阅读说明：本技术 智能五轴同动多相态水刀加工系统 (Intelligent five-axis same-motion multi-phase water jet cutting machining system ) 是由 苏友欣 郑品聪 林弘祥 于 2019-08-05 设计创作，主要内容包括：一种智能五轴同动多相态水刀加工系统,包含加工单元及监控单元。所述加工单元包括射流装置。所述射流装置具有机械臂、可被所述机械臂驱动的切割头,及设置于所述切割头上的惯性量测模块。所述监控单元包括水刀加工参数智能计算补偿模块,及智能化控制器。所述惯性量测模块可实时且准确地测得所述切割头的倾摆角度,使姿态补偿角参数可回授给所述智能化控制器,达到高精准度的倾斜角度补偿。加上所述切割头的2.5D枪头机构特性,及所喷射出的高能量混砂射流束属于可调式弹性刀长的加成,使本发明的加工精度能趋近机构定位精度,达到航天工业精密加工以上的等级。(An intelligent five-axis same-motion multi-phase water jet cutting machining system comprises a machining unit and a monitoring unit. The processing unit comprises a fluidic device. The fluidic device is provided with a mechanical arm, a cutting head driven by the mechanical arm and an inertia measuring module arranged on the cutting head. The monitoring unit comprises a water jet cutting processing parameter intelligent calculation compensation module and an intelligent controller. The inertia measurement module can accurately measure the tilt angle of the cutting head in real time, so that the attitude compensation angle parameter can be fed back to the intelligent controller, and the high-precision tilt angle compensation is achieved. In addition, the 2.5D gun head mechanism characteristic of the cutting head and the ejected high-energy sand-mixing jet beam belong to the addition of adjustable elastic cutter length, so that the processing precision of the invention can approach the positioning precision of the mechanism, and the precision processing grade of the invention reaches above the precision processing grade of the aerospace industry.)

1. An intelligent five-axis same-motion multi-phase water jet cutting machining system is used for machining a workpiece; the method is characterized in that: the intelligent five-axis same-motion multi-phase water jet machining system comprises a machining unit and a monitoring unit, wherein the machining unit comprises a jet device, a sand supply source connected with the jet device, a water supply source connected with the jet device and providing high-pressure water jet, the jet device is provided with a mechanical arm, a cutting head connected with the mechanical arm and connected with the sand supply source and the water supply source and capable of being controlled to eject mixed sand jet, a plurality of motors arranged on the mechanical arm to enable the mechanical arm to drive the cutting head to move along five axial directions, and an inertia measuring module arranged on the cutting head and capable of sensing spatial position and dynamic positioning of a cutter center point of the cutting head, the monitoring unit comprises a water jet machining parameter intelligent calculation and compensation module capable of calculating a compensation value according to target machining conditions and a water jet machining parameter intelligent calculation and compensation module in signal connection, The intelligent controller of the motor and the inertia measurement module is used for intelligently calculating the target processing conditions of the compensation module according to the water jet cutting processing parameters, wherein the target processing conditions comprise the angle to be processed on the workpiece, the compensation value comprises an attitude compensation angle parameter, the intelligent controller can converge the processed angle and the attitude compensation angle parameter to obtain an ideal value, then the actual swing angle of the motor and the tilt angle measured by the inertia measurement module are compared to obtain a difference value, the difference value and the ideal value are converged to obtain a feedback attitude angle, and the intelligent controller can control the motor in real time according to the feedback attitude angle to perform angle compensation in real time.

2. The intelligent five-axis same-motion multi-phase-state water jet machining system according to claim 1, characterized in that: the inertia measurement module of the processing unit is provided with a magnetometer, an accelerometer and a gyroscope.

3. The intelligent five-axis same-motion multi-phase-state water jet machining system according to claim 1, characterized in that: the processing unit still includes a plurality ofly set up in on the motor and signal connection the encoder of intelligent controller, the encoder is used for real-time detection the actual pendulum angle of turning of motor.

4. The intelligent five-axis same-motion multi-phase-state water jet machining system according to claim 1, characterized in that: the monitoring unit further comprises a positioning inspection module which is in signal connection with the intelligent controller and corresponds to the mechanical arm of the processing unit, and the positioning inspection module is used for detecting error values of a plurality of target positions and actual positions of the mechanical arm and inputting the error values into the intelligent controller so as to compensate the mechanical arm by adjusting the motor.

5. The intelligent five-axis same-motion multi-phase-state water jet machining system according to claim 4, characterized in that: the positioning inspection module is provided with at least one laser interferometer for detecting backlash and pitch errors.

6. The intelligent five-axis same-motion multi-phase-state water jet machining system according to claim 1, characterized in that: the target processing conditions of the water jet cutting processing parameter intelligent calculation compensation module of the monitoring unit further comprise abrasive material parameters and cutting head parameters.

7. The intelligent five-axis same-motion multi-phase dynamic water jet machining system according to claim 6, characterized in that: the abrasive parameters include abrasive particle size, abrasive shape, and abrasive density.

8. The intelligent five-axis same-motion multi-phase dynamic water jet machining system according to claim 6, characterized in that: the cutting head parameters comprise a gun head form, a sand mulling pipe length and a sand mulling pipe diameter.

9. The intelligent five-axis same-motion multi-phase-state water jet machining system according to claim 1, characterized in that: the intelligent controller of the monitoring unit can arrange the data into a VDW format and output the data in a communication platform unified architecture mode.

10. The intelligent five-axis same-motion multi-phase-state water jet machining system according to claim 1, characterized in that: the monitoring unit further comprises an early warning module which is in signal connection with the intelligent controller and the processing unit, and a consumable prompting module which is in signal connection with the intelligent controller and monitors the cutting head so as to prompt the replacement of consumable of the cutting head.

Technical Field

The invention relates to a jet flow cutting system, in particular to an intelligent five-axis same-motion multi-phase water jet cutting system.

Background

Water jet cutting is a technology for cutting a workpiece by converting high pressure into high kinetic energy water jet, wherein a high pressure water jet forms a radioactive jet through a nozzle hole (orifice) of a cutting head, and accordingly, the workpiece on a jet flow path is cut. The five-axis water jet cutting system is a high-order type commonly used in water jet cutting machines and comprises a mechanical arm capable of performing five axial movements, a cutting head arranged at the bottom end of the mechanical arm and used for outputting high-pressure mixed sand water jet, and a controller system used for controlling the actions of the mechanical arm and the opening and closing actions of the cutting head. After an operator inputs machining conditions, the controller can drive the motor on the mechanical arm, so that the mechanical arm drives the cutting head to perform five-axis motion and jet high-pressure sand mulling jet flow to the workpiece to perform cutting machining.

Because the high-energy sand-mixing jet beam is equivalent to an adjustable elastic cutter, namely the high-energy sand-mixing jet beam is not a rigid cutter with a fixed length, the jet beam can be deviated or bent under the influence of conditions of removing a workpiece and the like which move at a high speed after being ejected, so that defects such as water flow lag (trailer) and a notch bevel edge (spike) are generated on the workpiece.

However, although the motor on the robot arm can be controlled to rotate accurately, after the motor rotates, the robot arm and the cutting head are affected by a plurality of positioning accuracy factors such as backlash error and pitch error, or by other factors such as abrasive condition, water jet condition, motion condition, and processing material, so that the actual inclination angle of the cutting head is different from the ideal angle output by the motor, which results in reduction of processing accuracy and reduction of compensation effect.

In order to solve the above problems, the applicant of the present invention discloses a water jet cutting apparatus in taiwan patent No. I618602, wherein an Inertial Measurement Unit (IMU) is disposed on the cutting head to monitor the actual tilt angle of the cutting head in real time. The static positioning Accuracy (Accuracy of Position) range of the water jet cutting device is 0.0001-0.1 degrees, the optimal dynamic positioning Accuracy (TransmissionAccuracy) is operated at 0.001-0.05 degrees, the high Accuracy is sufficient, and the technology for monitoring the actual inclined attitude angle in real time also brings brand-new development possibility for a five-axis water jet cutting system, for example, programming correction of a processing program code can be corrected in real time. However, the controller of the five-axis water jet cutting system on the market at present cannot be applied to the water jet cutting device invented by the applicant.

Referring to fig. 1, OMAX discloses a method for generating optimized tool paths and machine tool commands for a jet cutting tool in U.S. Pat. No. US20180364679a1, which can generate tool paths through first and second order functions of empirical data, but data about tilt angles in the tool paths are still captured from actuators such as motors, non-Tool Center Point (TCP) position and attitude angle feedback, and programming error values of machining program codes cannot be corrected in real time, so that the accuracy is not high and the controller cannot be applied to a cutting head with an inertial measurement component in taiwan patent No. I618602.

U.S. Pat. No. US20180059638a1, incorporated by reference as well as to a fluid Jet cutting system and a method for controlling the movement of the system, the control unit of which is capable of operating the movement of the cutting head according to a predetermined tilt angle value (PIA) and automatically adjusting the speed of the cutting head relative to the workpiece according to the PIA, thereby controlling the Trailback Angle (TA) of the cutting surface of the workpiece and automatically compensating the angular displacement value (AD) caused by the Jet, but the system also uses sensors such as encoders to measure the output of the motor to calculate the tilt of the cutting head, and not the feedback of the Tool Center Point (TCP) position and attitude angle, which is not as precise as mentioned above and cannot be applied to the cutting head of taiwan patent No. I602 with an inertial measurement assembly.

Referring to fig. 2, the Flow company, in U.S. Pat. No. US9597772B2, discloses an adaptive vector control system capable of automatically determining the speed and orientation parameters of a cutting jet 2, which determines whether a specified tolerance of a three-dimensional curvature feature is beyond an expected value through points of an incident profile and an emergent profile of the jet, and if so, automatically determines a deviation correction angle to adjust the jet orientation to the specified tolerance by adjusting the tilt and rotation positions of a cutting head, wherein the deviation correction angle is automatically determined without compensating an actual deflection angle of the cutting head as a reference value, only belongs to a deviation compensation calculation of a mathematical model, and does not combine a deviation compensation calculation of an actual physical (the overall electrical control signal processing speed is matched with hardware and software parameters) model of a Tool Center Point (TCP), thereby generating the same problem as the aforementioned case. In summary, even though the present invention is a large plant of water jet cutting systems in various countries, there is no effective technical scheme for performing attitude angle compensation on an inclination angle by using an actual physical inclination angle, so that an applicant intends to propose a five-axis water jet cutting system capable of performing attitude angle compensation based on an actual inclination attitude angle, and the obtained attitude compensation angle parameter can be fed back to an intelligent controller, and the intelligent controller of the present invention can also be used for controlling a cutting head device of the large plant.

Disclosure of Invention

The invention aims to provide an intelligent five-axis same-motion multi-phase dynamic water jet cutting system of an intelligent controller, which can accurately compensate the position of a Tool Center Point (TCP) and the angle of an inclined posture in actual operation and can intelligently calculate and compensate water jet cutting parameters.

The intelligent five-axis same-motion multi-phase-state water jet cutting system is used for machining a workpiece; the method is characterized in that: the intelligent five-axis same-motion multi-phase water jet machining system comprises a machining unit and a monitoring unit, wherein the machining unit comprises a jet device, a sand supply source connected with the jet device, a water supply source connected with the jet device and providing high-pressure water jet, the jet device is provided with a mechanical arm, a cutting head connected with the mechanical arm and connected with the sand supply source and the water supply source and capable of being controlled to eject mixed sand jet, a plurality of motors arranged on the mechanical arm to enable the mechanical arm to drive the cutting head to move along five axial directions, and an inertia measuring module arranged on the cutting head and capable of sensing spatial position and dynamic positioning of a cutter center point of the cutting head, the monitoring unit comprises a water jet machining parameter intelligent calculation and compensation module capable of calculating a compensation value according to target machining conditions and a water jet machining parameter intelligent calculation and compensation module in signal connection, The intelligent controller of the motor and the inertia measurement module is used for intelligently calculating the target processing conditions of the compensation module according to the water jet cutting processing parameters, wherein the target processing conditions comprise the angle to be processed on the workpiece, the compensation value comprises an attitude compensation angle parameter, the intelligent controller can converge the processed angle and the attitude compensation angle parameter to obtain an ideal value, then the actual swing angle of the motor and the tilt angle measured by the inertia measurement module are compared to obtain a difference value, the difference value and the ideal value are converged to obtain a feedback attitude angle, and the intelligent controller can control the motor in real time according to the feedback attitude angle to perform angle compensation in real time.

Preferably, in the five-axis intelligent same-motion multi-phase water jet cutting system, the inertia measurement module of the processing unit includes a magnetometer, an accelerometer, and a gyroscope.

Preferably, the five-axis intelligent same-motion multi-phase water-jet cutting system further includes a plurality of encoders disposed on the motor and connected to the intelligent controller via signals, and the encoders are configured to detect an actual swing angle of the motor in real time.

Preferably, the monitoring unit further includes a positioning inspection module connected to the intelligent controller via signals and corresponding to the robot arm of the processing unit, and the positioning inspection module is configured to detect error values between a plurality of target positions and actual positions of the robot arm, and input the error values into the intelligent controller to compensate the robot arm by adjusting the motor.

Preferably, the intelligent five-axis same-motion multi-phase water jet machining system is characterized in that the positioning inspection module is provided with at least one laser interferometer for detecting backlash and pitch errors.

Preferably, in the intelligent five-axis same-motion multi-phase water jet machining system, the target machining conditions of the intelligent calculation and compensation module for the water jet machining parameters of the monitoring unit further include abrasive parameters and cutting head parameters.

Preferably, the intelligent five-axis same-motion multi-phase water jet machining system comprises an abrasive grain size, an abrasive shape and an abrasive density.

Preferably, the intelligent five-axis same-motion multi-phase water jet cutting system comprises a cutting head, a sand mulling pipe and a sand mulling pipe.

Preferably, in the foregoing intelligent five-axis same-motion multi-phase water jet machining system, the intelligent controller of the monitoring unit may arrange the data into a VDW format, and output the VDW format in a manner of a unified architecture of a communication platform

Preferably, the monitoring unit further includes an early warning module in signal connection with the intelligent controller and the processing unit, and a consumable prompting module in signal connection with the intelligent controller and monitoring the cutting head to prompt consumable replacement of the cutting head.

The invention has the beneficial effects that: the inertia measurement module is directly arranged on the cutting head, so that the space tilt angle of a tool center point TCP of the cutting head can be accurately measured in real time, the intelligent calculation and compensation module for the water jet cutting parameters can calculate attitude compensation angle parameters based on the tilt angle, the attitude compensation angle parameters can be fed back to the intelligent controller, high-precision attitude angle compensation is given to the position and the attitude angle of the Tool Center Point (TCP) in a feedback manner, the 2.5D gun head mechanism characteristic of the cutting head is added, and the ejected sand mixing jet flow belongs to addition of adjustable elastic cutter length, so that the processing precision of the invention can approach to the positioning precision, and the processing grade above precision of the aerospace industry is achieved. In addition, the intelligent controller can also be applied to a common cutting head device without an inertia measurement module, and has high universality.

Drawings

FIG. 1 is a flow chart illustrating the flow of the tool path generation of U.S. Pat. No. 4, 20180364679, 1;

FIG. 2 is a configuration diagram illustrating the adaptive vector control system of U.S. Pat. No. US9597772B 2;

FIG. 3 is a configuration diagram illustrating an embodiment of an intelligent five-axis same-motion multi-phase dynamic water jet machining system of the present invention;

FIG. 4 is a side partial cross-sectional view illustrating the fluidic device in this embodiment;

FIG. 5 is a flowchart illustrating the operating logic of the present embodiment;

FIG. 6 is a flowchart illustrating the GM code creation and operation flow of the present embodiment;

FIG. 7 is a flowchart illustrating the M-code execution step of the present embodiment;

FIG. 8 is a diagram illustrating an angle compensation process of the present embodiment; and

fig. 9 is a schematic diagram for assisting in explaining the angle compensation of fig. 8.

Detailed Description

The present invention will be described in detail below with reference to the accompanying drawings and examples.

Referring to fig. 3 and 4, an embodiment of the intelligent five-axis same-motion multi-phase water jet machining system 1 according to the present invention includes a machining unit 2 and a monitoring unit 3, where the machining unit 2 includes a jet device 21, a sand supply source 22 connected to the jet device 21, and a water supply source 23 connected to the jet device 21. The jet device 21 has a robot 211 having five axial degrees of freedom in mechanical configuration as shown in fig. 4, a cutting head 212 connected to the robot 211 and connected to the sand supply source 22 and the water supply source 23, two motors 213 provided at joints (joints) of the robot 211, an Inertial Measurement Unit (IMU) 214 provided at a tip end of the cutting head 212, and a plurality of encoders 215 (not shown in fig. 4) provided on the motors 213. In this embodiment, the cutting head 212 is an AWJ (Abrasive-WaterJet) type 2.5D head, the motor 213 is a Harmonic servo motor (Harmonic Drive) with a hollow structure for the pipeline to pass through, and the mechanical arm 211 is driven by the motor 213 to move linearly in three axial directions (x, y, z axes) and rotate in two axial directions (Pitch, yaw), so that the cutting head 212 performs 2.5D machining. Of course, in practical configurations, the motor 213 is not limited to the type described above, and the mechanism of the robot 211 is not limited to the type shown in fig. 4, as long as the robot 211 is driven to perform five-axis motion and the cutting head 212 is tilted in a yaw manner. The inertial measurement module 214 has a magnetometer 216, an accelerometer 217, and a gyroscope 218 (shown only in fig. 4). The aforementioned components can calculate the rotational tilt azimuth angle of the cutting head 212 through magnetic north direction, gravity and acceleration to sense the Tool Center Point (TCP) a spatial attitude of the cutting head 212. The encoder 215 passively senses the rotation of the motor 213 to detect and feed back the actual swing angle output by the motor 213 in real time. The sand supply source 22 provides abrasives such as garnet sand, the water supply source 23 provides a high-pressure water jet, the two are mixed in a sand mixing chamber and a sand mixing pipe (not shown) of the cutting head 212 through a venturi tube principle, and finally the mixture is output in a high-pressure sand mixing jet form for cutting, and the device belongs to an adjustable elastic cutter length (A beam cutting tools of adjustable jet cutting model).

The monitoring unit 3 includes an intelligent controller 31 connected to the motor 213 and the inertia measurement module 214 by signals, a water jet machining parameter intelligent calculation compensation module (Cuttingmodel)32 connected to the intelligent controller 31 by signals, a positioning inspection module 33 connected to the intelligent controller 31 by signals and corresponding to the robot arm 211, an early warning module 34 connected to the intelligent controller 31 by signals and the machining unit 2 by signals, and a consumable prompting module 35 connected to the intelligent controller 31 by signals and monitoring the cutting head 212 by signals. The intelligent Controller 31(Controller) may be connected to a computer 41, and arrange the acquired data into a VDW format, and then output the VDW format to the computer 41, other intelligent devices 42, or the cloud database 43 in a communication platform unified architecture (OPC UA), where the VDW format may be compatible with german machine tool data, thereby improving the versatility. In this embodiment, the intelligent controller 31 is a CNC controller that can control the operation of the motor 213, and controls the on/off valve of the cutting head 212 to emit or stop the jet flow, and further monitors the row number, the machining coordinate point, the actual speed, the yaw angle, and the like through data extraction.

The water jet cutting parameter intelligent calculation compensation module 32 is embedded in the programmable software CAD/CAM/CAE at the end of the computer 41, but may also be directly disposed in the intelligent controller 31, which may pre-construct an ideal model and calculate a compensation value and an analysis value according to a target processing condition. The target processing conditions may include, among other things, angles machined on the workpiece, abrasive parameters including abrasive grain size, abrasive shape, and abrasive density, cutting head 212 parameters, fluidic device 21 conditions, material property conditions, and surface quality requirements. The cutting head 212 parameters include the gun head form (T type or Ytype), the sand mulling pipe length and the sand mulling pipe diameter. The fluidic device 21 conditions include water jet output pressure, nozzle diameter, total horsepower, and optimum efficiency, among others. The material characteristic conditions comprise the type and the thickness of the material of the workpiece. The compensation value includes an attitude compensation angle parameter, and the calculation method thereof will be described in detail later. The analysis values include the range-off, attitude angle, cutting movement rate, total processing time, current mechanical output efficiency, system equipment energy use efficiency (kWE, kWD), approximate processing cost, and the like.

The positioning inspection module 33 has a plurality of laser interferometers for detecting the mechanical arm 211, the laser interferometers are respectively used for monitoring the actual positions of each target part (for example, each joint, pivot, joint, etc.) of the mechanical arm 211 and comparing the actual positions with the target positions in the intelligent controller 31 to obtain Error values, the laser interferometers can input the Error values into the intelligent controller 31, so that the intelligent controller 31 can adjust the motor 213 to compensate the mechanical arm 211, thereby eliminating a backlash (backlash) and a Pitch Error (Pitch Error) of the mechanical arm 211 during mechanism motion, and certainly, not only the mechanical arm 211, but also if the front end of the mechanical arm 211 is connected with a gantry-type sliding table or other motion mechanisms, monitoring can be performed through other laser interferometers. The early warning module 34 can monitor the sand supply source 22 and the water supply source 23 for the on/off and sand level, and whether the oil level, oil pressure, water pressure and stroke of the jet device 21 are overloaded. The consumable prompting module 35 may monitor the total processing time, the total water spraying time, and the total sand blasting time of the cutting head 212, and display the remaining life of the cutting head 212, the sealing ring, the nozzle, and the sand mixing pipe arranged on the cutting head 212, and the failure problem point of the high-voltage host computer on a Human-Machine Interface (Human Machine Interface) of the intelligent controller 31 after calculation.

Referring to fig. 3 and 5, the operation logic of the present embodiment will be described first, and the present embodiment first makes GM codes (the way of making will be described later) as shown in fig. 5, then performs a path idle running simulation on the computer 41, which belongs to a mathematical mode confirmation, if the simulated machining path is correct, simulates the operation of the water jet with a human-machine interface (HMI), which belongs to a physical mode confirmation, if the operation path is also correct, samples are made with pure water without adding sand for comparison, if the operation path is correct, the ultra-high pressure (UHP) water jet is finally turned on for machining, if the simulation of the tool idle path or the path of the operation of the water jet simulated with the human-machine interface is wrong, the GM codes are regenerated and simulated again according to the flow, and if the result of the water jet sampling test is wrong, the NC codes are modified according to the attitude compensation angle of the machining parameters (the modification way will be described later).

Referring to fig. 3, 6 and 7, the process of making and operating the GM code will be described, in which the design concept of the product is first configured and formed by CAD software (such as Solidwork or AutoCAD), then the file generated by CAD is analyzed by CAM software (such as Mastercam) and converted into a tool path file, the tool path file is converted into an NC file (i.e., GM code) by a post-processor, the intelligent controller 31 is converted into an automatic mode, then the processing and cutting parameters of the parameter intelligent calculation and compensation module 32 are loaded, the NC file is started to execute (confirming the material model and the geometric size), then the above-mentioned path idle running simulation, HMI water jet simulation operation and pure water sampling are performed, and the operation is started after confirming the simulated processing path. The M code for controlling the switching of water sand and low voltage is shown in FIG. 7. After the generated G code and M code are inputted into the intelligent controller 31, the Decoder (Decoder) of the intelligent controller 31 converts the GM code into a Data structure (this step is abbreviated as DEC), then the Coordinate Data Preprocessor (CDP) of the intelligent controller 31 converts the mechanical command into the coordinates of the tool and the workpiece (coordinate axis includes X, Y, Z, U, V, W), and the Interpolator (Interpolator) of the intelligent controller 31 performs real-time interpolation on the coordinates to obtain x (t), y (t), z (t), u (t), v (t), w (t), and the like, and then compensates the Data by (1) the error value obtained by the positioning check module 33, (2) the angle compensation (described in the following description of the angle compensation process) obtained by the components such as the inertia measurement module 214, and the like, (3) the output force path, obtaining compensation values Δ X, Δ Y, Δ Z, Δ U, Δ V, and Δ W, performing PID control (PID control) and Feed Forward control (Feed Forward control) with a Position Control Loop (PCL) of the intelligent controller 31, and using the PID control and the Feed Forward control as references for the intelligent controller 31 to correct NC codes, so as to control the motor 213 to adjust the Position of a Tool Center Point (TCP) a of the cutting head 212, thereby achieving the effect of online real-time NC code modification.

Referring to fig. 3, 8 and 9, the flow of the present embodiment for performing the angle compensation is described, first, the intelligent calculation and compensation module 32 outputs an attitude compensation angle parameter 52 (0.01 ° in the present embodiment) according to a target processing condition input by a user, that is, an angle 51 to be processed on a workpiece (6 ° in the present embodiment), and then the intelligent controller 31 converges the processed angle 51 and the attitude compensation angle parameter 52 to obtain an ideal value 53(6 ° +0.01 ° -6.01 °), on the other hand, the encoder 215 measures an actual swing angle 54 (6 ° in the present embodiment) of the motor 213 in real time, the angle 54 being obtained by converting the rotation amount output by the motor 213, but being affected by the positioning accuracy of the mechanism, the material characteristics of the workpiece, and other motion conditions, the tilt angle of the cutting head 212 is not equal to the actual swing angle 54, so that the actual swing angle 54 and the tilt angle 55 are subtracted from the tilt angle 55 (6.05 ° in this example) measured by the inertia measurement module 214 to obtain a difference 56(6.05 ° -6 ° -0.05 °), the ideal value 53 and the difference 56 are converged to obtain a feedback attitude angle 57(6.01 ° +0.05 ° -6.06 °), the intelligent controller 31 controls the motor 213 to perform angle compensation 58 according to the feedback attitude angle 57 (in this example, the motor 213 is controlled to correct 6.06 ° -6 ° -0.06 °), that is, the attitude feedback angle 57 is fed back to the intelligent controller 31 as a reference for correcting NC codes to perform on-line programming codes in real time, moreover, the communication port protocol TCP/IT is applicable to the global IT specification, and more applicable to a general cutting head, and a controller against the background technology cannot be applied to the cutting head 212 in the present application, which is sufficient for the present application to have higher universality. The posture angle compensation with high precision is carried out on the feedback of the position A and the posture angle of the Tool Center Point (TCP) in the mode.

Referring back to fig. 3 and 4, the intelligent five-axis same-motion multi-phase water jet machining system 1 of the present invention has the following advantages:

(1) the invention can accurately measure the actual physical tilt angle of the cutting head 212 in real time by matching the parameter processing module, the intelligent controller 31 and the inertia measuring module 214, can feedback compensate (less than or equal to 0.04 ℃) the attitude angle with high precision for the feedback of the position A and the attitude angle of the Tool Center Point (TCP), and can lead the processing precision of the invention to approach the positioning precision by adding the adjustable elastic tool length of the cutting head 212 and the mechanical characteristics of the 2.5D gun head, lead the cutting precision to reach within +/-0.1 mm, lead the inclination error to be less than 0.025mm, reach above the precision processing grade of the aerospace industry (less than +/-0.2 mm), and lead the cutting precision of the water jet to reach the standard of an ultra-precision CNC machine tool.

(2) The intelligent calculation and compensation module 32 for water jet machining parameters can analyze and calculate the relevant conditions of the gun head sand mixing group, including abrasive parameters and cutting head 212 parameters, so that the ratio relation between the nozzle diameter (do) and the sand mixing pipe diameter (df) of the jet device 21 condition can be controlled to be 2-4 optimal according to the abrasive parameters, and the machining precision is improved, in addition, the intelligent calculation and compensation module 32 for water jet machining parameters can analyze the sand mixing gun head group with an inclination angle (such as the Y type and the T type), the optimal flow rate ratio (ma/mw) of sand and water can be matched according to the high-pressure water flow mw and the abrasive flow rate ma to be 15-25%, the machining parameter items are complete compared with a common water jet system, and the analysis can be carried out even if the thickness of a machining material is less than 2mm, and the intelligent calculation and compensation module is more suitable for machining and use of composite materials such as CFRP.

(3) The data output of the intelligent controller 31 adopts an international communication OPC UA protocol, the data format is a VDW format compatible with a germany tool machine, the adaptability and the universality are high, data output such as an alarm, a machining coordinate position, a program name, the number of finished workpieces and the like can be realized, the output data can be transmitted to a database of a computer and also uploaded to a Network Attached Storage (NAS), a cloud database or an intelligent device through the internet of things (IoT), so that a manager can remotely master the machining situation of a plurality of intelligent five-axis same-motion multi-phase dynamic water knife machining systems 1 in real time, the data can be further summarized or machine-learned (for example, a VMX platform is used for collecting machining parameters and histories) so as to be used as the material characteristics of a machining algorithm development, a process improvement, a parameter adjustment and even a newly added material library, and according to the large direction of a machining production line, the method can also be used for drawing up operation strategies such as resource planning (ERP), material demand planning (MRP), production scheduling, quality management and the like, so that the production line is automated, intelligent and optimized.

(4) The back clearance and pitch error of the mechanical arm 211 can be eliminated through the laser interferometer of the positioning inspection module 33, so that the intelligent controller 31 compensates the mechanism motion to the correct target position, the volume compensation and the contour compensation are completed, the positioning precision is improved, and meanwhile, the type of the motion control shaft card is not limited, and the motion control shaft card has greater selection flexibility.

In summary, the intelligent calculation and compensation module 32 for water jet cutting parameters adds the attitude compensation angle parameter based on the inertia measurement module 214, combines with the deviation feedback compensation calculation of the actual physical model of the Tool Center Point (TCP) a, and can feed back the feedback attitude angle to the intelligent controller 31 as the reference for correcting the NC code, which belongs to a new technology for processing the NC code by online real-time programming, and can effectively improve the processing accuracy, and the processing accuracy can approach the positioning accuracy by matching with the adjustable elastic tool length of the cutting head 212 and the characteristics of the 2.5D gun head mechanism, so as to achieve the processing grade of the aerospace industry and the standard of the machine tool, and thus the purpose of the invention can be achieved.