CN115647611A - Laser cutting power-off continuous processing control method and system - Google Patents
Laser cutting power-off continuous processing control method and system Download PDFInfo
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Abstract
The invention discloses a method and a system for controlling laser cutting power-off continuous processing, belonging to the technical field of numerical control systems, wherein the method comprises the steps of starting laser processing on a laser cutting machine, and recording first processing time of a product in a processing process by a memory until the laser cutting machine stops working; judging whether the product is a product to be processed; performing power-off continuous processing on the product to be processed based on the product to be processed as the product to be processed to obtain the delay time of a power supply controller on the laser cutting machine, and obtaining second processing time based on the first processing time of the product to be processed and the delay time of the power supply controller; starting the simulation of the processing process of the product before power failure from the initial position of the product to be processed by the laser cutting machine until the simulation time is equal to the second processing time, restarting a laser on the laser cutting machine, and continuing processing; and comparing the product to be processed after the power-off continuous processing is finished with the standard product, and repairing the power-off continuous processing point of the product to be processed.
Description
Technical Field
The invention relates to the technical field of numerical control systems, in particular to a laser cutting power-off continuous processing control method and a laser cutting power-off continuous processing control system.
Background
The numerical control system adopts a digital control technology to control a machine tool in real time, is widely applied to the processing fields of milling machines, grinding machines, laser cutting/carving and the like, and is one of the core technologies of the manufacturing industry. The numerical control system may stop the machine tool due to non-human factors (such as power failure, machine tool failure, system error report, etc.) or human factors (such as an operator wants to move a machine tool spindle during the machining process, etc.) during the machining process, thereby causing the generation of machining breakpoints. When the machine tool is restarted after the breakpoint is generated, the machine tool can be machined according to the original program, so that the machining period is prolonged, and the machining quality of the product is poor. Especially in the laser cutting/carving industry, the secondary processing of the sheet metal leads to the severe damage of the precision of the sheet metal part, so that the sheet metal part is directly scrapped due to the generation of breakpoints.
The breakpoint continuous cutting technology is that a machine tool restarts cutting/carving from the position of a breakpoint, and can well overcome a series of problems caused by the occurrence of a processing breakpoint of a numerical control system. The existing breakpoint continuous cutting technology is generally that in hardware design, a power failure detection circuit is designed, when a power supply of a power grid falls to a threshold value, a non-shielded interrupt of a controller CPU is triggered, a highest priority interrupt is generated, various variables and various information of a processing site are recorded, then when the computer is started next time, the processing site which is powered off last time is recovered, and then continuous processing is performed.
When the power grid is cut off, the laser is closed instantly, and the switch power supply for supplying power to the controller is delayed to be closed for hundreds of milliseconds or even seconds due to the fact that energy storage components such as capacitors are arranged, so that the record of the power-off site is greatly delayed. Generally, how much stroke is reversed when the power failure is recovered can be set to determine the continuous processing, but due to the power failure instant, the processing speed is changed, which causes the reversed stroke to be inconsistent in each continuous processing and makes it difficult to accurately butt joint the processing patterns.
Therefore, it is an urgent technical problem to be solved by those skilled in the art to provide a control method for interrupted continuous processing so that the processing patterns can be precisely butted during each continuous processing.
Disclosure of Invention
Therefore, the invention provides a laser cutting power-off continuous processing control method and system, which aim to solve the problem that accurate butt joint of processing graphs is difficult due to inconsistency of each continuous processing in the prior art.
In order to achieve the above purpose, the invention provides the following technical scheme:
according to a first aspect of the present invention, there is provided a laser cutting power-off continuous processing control method, comprising the steps of:
s1: starting laser processing on a laser cutting machine, and recording first processing time of a product in a processing process by a memory until the laser cutting machine stops working;
s2: judging whether the product is a product to be processed or not;
s3: performing power-off continuous processing on the product to be processed based on the product to be processed, acquiring the delay time of a power supply controller on a laser cutting machine, and acquiring second processing time based on the first processing time of the product to be processed and the delay time of the power supply controller;
s4: starting the simulation of the processing process of the product before power failure from the initial position of the product to be processed by the laser cutting machine until the simulation time is equal to the second processing time, restarting a laser on the laser cutting machine, and continuously processing the product to be processed at the power failure position;
s5: and comparing the product to be processed after the power-off continuous processing is finished with a standard product, and repairing the power-off continuous processing point of the product to be processed.
Further, the step S2 specifically includes the following steps:
s201, shooting the processed product in real time by a camera to obtain an image of the product;
s202, establishing a first plane coordinate system by taking the center of the product image as an original point, wherein the edges of the product image respectively fall into four quadrants of the first plane coordinate system;
s203, acquiring an image of a standard product, and establishing a second plane coordinate system by taking the center of the image of the standard product as an original point, wherein the edges of the image of the standard product respectively fall into four quadrants of the second plane coordinate system;
and S204, coinciding the first plane coordinate system with the second plane coordinate system, wherein if the edge of the product image coincides with the edge of the standard product image, the product is processed completely, otherwise, the product is not processed completely, and the product is a product to be processed.
Further, the step S5 specifically includes the following steps:
s501: acquiring edge point coordinates near the power-off continuous processing of the product to be processed based on the first plane coordinate system in the step S2;
s502: acquiring edge point coordinates corresponding to the standard product based on the second plane coordinate system in the step S2;
s503: obtaining a machining precision deviation value of the product to be machined based on a machining precision algorithm, wherein the machining precision algorithm is as follows:
wherein psi is the processing precision offset value x i0 Is the X-axis coordinate value, y, of the ith edge point position of the standard product i0 Is the Y-axis coordinate value, x, of the ith edge point position of the standard product i The coordinate value of the X axis at the ith edge point position of the product to be processed, y i A Y-axis coordinate value at the ith edge point position of the product to be processed, n is the number of the edge points, and i is an integer which is more than or equal to 1 and less than or equal to n;
s504: and repairing the power-off continuous processing point of the product to be processed based on the processing precision deviation value.
Further, when the machining precision deviation value exceeds a preset threshold value, repairing a power-off continuous machining point; wherein, the repair time is calculated as follows:
wherein t is the repair time, v isThe speed of the laser cutting is controlled by the speed of the laser cutting,
to patch the trajectory function, ψ is the machining precision bias value.
Further, the step S504 of repairing the product to be processed includes forward repairing and reverse repairing, the repairing direction of the product to be processed is obtained based on a repairing edge-searching function, if the repairing edge-searching function is positive, the forward repairing is performed, otherwise, the reverse repairing is performed; wherein the repair edge finding function is as follows:
wherein x is i0 Is the X-axis coordinate value, y, of the ith edge point position of the standard product i0 Is the Y-axis coordinate value, x, of the ith edge point position of the standard product i Is the coordinate value of the X axis at the ith edge point position of the product to be processed, y i Is the Y-axis coordinate value of the ith edge point position of the product to be processed.
Further, the first processing time is a single-axis pulse time, and the single-axis pulse time is a time of an X-axis single-axis pulse or a Y-axis single-axis pulse.
Further, the memory periodically updates and records the first processing time, if the product processing is completed, the first processing time recorded by the memory is cleared, and if the product processing is not completed, the memory stores and records the first processing time.
Further, the memory is a FRAM ferroelectric memory.
Further, the update period of the memory is 5-7ms.
According to a second aspect of the present invention, there is provided a laser cutting power-off continuous processing control system for implementing any one of the above methods, including a memory, a comparison unit, an image acquisition unit, an image processing unit, a power controller and a timer, where the memory is configured to store and record the first processing time, the timer is configured to record the first processing time according to an update cycle, the image acquisition unit acquires an image of the product, the image processing unit processes the image of the product, the power controller is configured to control a power switch of a laser cutting machine, and the comparison unit is configured to compare a simulation time of simulated processing with a second processing time.
The invention has the following advantages:
the invention simplifies the hardware circuit, avoids the uncertain line of hardware power failure detection, and has consistent and reliable control algorithm; the high requirement on the control CPU is not required, for example, the CPU is not necessarily required to have a non-shielding interrupt function; the frequently recorded variables are limited, and only one unique time variable is provided, so that the operation of the system is not overloaded. The invention takes time as a reference, and the power-off delay of the switching power supply is fixed, and a backstepping delay is set, so that the graph which is powered off last time can be accurately continuously processed each time when power-off continuous processing is performed. The accurate butt joint is irrelevant to the processing speed before power failure, and for the conditions of different speeds and different processing working conditions, power failure continuous processing can carry out accurate butt joint on the graph powered down at the previous time. This application still repairs the continuous processing point of outage of product, guarantees the slick and sly of product, avoids the continuous processing back product of outage to appear rough edge.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below. It should be apparent that the drawings in the following description are merely exemplary, and that other embodiments can be derived from the drawings provided by those of ordinary skill in the art without inventive effort.
The structures, the proportions, the sizes, and the like shown in the specification are only used for matching with the contents disclosed in the specification, so that those skilled in the art can understand and read the present invention, and do not limit the conditions for implementing the present invention, so that the present invention has no technical essence, and any modifications of the structures, changes of the proportion relation, or adjustments of the sizes, should still fall within the scope of the technical contents disclosed in the present invention without affecting the efficacy and the achievable purpose of the present invention.
FIG. 1 is a flow chart of a laser cutting power-off continuous machining control method provided by the present invention;
FIG. 2 is a detailed flowchart of step S2 provided by the present invention;
fig. 3 is a specific flowchart of step S5 provided in the present invention.
Detailed Description
The present invention is described in terms of particular embodiments, other advantages and features of the invention will become apparent to those skilled in the art from the following disclosure, and it is to be understood that the described embodiments are merely exemplary of the invention and that it is not intended to limit the invention to the particular embodiments disclosed. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
According to a first aspect of the present invention, there is provided a laser cutting power-off continuous processing control method, as shown in fig. 1, including the steps of:
s1: and starting laser processing on the laser cutting machine, and recording the first processing time of the product in the processing process by the memory until the laser cutting machine stops working. The laser processing comprises processing technologies such as laser cutting, engraving and the like, and the two-dimensional interpolation motion of an XY plane is carried out on a processed product. The contour or motion track of the part processed by the numerical control system generally consists of straight lines and circular arcs, and for some non-circular curve contours, the straight lines or the circular arcs are used for approaching. The interpolation calculation is that the numerical control system describes the contour or motion track of the workpiece through calculation according to the input basic data, and sends a feeding instruction to each coordinate according to the calculation result while calculating. The two-dimensional interpolation motion enables the cutting/carving device to carry out cutting/carving operation in the X-axis direction and the Y-axis direction on the processing material.
The first processing time is a uniaxial pulse time, and the uniaxial pulse time is the time of an X-axis uniaxial pulse or a Y-axis uniaxial pulse. The time of the X-axis single-axis pulse is the product of the number of all the X-axis single-pulse recorded in the machining process and the corresponding time of the single pulse, and the time of the Y-axis single-axis pulse is the product of the number of all the Y-axis single-pulse recorded in the machining process and the corresponding time of the single pulse. The invention has only one unique time variable, thereby not generating excessive load on the operation of the system.
The memory is updated once every time the first machining time is recorded, and the memory is updated every 5ms to record the first machining time. If the last time before outage is processed, the record is still carried out once in less than 5ms, the integrity of the processing process is guaranteed, the processing process of the processed product before outage is conveniently simulated when outage continuous processing is carried out, and the butt joint time point of continuous processing is determined.
S2: judging whether the product is a product to be processed, as shown in fig. 2, specifically includes the following steps:
s201, shooting a processed product in real time by a camera to obtain an image of the product;
s202, establishing a first plane coordinate system by taking the center of the product image as an origin, wherein the edges of the product image respectively fall into four quadrants of the first plane coordinate system;
s203, acquiring an image of a standard product, establishing a second plane coordinate system by taking the center of the image of the standard product as an original point, and enabling the edges of the image of the standard product to respectively fall into four quadrants of the second plane coordinate system;
and S204, coinciding the first plane coordinate system with the second plane coordinate system, wherein if the edge of the product image coincides with the edge of the standard product image, the product is processed completely, otherwise, the product is not finished and is a product to be processed.
And establishing a first plane coordinate system and a second plane coordinate system, and comparing the processed product with the standard product by using a graph, so that whether the product is a product to be processed can be quickly obtained, and the redundancy of data in the system is reduced.
And if the product processing is finished, clearing the first processing time recorded by the memory, and if the product processing is not finished, storing the first processing time recorded by the memory. Avoiding the load on the memory of the system. When the laser processing is started next time, the first processing time recorded in the machine is inquired, the first processing time is zero, it is indicated that the processed product does not need to be powered off and processed continuously, and the first processing time is nonzero, it is indicated that the processed product needs to be powered off and processed continuously. And only zero and non-zero possibility exists in the judgment process, so that the system operation is reduced, and the system load is reduced.
S3: and performing power-off continuous processing on the product to be processed based on that the first processing time is nonzero and the product is the product to be processed, so as to obtain the delay time of a power supply controller on the laser cutting machine. And obtaining second processing time based on the first processing time of the product to be processed and the delay time of the power supply controller. Due to the fact that the power-off delay exists in the power supply switching power supply of the power supply controller, when the laser cutting machine stops supplying power, the power supply controller on the laser is delayed, the laser still conducts machining on a product, and the first machining time and the delay time of the power supply controller are added to obtain the second machining time.
The delay time of the switching power supply needs to be tested before the machine leaves a factory, and finally accurate butt joint can be achieved when power failure continues to be processed. After the test is well carried out, the power-off continuous processing can be carried out under different working conditions of different subsequent processing speeds, different tracks and the like, and the accurate butt joint can be carried out.
S4: and the laser cutting machine starts to simulate the processing process of the product before power failure from the initial position of the product to be processed until the simulation time is equal to the second processing time, restarts the laser on the laser cutting machine and continues processing from the power failure position of the product to be processed. Before the power-off continuous processing, only the processing process of the processed product before the power-off is simulated, and the XY axes and the laser are not driven to move. And when the real-time recorded by the simulation machining is equal to the second machining time recorded last time, starting the actual machining.
S5: and comparing the product to be processed after the power-off continuous processing is finished with the standard product, and repairing the power-off continuous processing point of the product to be processed. Because the laser cutting machine is restarted at the power-off continuous processing position of the product to be processed, the restarted laser cutting machine needs to continue to process backwards along the track of the power-off position, but the discontinuity of the laser cutting machine can cause the power-off processing position to have smaller deviation compared with a standard product. The deviation does not affect the completion of the product, but can cause the power failure processing points of the product to have rough edges, and the power failure processing points of the product are repaired in order to smooth the edges of the product.
Repairing a power-off continuous processing point of a product to be processed, as shown in fig. 3, specifically comprises the following steps:
s501: acquiring edge point coordinates near the power-off continuous processing of the product to be processed based on the first plane coordinate system in the step S2;
s502: acquiring edge point coordinates corresponding to the standard product based on the second plane coordinate system in the step S2;
s503: obtaining a machining precision deviation value of a product to be machined based on a machining precision algorithm, wherein the machining precision algorithm is as follows:
where psi is the machining precision offset, x i0 Is the X-axis coordinate value, y, of the ith edge point position of the standard product i0 Is the Y-axis coordinate value, x, of the ith edge point position of the standard product i Is the coordinate value of the X axis at the ith edge point position of the product to be processed, y i A Y-axis coordinate value at the ith edge point position of the product to be processed, n is the number of the edge points, and i is an integer which is more than or equal to 1 and less than or equal to n;
s504: and repairing the power-off continuous processing point of the product to be processed based on the processing precision deviation value.
When the machining precision deviation value exceeds a preset threshold value, repairing the power-off continuous machining point; wherein, the repair time is calculated as follows:
wherein t is the repair time, v is the laser cutting speed,
to patch the trajectory function, ψ is the machining precision bias value.
Step S504, repairing the product to be processed comprises forward repairing and reverse repairing, the repairing direction of the product to be processed is obtained based on the repairing edge searching function, if the repairing edge searching function is positive, the forward repairing is carried out, otherwise, the reverse repairing is carried out; wherein, the repairing edge-finding function is as follows:
wherein x is i0 Is the X-axis coordinate value, y, of the ith edge point position of the standard product i0 Is the Y-axis coordinate value, x, of the ith edge point position of the standard product i Is the coordinate value of the X axis at the ith edge point position of the product to be processed, y i And the Y-axis coordinate value of the ith edge point position of the product to be processed is obtained.
The restarted laser cutting machine needs to continue to perform backward machining along the track of the power cut, and the backward machining deviation of the power cut machining point is likely to be outward or inward deviation. If the backward processing deviation of the power failure processing point is outward deviation, forward repairing is needed during repairing, and repairing is carried out towards the back of the power failure processing point; if the deviation of the power-off processing point towards the back processing is inward deviation, reverse repairing is needed during repairing, and repairing is carried out towards the front of the power-off processing point, so that the power-off continuous processing position of the product becomes smooth.
According to a second aspect of the present invention, a laser cutting power-off continuous processing control system is provided, which is used for implementing a laser cutting power-off continuous processing control method, and includes a memory, a comparison unit, an image acquisition unit, an image processing unit, a power controller and a timer, wherein the memory is used for storing and recording a first processing time, the timer is used for recording the first processing time according to an update cycle, the image acquisition unit is used for acquiring an image of a product, the image processing unit is used for processing the image of the product, the power controller is used for controlling a power switch of a laser cutting machine, and the comparison unit is used for comparing an analog time of simulated processing with a second processing time.
The memory is an FRAM ferroelectric memory, and variables in the memory can still be reserved when the memory is powered down, so that the loss of records due to power failure is avoided.
The invention simplifies the hardware circuit, avoids the uncertain line of hardware power failure detection, and has consistent and reliable control algorithm; the high requirement on the control CPU is not required, for example, the CPU is not necessarily required to have a non-shielding interrupt function; the frequently recorded variable is limited, and only one unique time variable is provided, so that the operation of the system is not overloaded. The invention takes time as a reference, and the power-off delay of the switching power supply is fixed, and a reverse delay is set, so that the graph which is powered off last time can be accurately processed continuously when power-off continuous processing is carried out each time. This accurate butt joint is irrelevant with the machining speed before the outage, and to the condition under different speed, different processing operating mode, outage continuation processing can both carry out accurate butt joint to the figure of losing power last time. This application still repairs the continuous processing point of outage of product, guarantees the slick and sly of product, avoids the continuous processing back product of outage to appear rough edge.
The invention is mainly applied to a laser cutting/carving control system, if the power grid is suddenly powered off, the current processing is stopped, and in order to prevent the processed product from being wasted, the precise continuous processing is carried out at the last power-off position when the machine is started next time.
Although the invention has been described in detail above with reference to a general description and specific examples, it will be apparent to one skilled in the art that modifications or improvements may be made thereto based on the invention. Accordingly, such modifications and improvements are intended to be within the scope of the invention as claimed.
Claims (10)
1. A laser cutting power-off continuous processing control method is characterized by comprising the following steps:
s1: starting laser processing on a laser cutting machine, and recording first processing time of a product in a processing process by a memory until the laser cutting machine stops working;
s2: judging whether the product is a product to be processed or not;
s3: performing power-off continuous processing on the product to be processed based on the product to be processed, acquiring the delay time of a power supply controller on a laser cutting machine, and acquiring second processing time based on the first processing time of the product to be processed and the delay time of the power supply controller;
s4: starting the laser cutting machine from the initial position of the product to be processed to simulate the processing process of the product before power failure until the simulation time is equal to the second processing time, restarting a laser on the laser cutting machine, and continuously processing the product to be processed at the power failure position of the product to be processed;
s5: and comparing the product to be processed after the power-off continuous processing is finished with a standard product, and repairing the power-off continuous processing point of the product to be processed.
2. The laser cutting power-off continuous processing control method of claim 1, wherein the step S2 specifically comprises the steps of:
s201, shooting the processed product in real time by a camera to acquire an image of the product;
s202, establishing a first plane coordinate system by taking the center of the product image as an original point, wherein the edges of the product image respectively fall into four quadrants of the first plane coordinate system;
s203, acquiring an image of a standard product, and establishing a second plane coordinate system by taking the center of the image of the standard product as an origin, wherein the edges of the image of the standard product respectively fall into four quadrants of the second plane coordinate system;
and S204, coinciding the first plane coordinate system with the second plane coordinate system, if the edge of the product image coincides with the edge of the standard product image, indicating that the product is processed, otherwise, indicating that the product is not processed, wherein the product is a product to be processed.
3. The laser cutting off-machining continuation control method of claim 2, wherein the step S5 specifically includes the steps of:
s501: acquiring edge point coordinates near the power-off continuous processing of the product to be processed based on the first plane coordinate system in the step S2;
s502: acquiring edge point coordinates corresponding to the standard product based on the second plane coordinate system in the step S2;
s503: obtaining a machining precision deviation value of the product to be machined based on a machining precision algorithm, wherein the machining precision algorithm is as follows:
where psi is the machining precision offset, x i0 Is the coordinate value of the X axis at the ith edge point position of the standard product, y i0 Is the Y-axis coordinate value, x, of the ith edge point position of the standard product i Is the coordinate value of the X axis at the ith edge point position of the product to be processed, y i Is a Y-axis coordinate value at the ith edge point position of a product to be processed, n is the number of the edge points, and i is an integer which is more than or equal to 1 and less than or equal to n;
s504: and repairing the power-off continuous processing point of the product to be processed based on the processing precision deviation value.
4. The method for controlling continuous machining during laser cutting according to claim 3, wherein when the machining precision deviation exceeds a preset threshold, the point of continuous machining during laser cutting is repaired; wherein, the repair time is calculated as follows:
wherein t is the repair time, v is the laser cutting speed,
for the patch track function, ψ is the machining precision bias value.
5. The laser cutting power-off continuous processing control method of claim 3, wherein the step S504 of repairing the product to be processed comprises a forward repairing and a reverse repairing, a repairing direction of the product to be processed is obtained based on a repairing edge-seeking function, if the repairing edge-seeking function is positive, the forward repairing is performed, otherwise, the reverse repairing is performed; wherein the repair edge finding function is:
wherein x is i0 Is the coordinate value of the X axis at the ith edge point position of the standard product, y i0 Is the Y-axis coordinate value, x, of the ith edge point position of the standard product i The coordinate value of the X axis at the ith edge point position of the product to be processed, y i Is the Y-axis coordinate value of the ith edge point position of the product to be processed.
6. The method for controlling continuous processing during laser cutting according to claim 1, wherein the first processing time is a uniaxial pulse time, and the uniaxial pulse time is a time of an X-axis uniaxial pulse or a Y-axis uniaxial pulse.
7. The laser cutting power-off continuous processing control method according to claim 1, wherein the memory periodically updates and records the first processing time, clears the first processing time recorded by the memory if the processing of the product is completed, and stores the recorded first processing time if the processing of the product is not completed.
8. The laser off-cutting continuous processing control method according to claim 1, wherein the memory is a FRAM ferroelectric memory.
9. The laser cutting off-machining continuation control method according to claim 7, wherein an update cycle of the memory is 5 to 7ms.
10. A laser cutting power-off continuous processing control system for implementing the laser cutting power-off continuous processing control method according to any one of claims 1 to 9, comprising a memory, a comparison unit, an image acquisition unit, an image processing unit, a power controller and a timer, wherein the memory is used for storing and recording the first processing time, the timer is used for recording the first processing time according to an update cycle, the image acquisition unit is used for acquiring an image of the product, the image processing unit is used for processing the image of the product, the power controller is used for controlling a power switch of a laser cutting machine, and the comparison unit is used for comparing the simulation time of simulated processing with the second processing time.
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| CN116475583A (en) * | 2023-05-16 | 2023-07-25 | 深圳原子智造科技有限公司 | Continuous engraving system for power failure of laser engraving machine and control method |
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