Views: 98 Author: Site Editor Publish Time: 2022-01-04 Origin: Site
With the development of the laser industry, laser technology as a processing technology is widely used in various fields. Laser cutting technology has also been widely used in the processing industry. Among them, the bevel processing of thick steel plates is an indispensable process. In order to ensure that some workpieces are seamlessly connected during welding, the requirements for workpiece processing are relatively high, and the cutting surface needs to have a certain bevel angle.
Laser bevel cutting of new air outlets is critical to the software system
Under the demand of market applications, many laser equipment companies have launched bevel laser cutting machines. However, for end users in the application field, in order to improve processing efficiency and quality, in addition to choosing a useful bevel laser cutting machine, the supporting bevel cutting software system is also very important.
In "Entering the Software-Defined Era", Academician Mei Hong explained the fundamentals of software technology as follows: "From the perspective of enabling technology, software technology is always in the'soul' position in information technology. New information technology applications, platforms and service models are inseparable from software technology as a basic support; more importantly, in the era of digital economy, software technology has become the core competitiveness of enterprises, not only leading the transformation of the information technology industry, In many traditional fields (such as automobiles, energy, manufacturing, retail, etc.), the proportion and importance of existence are also increasing. It plays a key role in supporting the upgrading of industrial structure in these traditional fields and even subversive innovation. And further accelerate the reconstruction of the global division of labor system and competitive landscape."
1. The high-power laser cutting control system still needs domestic replacement
In the whole set of laser cutting equipment, the motion control system can be described as the brain when the equipment is working. Motion control systems generally consist of controllers, power amplifiers and converters, motors, loads and related sensors. After the controller issues an instruction, the driver converts it into the current that can run the motor, drives the motor to rotate, and drives the working machinery to run. At the same time, the sensor on the motor feedbacks the real-time information of the motor to the controller through signal processing, and the controller makes real-time adjustments. , So as to ensure the stable operation of the entire system.
From the perspective of the degree of localization of laser cutting systems, in the field of low- and medium-power laser cutting control systems, the current domestic laser motion control systems have occupied a leading position in the Chinese market. In the field of high-power laser cutting control systems, international manufacturers still have an absolute advantage. Well-known companies include Beckhoff, Germany, and Siemens.
Take the three-dimensional five-axis laser cutting machine as an example, which is mainly suitable for carbon steel, stainless steel, titanium alloy, aluminum alloy and other materials in the fields of aerospace, automobile manufacturing, engineering machinery, molds, and fitness equipment. However, there are still some difficulties in the supporting software system of the three-dimensional five-axis laser cutting machine.
1) Domestic supporting software system is in the accumulation stage
At present, a few domestic laser equipment manufacturers have launched a three-dimensional five-axis laser cutting machine. And to complement it, in terms of three-dimensional five-axis spatial trajectory motion control, domestic mainstream laser cutting control system suppliers have almost started from scratch in this field, requiring technical capabilities and experience accumulation.
2) The high cost of foreign purchase of nesting software
On the other hand, nesting software is a type of CAM software (computer-aided manufacturing) that is used to create nests and prepare parts for cutting. First, the part geometry is usually imported from CAD. Secondly, apply various cutting parameters and prepare files for processing. Finally, the user creates the nest manually, or the software automatically creates the nest. Automatic nesting uses one or more mathematical algorithms to automatically add graphics to the nesting, while rotating and assembling parts to achieve optimal utilization. In many cases, the software will consider different combinations of parts, plates, and nesting strategies to achieve the best overall effect. However, the cost of purchasing groove nesting software software is too high, and domestic companies are still immature in this aspect, and software functions are lacking.
3) Equipment manufacturers lack experience in bevel cutting
In addition, due to the lack of experience of equipment manufacturers in bevel cutting, market capacity has not yet been released. At the same time, the structure of the swing head must be precisely matched with the control system software to facilitate installation and debugging, and achieve the final use effect, and achieve the cutting speed and accuracy requirements. Therefore, if the equipment manufacturer designs and manufactures the bevel head by itself, there is both a risk of failure and cost pressure.
4) The laser groove cutting process still needs precipitation
In the new market application field of laser bevel cutting, laser equipment manufacturers and terminals still have insufficient experience. As a market direction, laser bevel cutting requires time accumulation and experience precipitation, and the future demand will surge. At this time, a powerful and open control software process database is needed so that users can gradually form a mature expert process database on this basis.
2. How to choose the bevel laser cutting software system
The following will introduce WisCut B groove laser cutting control software system as an example. Wisdom has independently developed professional bevel nesting software, which has the basic functions of bevel cutting and nesting, which can meet most of the production needs, and can provide an overall solution for the software and hardware of the bevel swing head structure.
The WisCut B bevel laser cutting control system and software is a high-end laser cutting software independently developed by Wuhan Wisdom based on the German Beckhoff three-dimensional five-axis CNC system. The entire control system and software are composed of the core "3" + "3" = "6" core software and hardware. It is a world-renowned large-brand CNC system and the most mature and widely installed bevel laser cutting system on the market. Control System.
"3" big core hardware
Beckhoff three-dimensional five-axis CNC system
As mentioned earlier, domestic companies are still in the stage of accumulating experience on the three-dimensional five-axis CNC system. Beckhoff Germany is a world-renowned big brand, as well as the invention and advocate of the EtherCAT bus. The WisCut software is based on a hardware platform with the best stability and reliability. The core hardware consists of a Beckhoff industrial PC controller and a bus IO module. The C6xxx series of ultra-compact industrial PCs use the industrial PC motherboard independently developed and produced by Beckhoff, and use a sturdy aluminum casing, which combines powerful computing power and expandability into a stable and reliable industrial PC; the Beckhoff EtherCAT terminal module is robust The shell, safe and reliable contacts and stable electronic components, EtherCAT high-speed real-time bus communication, arbitrary expansion of IO points and signal types, flexible and convenient.
The Beckhoff 3-D 5-axis CNC system based on PC and EtherCAT bus has the world's most mature RTCP 3-D 5-axis spatial motion control algorithm. The bevel laser cutting must be based on the RTCP function to realize the spatial motion control function of the cutting head. The RTCP function of Beckhoff CNC system has more than 20 years of mature application experience, and it is widely used in laser bevel cutting, plasma/flame bevel cutting, three-dimensional five-axis laser cutting, five-axis CNC machining center and other fields.
Bus height controller
Bus control system refers to a professional control system that integrates motion controllers, computers, and height controllers, connects peripherals with network cables and communicates with other peripherals through real-time Ethernet protocols, and has higher real-time performance and stability. The WSD-M-TG-Epro bus-based capacitance follow-up height adjustment system is independently developed, designed and manufactured by Wuhan Wisdom Company, with a maximum acceleration of 3G and a maximum speed of 999mm/s. It adopts high-performance real-time industrial Ethernet EtherCAT bus and The controller communicates with an accuracy of up to 0.001mm. It has the following functions:
With anti-collision function, it can effectively avoid plate lift and foreign body collision with nozzle/ceramic ring during idle running and cutting; with WisCut software, it has three-point edge finding function, and has edge finding protection function; vibration suppression function , It can effectively suppress the vibration phenomenon due to the plate jitter and the cutting head following process; when used with WisCut, it can achieve leapfrog, high-speed follow-up, high, middle and low perforation, as well as multi-stage perforation, progressive perforation, extreme speed perforation, non-inductive perforation, etc. Perforation pattern.
Groove swing head structure
The groove head structure independently developed and designed by Wuhan Wisdom is deeply integrated with the German Beckhoff CNC system and combined with WisCut B series software to become a complete overall solution. The structure has these technical characteristics: flexible and changeable, strong expandability, can be connected with different types and configurations of laser cutting heads; adopts integrated design of AC servo harmonic reducer, AB axis rotary swing actuator; lightweight and stable Structural design; high dynamic characteristics, high precision, high rigidity; reliable dust-proof design; absolute encoder feedback, safe angle protection function.
The technical parameters are shown in the figure below:
"3" Big Core Software
WisCNC laser motion control software
Wuhan Wisdom Company developed laser motion control and logic control software based on the German Beckhoff TwinCAT CNC real-time bottom core platform. Technical highlights include: three-dimensional five-axis G-code architecture program, RTCP tool tip calibration algorithm, high-speed gantry dual-drive motion control protection program, CNC Z-axis high-speed motion control algorithm, high-speed CNC intelligent leaping algorithm, lightning cutting/flying cutting algorithm, fast Perforation/non-inductive perforation algorithm, breakpoint/resumed cutting function algorithm.
WisCut B bevel laser cutting software
Wisdom adopts the high-power special laser cutting software developed by the Python high-level language, which has perfect functions, excellent performance, convenient operation and simple use. The software consists of the following functional modules:
WisHMI: Humanized UI man-machine interface
WisDebug: Integrated integrated debugging software
WisCDB: Cutting Process Expert Database
WisVision: Laser cutting machine vision software and other functional module software components support multi-camera visual monitoring, support cutting software and monitoring software to run on the same display (standard), with machine vision to perceive people and objects entering the monitoring area and trigger an alarm function (optional) ).
WisNest B groove editing software
Online editing of bevel cutting trajectory, multiple bevel types and different bevel angles and thicknesses can be set to meet customer's proofing and rapid processing needs; WisNest plane nesting software is included, and plane cutting and bevel cutting modes can be changed at will; AutoCAD operating custom drawing software, provides a wealth of graphic editing tools, you can directly draw on the software interface or import DXF graphics for editing, and cut directly without converting the graphics G code again; provide a diversified graphics parts library, import the map File, convenient and quick for proofing cutting and process testing. Concise, easy-to-use, typesetting nesting software that conforms to operating habits in the laser cutting field, intelligent and efficient typesetting algorithms, multiple trajectory optimization algorithms, and advanced functions such as micro-connection, bridging, coedge, ring cutting, and compensation.
In addition, the accessories include a wireless handheld operating box specially designed and developed for laser cutting, with multiple operation function keys, which can conveniently and quickly operate and debug the laser cutting machine. A complete set of EtherCAT real-time industrial Ethernet bus cables, DP/DVI/VGA and other display conversion connectors.
Special-shaped curve and 45 degree bevel cutting
Considering the space trajectory and motion control, the standard straight line and circular arc bevel cutting is relatively simple, but for the bevel cutting of the special-shaped curve, it will more test the three-dimensional and five-axis RTCP underlying algorithm function of the CNC system.
The bevel cutting at a large angle of 45 degrees has always been a difficult point for the entire industry. Because the greater the angle, the higher the requirements for the stability of the machine tool structure and the perpendicularity between the XYZ three axes, and the rigidity and rotation accuracy of the AB-axis swing head mechanism. Even so, it still needs a powerful underlying algorithm, complete upper cutting software function, flexible and convenient cutting software for bevel cutting process database, and continuous optimization of mechanical structure and cutting process, in order to do a 45-degree bevel cutting.
The following are part of the special-shaped curve and 45-degree bevel cutting parts produced by the machine using WisCut B laser bevel cutting software at the user's site.
The control system is equivalent to our human brain. All external commands are processed and issued through it after entering the control system. In the bevel cutting, a large number of states need to be processed and adjusted by the control system. At the same time, it also needs to calculate various set data relationships. It also needs to be able to handle various cutting processes and various changing factors in the cutting motion. Based on this consideration, Wisdom adopted German Beckhoff, one of the most mature three-dimensional five-axis CNC systems in the world
The Twin CAT CNC bottom-level control system has the RTCP three-dimensional five-axis function that has been used maturely for 20 years. On this basis, the bevel laser cutting control system is integrated. Among the six key core technologies of the overall solution, it has been implemented. Five breakthroughs in localization only retain the most core underlying CNC system. Wisdom continues to break through bottlenecks in key core technologies and cutting software, and has achieved most of the localization while also possessing superior stability and advancement.