Intelligent straightening and positioning device for metal profile machining

Abstract

The utility model discloses a kind of intelligent straightening positioning equipment for metal profile processing, including rack, feed drive system, measurement system, straightening execution system and intelligent control system.Feed drive system is used for uniform velocity conveying metal profile;Measurement system adopts multiple sensor array, through a main laser displacement sensor and two symmetrically arranged auxiliary sensors, the bending and torsional deformation of profile are synchronously detected in real time;Straightening execution system includes a straightening robot unit driven by linear motor module, and the unit can track profile synchronously in motion.The utility model realizes the online dynamic measurement and synchronous tracking straightening of profile in continuous feeding process, greatly improves processing efficiency and precision, and can effectively handle bending and torsional composite deformation.

Description

Technical Field

[0001] This utility model relates to the field of metal profile processing technology, and in particular to an intelligent straightening and positioning device for metal profile processing. Background Technology

[0002] During production, transportation, or storage, metal profiles often undergo plastic deformation such as bending and twisting due to external forces, temperature, or internal stress, affecting their accuracy. Traditional straightening methods rely heavily on manual experience, judging the location and extent of deformation by visual inspection or simple tools, and then using mechanical pressure devices for straightening. This method is inefficient, labor-intensive, and difficult to guarantee straightening accuracy, especially for long profiles with complex cross-sections, where manual straightening is even less effective.

[0003] Therefore, how to design an intelligent straightening and positioning device for metal profile processing has become a problem that we need to solve. Utility Model Content

[0004] To address the shortcomings of existing technologies, this utility model provides an intelligent straightening and positioning device for metal profile processing, solving the problems mentioned in the background section.

[0005] To achieve the above objectives, this utility model provides the following technical solution: an intelligent straightening and positioning device for metal profile processing, comprising a frame, a feed drive system, a measurement system, a straightening execution system, and an intelligent control system. The feed drive system is mounted on the frame and is used to clamp and convey metal profiles at a constant speed. The measurement system includes a multi-sensor array module, which has a main laser displacement sensor and at least two auxiliary laser displacement sensors. The main sensor is installed perpendicular to the profile feeding direction to measure vertical deformation. The two auxiliary laser displacement sensors are symmetrically arranged on both sides of the main sensor at a 45° angle to measure the height of the profile feature edge points, thereby simultaneously detecting the bending and torsional deformation of the profile. The straightening execution system includes a high-precision slide table driven by a linear motor module, and a straightening robot unit mounted on the slide table. The linear motor module enables the straightening robot unit to move along the profile feeding direction and keep synchronously tracking the profile. The straightening robot unit is equipped with a three-degree-of-freedom straightening head, which is used to apply straightening force to the profile from the vertical, horizontal and rotational directions; The intelligent control system is electrically connected to the feed drive system, measurement system, linear motor module and straightening robot unit, and is used to control the coordinated action of each component. It also has a built-in adaptive straightening algorithm that can dynamically adjust the straightening parameters based on measurement feedback.

[0006] Preferably, the three-degree-of-freedom straightening head includes: A vertical servo electric cylinder is used to apply a corrective force in the vertical direction; A horizontal servo electric cylinder is used to apply a corrective force in the horizontal direction; A servo rotation mechanism is used to drive the straightening head to rotate in the horizontal plane to adjust the applied force angle.

[0007] Preferably, the end of the three-degree-of-freedom straightening head is provided with a pressure head with a universal ball joint.

[0008] Preferably, the feed drive system is a roller servo drive wheel or a three-jaw chuck traction machine.

[0009] Preferably, the device further includes a profile cross-section recognition unit, which is an industrial camera or a laser profile scanner, installed at the device inlet, for recognizing the profile cross-section type and transmitting it to the intelligent control system.

[0010] Preferably, the adaptive straightening algorithm module of the intelligent control system can compensate for material rebound based on the secondary scanning results of the measurement system after a straightening action, and self-learn to optimize the force parameters of subsequent straightening points.

[0011] Preferably, the included angle between the main laser displacement sensor and the auxiliary laser displacement sensor is in the range of 30° to 60°.

[0012] Preferably, the entire straightening process is completed synchronously during the continuous and uniform feeding of the profile. Beneficial effects

[0013] This utility model provides an intelligent straightening and positioning device for metal profile processing, which has the following beneficial effects: High efficiency and online processing: It enables simultaneous measurement, tracking and straightening, without interrupting the profile production, which greatly improves the processing cycle and production efficiency, and truly integrates into the continuous production line.

[0014] Composite deformation handling capability: The innovative multi-sensor array design solves the problem of simultaneous detection of single bending and torsional deformation, expanding the application range of the equipment.

[0015] High precision and adaptive intelligence: Through the built-in springback model and secondary measurement self-learning algorithm, the system can automatically compensate for the springback of different materials, which significantly improves the straightening accuracy and first pass rate, and reduces the dependence on the operator's experience.

[0016] Flexibility and versatility: Through cross-section recognition and parameterized settings, processing tasks for different profiles can be quickly switched to adapt to the flexible production needs of small batches and multiple varieties. Attached Figure Description

[0017] Figure 1 This is a side view of the overall structure of this utility model; Figure 2 This is a side view of the main laser displacement sensor and two auxiliary laser displacement sensors of this utility model.

[0018] In the diagram: 1. Frame; 2. Rolling servo drive wheel; 3. Measurement system; 301. Main laser displacement sensor; 302. Auxiliary laser displacement sensor; 303. Section recognition unit; 4. Straightening robot unit; 41. Linear motor module. Detailed Implementation

[0019] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0020] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0021] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "multiple" means two or more, unless otherwise explicitly specified. Example

[0022] like Figures 1-2 As shown, an intelligent straightening and positioning device for metal profile processing mainly includes a frame 1, a feed drive system, a measurement system 3, a straightening execution system, and an intelligent control system.

[0023] The frame 1 is welded from high-quality steel, which has high rigidity and stability, providing a supporting foundation for the entire equipment.

[0024] The feed drive system employs a pair of opposing roller servo drive wheels 2, mounted on the frame 1 at the equipment inlet. The surfaces of the opposing roller servo drive wheels 2 are covered with a polyurethane wear-resistant layer to increase friction with the metal profile and prevent slippage. The servo drive wheels 21 are precisely controlled by an intelligent control system, capable of pulling the profile through the equipment at a set constant speed, and can also pause upon command.

[0025] The measurement system 3 is located after the feed drive system, and its core is a multi-sensor array module. This module is mounted directly above the profile conveying channel via a crossbeam. The module includes a main laser displacement sensor 301 and two auxiliary laser displacement sensors 302. The main sensor is mounted vertically downwards and is used to accurately measure the height data (Z-axis) of the centerline position of the top surface of the profile. The two auxiliary laser displacement sensors 302 are symmetrically arranged on both sides of the main sensor at a 45° angle, and their laser spots are aimed at feature points near the two side edges of the top surface of the profile. The three sensors are connected to the data acquisition card in the intelligent control system to acquire data synchronously at high frequency. Through the three-point ranging principle, the system can calculate the vertical bending amount (ΔZ) and horizontal torsional deformation amount (Δθ) of the current section of the profile in real time.

[0026] A profile cross-section recognition unit 303 is also provided in front of the measurement system 3. In this embodiment, a 5-megapixel industrial camera is used in conjunction with a strip light source. When the front end of the profile enters, the camera captures its end face image, identifies the profile cross-section type (such as "10mm equilateral angle steel") through image processing algorithms, and sends this information to the intelligent control system so that it can automatically call the pre-stored straightening process parameters, sensor calibration parameters and springback model of the profile in the database.

[0027] The straightening execution system includes a high-precision linear motor module 41 and a straightening robot unit 4 mounted on its slide. The linear motor module 41 is mounted on the frame 1 along the profile feeding direction (X direction), and has high dynamic response and positioning accuracy of ±0.01mm, enabling the straightening robot unit 4 to maintain precise synchronization with the moving profile under servo drive.

[0028] The straightening robot unit 4 integrates a three-degree-of-freedom straightening head. This straightening head includes: A vertical servo electric cylinder is used to provide corrective force or displacement in the vertical direction (Z direction); A horizontal servo electric cylinder is used to provide a corrective force or displacement in the horizontal direction (Y direction) to correct torsion or lateral bending; A servo rotary mechanism (such as a hollow rotary platform) is mounted at the bottom of a vertical electric cylinder to drive the actuator at its end to rotate 360° in the horizontal plane for positioning.

[0029] The end of the straightening head uses an alloy steel pressure head with a universal ball joint. This pressure head can adapt to small angle changes on the profile surface and avoid damaging the profile surface.

[0030] The intelligent control system, the brain of the equipment, is installed in the control cabinet on one side of rack 1. Its core hardware includes an industrial computer (IPC), a multi-axis motion control card, a high-speed data acquisition card, and a servo drive assembly. Its software system integrates: Data acquisition and fusion module: Receives data from all sensors in real time and performs filtering, coordinate transformation, and other processing.

[0031] Motion control module: coordinates and controls the synchronous motion of the feed drive system, linear motor module 41, and each servo axis.

[0032] Adaptive Straightening Algorithm Module: This is the core innovation. This module incorporates a springback model database for common metal materials (such as Q235 steel, 6061 aluminum alloy, etc.) and common cross-sections. During operation, the system initially calculates the required applied force (Fz, Fy) and angle based on the identified profile type and the real-time detected deformation (ΔZ, Δθ). Within a very short time (e.g., ms) after the straightening action, the command measurement system 3 performs a secondary scan of the just-straightened point to detect residual deformation (springback). The system compares this springback data with the predicted value and dynamically corrects the subsequent force parameters applied to other bending points on the same profile through a self-learning algorithm, achieving increasingly accurate closed-loop intelligent control.

[0033] Work process: The operator feeds a slightly bent and twisted long angle steel into the equipment inlet. The feed drive system clamps the profile and feeds it in at a constant speed. The section recognition unit 303 identifies its specifications, and the intelligent control system automatically loads the corresponding parameters.

[0034] The profile passes through the measuring system 3 at a constant speed. The multi-sensor array 31 continuously scans, and when a bend (ΔZ=+3.0mm) is detected and torsional deformation (Δθ=1.5°) is found at this point, the data is immediately sent to the intelligent control system.

[0035] The system immediately calculates: 1) instructs the linear motor module 41 to drive the straightening robot unit 4 to accelerate, keeping in sync with the current feed speed of the profile (e.g., 50 mm / s); 2) instructs the servo rotation mechanism to rotate, so that the force applied by the pressure head is opposite to the twisting direction; 3) calculates the vertical and horizontal forces to be applied based on the preliminary algorithm.

[0036] While maintaining synchronized motion, the vertical and horizontal servo electric cylinders work together to push the pressure head to apply a calculated corrective force to the profile. After the force is applied, the electric cylinders quickly retract.

[0037] Almost simultaneously, measurement system 3 performs a second scan of the point that was just straightened and finds residual deformation of ΔZ_res = 0.4 mm and Δθ_res = 0.2°. The intelligent control system determines that springback exists and then adaptively updates the gain coefficient in the algorithm based on this difference. When the next bending point on the profile is detected, the system will apply the updated parameters and apply a larger force (e.g., Fz = 6.0 kN, Fy = 2.0 kN) to completely eliminate the deformation.

[0038] The entire profile completes the detection and straightening of all bending and twisting points in a single continuous pass through the equipment, without stopping or retraction, resulting in extremely high processing efficiency and excellent precision.

[0039] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0040] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An intelligent straightening and positioning device for metal profile processing, comprising a frame (1), a feed drive system, a measurement system (3), a straightening execution system, and an intelligent control system, characterized in that: The feed drive system is mounted on the frame (1) and is used to clamp and convey metal profiles at a constant speed; The measurement system (3) includes a multi-sensor array module, which has a main laser displacement sensor (301) and at least two auxiliary laser displacement sensors (302). The main laser displacement sensor (301) is installed perpendicular to the profile feeding direction to measure vertical deformation. The auxiliary laser displacement sensors (302) are arranged symmetrically at an angle on both sides of the main sensor to measure the height of the profile feature edge points, thereby simultaneously detecting the bending and torsional deformation of the profile. The straightening execution system includes a high-precision slide table driven by a linear motor module (41) and a straightening robot unit (4) mounted on the slide table. The linear motor module (41) enables the straightening robot unit (4) to move along the profile feeding direction and keep synchronously tracking the profile. The straightening robot unit (4) is equipped with a three-degree-of-freedom straightening head, which is used to apply straightening force to the profile from the vertical, horizontal and rotational directions; The intelligent control system is electrically connected to the feed drive system, measurement system (3), linear motor module (41) and straightening robot unit (4), and is used to control the coordinated action of each component. It also has an adaptive straightening algorithm built in, which can dynamically adjust the straightening parameters according to the measurement feedback.

2. The intelligent straightening and positioning device for metal profile machining according to claim 1, characterized in that, The three-degree-of-freedom straightening head includes: A vertical servo electric cylinder is used to apply a corrective force in the vertical direction; A horizontal servo electric cylinder is used to apply a corrective force in the horizontal direction; A servo rotation mechanism is used to drive the straightening head to rotate in the horizontal plane to adjust the applied force angle.

3. The intelligent straightening and positioning device for metal profile processing according to claim 2, characterized in that, The end of the three-degree-of-freedom straightening head is provided with a pressure head with a universal ball joint.

4. The intelligent straightening and positioning device for metal profile processing according to claim 1, characterized in that, The feed drive system is a roller servo drive wheel (2) or a three-jaw chuck traction machine.

5. The intelligent straightening and positioning device for metal profile processing according to claim 1, characterized in that, The device also includes a profile section recognition unit (303), which is an industrial camera or laser profile scanner, installed at the device entrance, and used to identify the profile section type and transmit it to the intelligent control system.

6. The intelligent straightening and positioning device for metal profile processing according to claim 1, characterized in that, The adaptive straightening algorithm module of the intelligent control system can compensate for the material rebound based on the secondary scanning results of the measurement system (3) after a straightening action, and self-learn to optimize the force parameters of subsequent straightening points.

7. The intelligent straightening and positioning device for metal profile processing according to claim 1, characterized in that, The angle between the main laser displacement sensor (301) and the auxiliary laser displacement sensor (302) is in the range of 30° to 60°.

8. The intelligent straightening and positioning device for metal profile processing according to claim 1, characterized in that, The entire straightening process is completed simultaneously during the continuous and uniform feeding of the profile.

Images