining amount is adjusted to meet the size requirement, and profiling machining is achieved. The utility model solves the problems in the prior art that in the profiling edge milling processing of long and straight structural members, especially airfoil grooves of C-shaped structural beams, real-time automatic profiling processing cannot be realized by the existing processing technology due to straightness deviation of workpieces, so that the groove size control precision is poor, the processing efficiency is low, and the processing cost is high.

Description

Technical Field

[0001] This utility model belongs to the field of automotive parts processing, and specifically relates to a milling machine for profile milling of long straight structural parts. Background Technology

[0002] Currently, some special automotive beams are constructed using C-shaped channel steel welded together. This structure is characterized by its long longitudinal dimension, short transverse dimension, large plate thickness, and high welding difficulty, requiring beveling before welding to meet welding requirements. The conventional method for beveling is milling. Traditional automated milling machines, once the Y-axis (transverse) displacement is set, travel on a fixed track in the X-axis (longitudinal) direction, and cannot dynamically adjust the Y-axis displacement. For roll-formed profiles with large longitudinal dimensions, the flanges often have straightness deviations. After beveling along a fixed Y-axis displacement, the blunt edge dimensional accuracy is poor, easily leading to excessively large local gaps and weld leaks after welding, resulting in rework. While manually adjusting the Y-axis position during beveling can improve accuracy, this method reduces processing efficiency, requires a high level of operator skill, and is not conducive to automated production. Summary of the Invention

[0003] This utility model provides a contour milling processing equipment for long straight structural parts, which solves the problems of poor precision control of bevel size, low processing efficiency and high processing cost in the contour milling processing of long straight structural parts, especially for the bevel of C-shaped structural beams, due to the deviation of the straightness of the workpiece itself.

[0004] This utility model is achieved using the following technical solution:

[0005] This utility model provides a milling machine for profile milling of long straight structural parts, including a milling power head, a workpiece ranging device, a PLC control system, and a servo motor control system;

[0006] The milling power head is connected to the lifting column, and the Z-axis movement of the milling power head is achieved through the top motor and Z-axis lead screw installed inside the lifting column; the bottom of the lifting column is connected to the traveling trolley, and the Y-axis movement of the milling power head and the lifting column as a whole is achieved through the Y-axis lead screw installed inside the traveling trolley; the traveling trolley is set on the worktable guide rail, and the X-axis movement is achieved by the traveling trolley moving along the worktable guide rail through its own motor;

[0007] The servo motor control system includes a servo motor driver, a servo motor, and a Y-axis lead screw connected to the servo motor. The servo motor driver controls the Y-axis displacement of the lifting column and the milling power head by driving the Y-axis lead screw through the servo motor.

[0008] The PLC control system includes a PLC controller, which is connected to the touch screen via a touch screen transmission harness and to a displacement sensor via a sensor transmission harness to receive signals; the PLC controller is connected to a servo motor driver to transmit signals and control the servo motor, thereby controlling the Y-axis displacement of the milling power head.

[0009] The top motor, the motor on the traveling trolley, and the milling power head cutter head motor are all ordinary motors. They are controlled by their respective frequency converters through a touch screen to realize their start, stop, forward and reverse rotation actions, thereby realizing the control of the Z-axis displacement of the milling power head, the X-axis movement of the traveling trolley, and the self-rotation milling operation of the milling power head cutter head.

[0010] The workpiece distance measuring device includes a displacement sensor disposed between the workpiece and the milling power head. The displacement sensor is fixed on the lifting column and monitors the distance between the workpiece and the milling power head in real time.

[0011] As a further explanation of this utility model: the workpiece distance measuring device realizes real-time monitoring of the distance between the milling power head and the workpiece through a displacement sensor, and realizes the transmission of distance parameters through the output of analog quantities;

[0012] The PLC controller receives data from the touch screen and displacement sensor, and sends forward and reverse rotation commands to the servo motor of the servo motor control system through program control.

[0013] The servo motor control system receives instructions from the PLC controller and controls the Y-axis displacement of the milling power head in real time to achieve contour machining of the workpiece.

[0014] Preferably, the worktable has a convex cross-section, and the workpiece is fixed on the top of the worktable; worktable guide rails are provided at both ends of the worktable.

[0015] Preferably, the PLC controller and servo motor driver are arranged inside the base of the traveling trolley.

[0016] This utility model also provides a method for contour milling of long straight structural parts, using the aforementioned processing equipment; employing the aforementioned displacement sensor to monitor the displacement between the workpiece and the milling power head in real time, and inputting it as an analog signal to the PLC control system and touch screen display; according to the product drawing size requirements, the median displacement is determined by manual adjustment through the initial touch screen and a control program is compiled; the PLC controller judges the real-time Y-axis displacement of the workpiece during processing and sends forward and reverse rotation commands to the servo motor to control the Y-axis position of the milling power head in real time, adjust the processing amount to the size requirements, and realize real-time contour milling.

[0017] As a further explanation of this utility model: This method has two control modes. The first is a touchscreen control mode. In the initial stage of processing, the milling head motor is started on the touchscreen, and preset Y and Z displacement values ​​are input. The PLC control system receives the Y-axis parameters from the touchscreen and controls the servo motor control system to adjust the Y-axis displacement of the milling head. The Z-axis displacement of the milling head is adjusted and controlled by the top motor. Under the combined action of the servo motor and the top motor, the milling head begins initial milling until the workpiece bevel dimensions meet the drawing requirements. The reading of the displacement sensor at this time is recorded as the median displacement and input to the touchscreen. The second is a displacement sensor contour control mode, which is activated after the median machining displacement is determined. During processing, the sensor monitors and transmits distance signals to the PLC control system. The program controls the comparison between the real-time displacement value and the median displacement, and then outputs forward and reverse commands to the servo motor control system to control the real-time contour change of the Y-axis displacement of the milling head.

[0018] As a further explanation of this utility model, the processing method comprises the following steps:

[0019] S1: Fix the workpiece on the worktable, start the milling power head motor power, use the touch screen control mode, input the Y and Z displacement, adjust the position of the milling power head, start the feed machining until the bevel meets the drawing requirements, lock the displacement sensor reading at this time as the displacement median value, and record it in the touch screen;

[0020] S2: Switch the displacement sensor control mode; start the X-axis feed motor power of the traveling carriage on the touch screen, and the traveling carriage drives the milling power head to start X-axis feed machining;

[0021] S3: In displacement sensor control mode, the displacement sensor monitors the distance between the workpiece and the milling power head in real time and transmits the data to the PLC controller and touch screen display. The PLC controller compares the real-time displacement with the median displacement data through its internal program and outputs forward and reverse rotation commands to the servo motor control system. The servo motor control system receives the forward and reverse rotation commands from the PLC controller and adjusts the Y-axis displacement of the milling power head by rotating the Y-axis lead screw until the Y-axis displacement returns to the median displacement range. At this point, the servo motor stops and the displacement is locked.

[0022] S4: Repeat step S3 until the workpiece milling is completed, then turn off the X-axis feed power.

[0023] Preferably, in step S1,

[0024] Using a touchscreen control mode, the position of the milling power head is adjusted to the position required by the bevel blunt edge dimension in the drawing by inputting the Y and Z displacements. The sensor measurement data at this time is defined as the displacement median A0, and the tolerance A0±d is set. The displacement median is locked at this time through the touchscreen.

[0025] Preferably, in step S3,

[0026] The sensor measures the distance A between the milling power head and the workpiece in real time and transmits it to the PLC control system in analog form. The program makes a judgment on A. When A is within the tolerance range of A0±d of the displacement, the servo motor does not work and the Y-direction displacement does not change.

[0027] When the value of A exceeds the range of the median displacement, the PLC control system sends forward and reverse commands to the servo motor control system to control the Y-axis displacement of the milling power head and make adjustments in real time until A is again within the range of the median displacement A0. Then the servo motor stops, the Y-axis displacement is locked, and this step is repeated until the machining is completed.

[0028] Preferably, in step S3, the adjustment process specifically includes:

[0029] When the sensor measures the distance A between the milling head and the workpiece in real time to be greater than A0±d, the PLC control system sends a forward rotation command to the servo motor control system. The servo motor works and controls the Y-direction displacement of the milling head to decrease until A enters the tolerance range A0±d of the displacement value again.

[0030] When the sensor measures in real time that the distance A between the milling power head and the workpiece is less than A0±d, the PLC control system sends a reverse command to the servo motor control system. The servo motor then operates, controlling the milling power head to increase its Y-direction displacement until A re-enters the tolerance range A0±d of the displacement median.

[0031] Compared with the prior art, the present invention has the following beneficial effects:

[0032] This invention addresses the problems of poor bevel size control, low processing efficiency, and high processing costs in the milling of bevels on the flanges of long, straight structural components, particularly C-shaped beams, where the straightness of the workpiece itself is often compromised, preventing real-time automatic contour milling. This invention achieves real-time contour milling, improving processing accuracy by 50% and increasing processing efficiency by 30%. Attached Figure Description

[0033] Appendix Figure 1 This is a schematic diagram of the contouring machining control principle of this utility model;

[0034] Appendix Figure 2 This is a schematic diagram of the contour processing equipment of this utility model (the milling machine, the power walking trolley and other components are hidden).

[0035] Appendix Figure 3 This is a structural layout diagram of the contour processing equipment of this utility model;

[0036] Appendix Figure 4 This is a flowchart of the contour milling method of this utility model;

[0037] In the diagram, 1. Displacement sensor; 2. PLC controller; 3. Touch screen; 4. Servo motor driver; 5. Servo motor; 6. Workpiece; 7. Touch screen connection harness; 8. Sensor transmission harness; 9. Servo motor transmission harness; 10. Y-axis lead screw; 11. Traveling trolley; 12. Lifting column; 13. Milling power head; 14. Worktable guide rail; 15. Z-axis lead screw; 16. Worktable; 17. Top motor. Detailed Implementation

[0038] To enable those skilled in the art to better understand the technical solutions of this utility model, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of this utility model. Example

[0039] Combination Figures 1-3 As shown, this utility model relates to a contour milling machine and method for long, straight structural parts. This utility model comprises four modules: a milling power head 13, a workpiece ranging device, a PLC control system, and a servo motor control system.

[0040] The workpiece distance measuring device uses displacement sensor 1 to monitor the distance between milling power head 13 and workpiece 6 in real time, and outputs analog signals to PLC controller 2 to transmit distance parameters.

[0041] The PLC controller 2 receives data from the touch screen 3 and the displacement sensor 1, and sends forward and reverse rotation commands to the servo motor driver 4 of the servo motor control system through program control.

[0042] The servo motor control system receives forward and reverse rotation commands from the PLC controller 2 via the servo motor driver 4, controls the servo motor 5, and adjusts the Y-axis displacement of the milling power head 13 in real time to achieve workpiece contour machining.

[0043] The milling power head 13 is connected to the lifting column 12, and the Z-axis movement of the milling power head 13 is realized by the top motor 17 and Z-axis lead screw 15 installed in the lifting column 12; the bottom of the lifting column 12 is connected to the traveling trolley 11, and the Y-axis movement of the milling power head 13 and the lifting column 12 as a whole is realized by the Y-axis lead screw 10 installed in the traveling trolley 11; the traveling trolley 11 is set on the worktable guide rail 14, and the X-axis movement is realized by the traveling trolley's own motor moving along the worktable guide rail 14.

[0044] The workpiece distance measuring device includes a displacement sensor 1 disposed between the workpiece 6 and the milling power head 13. The displacement sensor 1 is fixed on the lifting column 12 and monitors the distance between the workpiece 6 and the milling power head 13 in real time, transmitting the data to the PLC control system and the touch screen 3 in real time.

[0045] The PLC control system receives data signals from displacement sensor 1 and touch screen 3 and sends forward and reverse rotation commands to the servo motor control system through the control program.

[0046] The servo motor control system receives instructions from the PLC controller and drives the Y-axis lead screw 10 in real time via the servo motor 5 to control the Y-axis displacement of the lifting column 12 and the milling power head 13.

[0047] For the profile milling of the flange bevel of a C-shaped structural beam, the milling equipment is arranged as follows: Figure 3 As shown.

[0048] The worktable 16 has a convex cross-section, and the workpiece 6 is fixed on the top of the worktable 16; worktable guide rails 14 are provided at both ends of the worktable 16.

[0049] Displacement sensor 1 is positioned between workpiece 6 and milling head 13, fixed to lifting column 12, to monitor the distance between workpiece 6 and milling head 13 in real time. PLC controller 2 and servo motor driver 4 are located inside the base of traveling carriage 11. Servo motor 5 controls the Y-axis displacement of traveling carriage 11 by driving Y-axis lead screw 10.

[0050] The top motor 17, the motor of the traveling carriage, and the cutter head motor of the milling power head 13 are all ordinary motors. They are controlled by their respective frequency converters through the touch screen 3 to control their start, stop, forward and reverse rotation, etc., thereby realizing the Z-axis displacement of the milling power head, the X-axis movement of the traveling carriage 11, and the control of the milling power head cutter head rotation for milling. Example

[0051] This application discloses a contour milling method for long, straight structural components, which has two control modes:

[0052] The first mode is touchscreen control. In the initial processing stage, the power head cutter head motor is started on touchscreen 3, and preset Y and Z displacement values ​​are input. The PLC control system receives the Y-axis parameters from the touchscreen and controls the servo motor control system to adjust the Y-axis displacement of the milling power head. The Z-axis displacement of the milling power head is adjusted via the top motor 17. Under the combined action of the servo motor 5 and the top motor 17, the milling power head begins initial milling until the workpiece bevel dimensions meet the drawing requirements. The reading of displacement sensor 1 at this point is recorded as the median displacement and input to touchscreen 3.

[0053] Another mode is the displacement sensor contour control mode, which is activated after the median value of the machining displacement is determined. During machining, the sensor monitors and transmits distance signals to the PLC control system. The program controls the comparison between the real-time displacement value and the median displacement, and then outputs forward and reverse commands to the servo motor control system to control the real-time contour change of the Y-axis displacement of the milling power head 13.

[0054] The contour milling process based on displacement sensors is as follows: Figure 4 As shown, the workpiece 6 is fixed on the worktable 16, the milling power head cutter head motor power is turned on, the touch screen control mode is used, the Y and Z displacements are input, the position of the milling power head 13 is adjusted, and the feed machining begins until the bevel meets the drawing requirements. At this time, the reading of the displacement sensor 1 is locked as the displacement median value A0, and the tolerance A0±d is set. The displacement median value is locked at this time through the touch screen.

[0055] Switch to displacement sensor control mode; start the X-axis feed motor power of the traveling carriage on the touch screen, and the traveling carriage 11 drives the milling power head 13 to start X-axis feed machining; in displacement sensor control mode, displacement sensor 1 monitors the distance between workpiece 6 and milling power head 13 in real time and transmits it to PLC controller 2 and touch screen 3 for display. PLC controller 2 compares the real-time displacement with the median displacement data through its internal program and outputs forward and reverse commands to the servo motor control system accordingly; the servo motor control system receives the forward and reverse commands from PLC controller 2 and adjusts the Y-axis displacement of the milling power head by rotating the Y-axis lead screw 10 until the Y-axis displacement returns to the median displacement range. The servo motor 5 stops, the displacement is locked, and this step is repeated until the machining is completed.

[0056] The above description is merely an example of the embodiments of this utility model and is not intended to limit the utility model in any way. The scope of protection of this utility model is defined by the claims and is not limited to the specific embodiments described above. Any simple modifications or equivalent changes and alterations made to the above embodiments based on the technical essence of this utility model shall fall within the scope of protection of this utility model.

Claims

1. A long straight structural member edge profiling apparatus, characterised in that: It comprises a milling power head (13), a workpiece distance measuring device, a PLC control system and a servo motor control system. The milling power head (13) is connected with the lifting column (12), and the Z-direction movement of the milling power head (13) is realized through the top motor (17) and the Z-direction lead screw (15) arranged in the lifting column (12); the bottom of the lifting column (12) is connected with the walking trolley (11), and the Y-direction movement of the milling power head (13) and the lifting column (12) as a whole is realized through the Y-direction lead screw (10) arranged in the walking trolley (11); the walking trolley (11) is arranged on the workbench guide rail (14), and the X-direction movement is realized by moving along the workbench guide rail (14) through the motor of the walking trolley. The servo motor control system comprises a servo motor driver (4), a servo motor (5) and a Y-direction lead screw (10) connected with the servo motor (5); the servo motor driver (4) drives the Y-direction lead screw (10) through the servo motor (5) to control the Y-direction displacement of the lifting column (12) and the milling power head (13). The PLC control system comprises a PLC controller (2); the PLC controller (2) is connected with the touch screen (3) through the touch screen transmission line bundle (7) and is connected with the displacement sensor (1) through the sensor transmission line bundle (8) to receive signals; the PLC controller (2) is connected with the servo motor (5) through the transmission signal connected with the servo motor driver (4) to control the Y-direction displacement of the power head. The top motor (17), the motor of the walking trolley and the cutter head motor of the milling power head are all ordinary motors, and the start-stop and forward-reverse rotation of each frequency converter are realized through the touch screen (3), so as to realize the control of the Z-direction displacement of the power head, the X-direction movement of the walking trolley (11) and the self-rotation milling of the cutter head of the milling power head. The workpiece distance measuring device comprises a displacement sensor (1) arranged between the workpiece (6) and the milling power head (13); the displacement sensor (1) is fixed on the lifting column (12) to monitor the distance between the workpiece (6) and the milling power head (13) in real time.

2. The long straight structure profiling and edge milling equipment according to claim 1, wherein: The workpiece distance measuring device realizes the real-time monitoring of the distance between the milling power head (13) and the workpiece (6) through the displacement sensor (1) and transmits the distance parameter to the PLC controller (2) through the output analog quantity; The PLC controller (2) receives the data of the touch screen (3) and the displacement sensor (1) and sends forward-reverse rotation instructions to the servo motor driver (4) of the servo motor control system through program control; The servo motor control system receives the forward-reverse rotation instructions of the PLC controller (2) through the servo motor driver (4), controls the servo motor (5) and adjusts the Y-direction displacement of the milling power head (13) in real time to realize the profiling of the workpiece.

3. The long straight structure profiling and edge milling apparatus according to claim 1, characterized in that: The workbench (16) has a convex cross section, and the workpiece (6) is fixed on the top of the workbench (16); the workbench (16) is provided with workbench guide rails (14) at both sides.

4. The long straight structure profiling and edge milling apparatus according to claim 1, characterized in that: The PLC controller (2) and the servo motor driver (4) are arranged inside the base of the walking trolley (11).

Images