CN102166723A - Torque overload monitoring device - Google Patents
Torque overload monitoring device Download PDFInfo
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- CN102166723A CN102166723A CN 201110077351 CN201110077351A CN102166723A CN 102166723 A CN102166723 A CN 102166723A CN 201110077351 CN201110077351 CN 201110077351 CN 201110077351 A CN201110077351 A CN 201110077351A CN 102166723 A CN102166723 A CN 102166723A
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Abstract
The invention discloses a torque overload monitoring device. An instrument input connecting terminal, a three-phase alternating current (AC) current sampling circuit and a three-phase operation amplifier circuit are connected in series in turn; the three-phase operation amplifier circuit, a load analog quantity comparator, a load switch circuit, a load detection output circuit and an instrument output connecting terminal are connected in series in turn; the three-phase operation amplifier circuit, an overload analog quantity comparator, an overload switch circuit, an overload detection output circuit and the instrument output connecting terminal are connected in series in turn; the three-phase operation amplifier circuit, a monitor self-checking and motor running state monitoring circuit, a monitoring output circuit and the instrument output connecting terminal are connected in series in turn; and the instrument input connecting terminal is connected with a three-phase AC power supply and a three-phase motor respectively. Compared with the prior art, the torque overload monitoring device has dual monitoring functions.
Description
Technical field
The present invention relates to the numerical control of machine tools field, exactly be meant a kind of torque overload supervising device.
Background technology
Tool wear is a kind of ubiquitous phenomenon in machining, the wearing and tearing of cutter and state of wear directly affect precision, efficient and the economic benefit of machining, the research tool wear can improve machining efficient greatly, cuts down finished cost, and has bigger economic benefit.The on-line monitoring of tool wear is a crucial problem of flexible manufacturing system research engineering.
In recent years, extensive use along with high-performance CNC (Computerized digital control system) lathe, FMS (flexible manufacturing system) and CIMS (Modern Integrated Manufacturing System), efficient, the crudy of machining are significantly improved, simultaneously full-automation is produced and also have higher requirement, operate man-machine ratio and develop into the situation that present operating personnel control multiple devices one to one by original.Like this, can numerically-controlled machine tool system monitor cutting tool state automatically, the abrasion condition of cutter is being used in understanding in time, and then the cutter duty is monitored according to cutter faults such as cutter life, wear extent, cutter break, and when tool wear reaches the setting wear extent, report to the police, just seem extremely important.
Industrial statistics shows that tool failure is the primary factor that causes machine failure, accounts for 1/5～1/3 of Digit Control Machine Tool total down-time the downtime that causes thus.In the machining, if tool wear can not in time find, will cause the interruption of whole process, cause that workpiece scraps, even the stopping of whole system.Studies show that Digit Control Machine Tool can reduce by 75% downtime after being equipped with tool monitoring system, boosts productivity 10%～60%, improve machine tool utilization rate more than 50%.Be equipped with the digital control system of tool monitoring system, can save processing charges and reach 30%.Therefore research and develop the intellectual monitoring technology, prevent because of the workpiece that tool failure causes is scrapped, device damage and guarantee that lathe failure-free operation is very important.
Realize the theoretical of tool wear on-line monitoring and test more.(be installed in strain gauge on the transmission path of cutting force on the lathe as the cutting force monitoring method, the collection force signal), (cutter can send sound wave to the acoustic emission monitor(ing) method during cutting, during tool failure, the sound wave that sends has big variation, be installed on the lathe with acoustic receiver spare, acoustic signals when receiving cutting), current monitoring method (collect the three phase electric machine operating current signal of cutter, be current sampling, the size variation of this electric current is directly proportional by the size variation of torsion with cutter).Owing to reasons such as reliability, antijamming capability, ease for use, cost performances, at present domesticly introduce to the market with going back the real ripe product lot quantity of neither one.And this torque overload supervising device proves that practicality is reliable after user's long-time continuous is used, and now produces in batches.
The present domestic product that special applied current monitoring method realizes tool wear is carried out on-line monitoring of not producing, present the motor driver product such as the frequency converter of popularization and application, AC servo driver etc., (product itself provides the user series of parameters generally only to possess the available parameter setting, each parameter has specific purposes, the user can be by the display and the key-to-disk of product, find the parameter that needs and change parameter value, reach the different functions of use that product provides) over torque monitoring output and output torque limit function, but the special function of these products is drive motors, and its torque monitoring and restriction mainly are to be used to protect motor and driver itself; When overload situations occurs generally speaking, mean that the object of controlling has surpassed the rated value of its permission, cisco unity malfunction.And during actual the use, be to consider from the angle of process for machining and manufacturing mostly, protection tool using (as drill bit, cutter or emery wheel etc.) and use equipment.In this case, often can not exceed damage or the wearing and tearing that the control appliance rated values thereof just may cause tool using.So these are applied in tool wear on-line monitoring aspect forced a bit, and use very inconvenient.
Some application scenario technical staff simply transforms by temp controlled meter, ammeter, adjusts or sets according to the empirical value of practical application, improves its control effect with this.Because it can not provide corresponding feedback signal, just pass through hard connection and cut off power supply or termination device work, or come assist process by observation or field monitor by operating personnel.It is poor to use its real-time like this, and sensitivity is low, and automation efficient is not high, can not play effective monitoring and intervention effect.
Summary of the invention
At above-mentioned defective; the technical problem that the present invention solves is to provide a kind of torque overload supervising device; have dual monitoring and protection, i.e. load monitoring and overload monitoring function, cutter is in overload monitoring; because of some uncertain or unpredictable reason causes breaking; digital control system still can monitor breaking by the function of overload monitoring and load monitoring, takes then to shut down and handles; shorten the dry running time, raise the efficiency.
In order to solve above technical problem, torque overload supervising device provided by the invention, comprise that instrument input wires terminal, three-phase alternating current sample circuit, three-phase operational amplification circuit, load simulation amount comparator, overload analog quantity comparator, load switching circuit, overload cut-out circuit, load detection output circuit, overload detection output circuit, the 3rd analog to digital conversion circuit, motor torque show decoding, motor torque status displays, watch-dog self check and motor operating state observation circuit, monitoring output circuit and instrument output wiring terminal, wherein:
Described instrument input wires terminal, three-phase alternating current sample circuit, three-phase operational amplification circuit are connected in series successively;
Described three-phase operational amplification circuit, load simulation amount comparator, load switching circuit, load detection output circuit and described instrument output wiring terminal are connected in series successively;
Described three-phase operational amplification circuit, overload analog quantity comparator, overload cut-out circuit, overload detection output circuit and described instrument output wiring terminal are connected in series successively;
Described three-phase operational amplification circuit, watch-dog self check and motor operating state observation circuit, monitoring output circuit and described instrument output wiring terminal are connected in series successively;
Described instrument input wires terminal is connected with three phase electric machine with three-phase alternating-current supply respectively;
Described three-phase operational amplification circuit, the 3rd analog to digital conversion circuit, motor torque show that decoding and motor torque status displays are connected in series successively.
Preferably, described torque overload supervising device also comprises load D/A converting circuit and load set digital switch, and described load simulation amount comparator, load D/A converting circuit, load set digital switch are connected in series successively.
Preferably, described torque overload supervising device also comprises overload D/A converting circuit and overload setting digital switch, and described overload analog quantity comparator, overload D/A converting circuit, overload are set digital switch and be connected in series successively.
Torque overload supervising device provided by the invention, instrument input wires terminal, three-phase alternating current sample circuit, three-phase operational amplification circuit are connected in series successively; Three-phase operational amplification circuit, load simulation amount comparator, load switching circuit, load detection output circuit and instrument output wiring terminal are connected in series successively; Three-phase operational amplification circuit, overload analog quantity comparator, overload cut-out circuit, overload detection output circuit and instrument output wiring terminal are connected in series successively; Three-phase operational amplification circuit, watch-dog self check and motor operating state observation circuit, monitoring output circuit and instrument output wiring terminal are connected in series successively; Instrument input wires terminal is connected with three phase electric machine with three-phase alternating-current supply respectively.Compared with prior art, torque overload supervising device provided by the invention, can set in advance 2 monitoring values: be defined as load monitoring value and overload monitoring value respectively, if the monitored object moment of torsion exceeds the monitoring value of setting, control device is exported corresponding feedback signal immediately.Controller (as numerical control system, master controller etc.) signal whereby (for example: instant withdrawing is protected monitored object; feed velocity slows down; prompting user excessive tool wear must be changed cutter etc.); after setting the monitoring value; the user of service does not worry taking place as drill bit excessive wear or the breaking of rod and ignorant situation; can prevent the fracture of drill bit, saw blade, cutter, emery wheel and hurt sb.'s feelings; more can effectively avoid monitored object to be damaged, reduce that dry running time workpiece is done over again and the generation of waster rate.
In addition, torque overload supervising device provided by the invention comprises that also the 3rd analog to digital conversion circuit, motor torque show decoding and motor torque status displays, three-phase operational amplification circuit, the 3rd analog to digital conversion circuit, motor torque show that decoding and motor torque status displays are connected in series successively, the real-time change in torque of the online monitoring real-time of the energy object of controlling, the user shows according to the real-time moment of torsion of this device, can grasp the stress of monitored object very easily.
Description of drawings
Fig. 1 dashed rectangle partly is the theory diagram of torque overload supervising device among the present invention;
Fig. 2 is the structure chart of display floater in the torque overload supervising device of the present invention;
Fig. 3 is the structure chart of the binding post in the torque overload supervising device of the present invention;
Fig. 4 is the output state signal figure of torque overload supervising device of the present invention.
The specific embodiment
For those skilled in the art can understand technical scheme provided by the present invention better, set forth below in conjunction with specific embodiment.
See also Fig. 1, this figure dashed rectangle partly is the theory diagram of torque overload supervising device among the present invention.
Torque overload supervising device provided by the invention, comprise instrument input wires terminal, three-phase alternating current sample circuit, three-phase operational amplification circuit, load simulation amount comparator, overload analog quantity comparator, load switching circuit, overload cut-out circuit, load detection output circuit, overload detection output circuit, watch-dog self check and motor operating state observation circuit, monitoring output circuit and instrument output wiring terminal, wherein: instrument input wires terminal, three-phase alternating current sample circuit, three-phase operational amplification circuit are connected in series successively; Three-phase operational amplification circuit, load simulation amount comparator, load switching circuit, load detection output circuit and instrument output wiring terminal are connected in series successively; Three-phase operational amplification circuit, overload analog quantity comparator, overload cut-out circuit, overload detection output circuit and instrument output wiring terminal are connected in series successively; Three-phase operational amplification circuit, watch-dog self check and motor operating state observation circuit, monitoring output circuit and instrument output wiring terminal are connected in series successively; Instrument input wires terminal is connected with three phase electric machine with three-phase alternating-current supply respectively.
The torque overload supervising device also comprises load D/A converting circuit and load set digital switch, and load simulation amount comparator, load D/A converting circuit, load set digital switch are connected in series successively.
The torque overload supervising device also comprises overload D/A converting circuit and overload setting digital switch, and overload analog quantity comparator, overload D/A converting circuit, overload are set digital switch and be connected in series successively.
The torque overload supervising device comprises that also the 3rd analog to digital conversion circuit, motor torque show decoding and motor torque status displays, and three-phase operational amplification circuit, the 3rd analog to digital conversion circuit, motor torque show that decoding and motor torque status displays are connected in series successively.
The concrete operation principle of torque overload supervising device provided by the invention is as follows:
Three-phase alternating-current supply is introduced from U-, V-, W-terminal, and the three-phase alternating current sample circuit of flowing through outputs to the target to be monitored three phase electric machine from U+, V+, W+ terminal.Like this, the operating current of three phase electric machine just flows through the sampled generation sampled signal of three-phase alternating current sample circuit, because the size variation of current of electric is directly proportional by the size variation of torsion with monitored target, so the size variation of sampled signal can reflect that monitored target is subjected to the size variation of torsion.Sampled signal is through the three-phase operational amplification circuit, be scaled and display show value 000～999 corresponding simulating value (be equivalent to motor rated current 0%～200%), cross analog to digital conversion circuit through the 3rd again, analog quantity is converted to video data, data are through motor torque display decoder decoding rear drive motor torque status displays, and the numerical values recited of display reflection is subjected to the size of moment of torsion in real time corresponding with target to be monitored.
The judgement of overload monitoring and load monitoring is finished by the load simulation amount comparator and the overload analog quantity comparator of this torque overload supervising device respectively, set the digital quantity of digital switch and the input of load set digital switch by overload, via load D/A converting circuit and overload D/A converting circuit the digital quantity of importing is converted to analog quantity, insert load simulation amount comparator and overload analog quantity comparator then respectively, load simulation amount comparator and overload analog quantity comparator receive the operating current sampled signal from the target to be monitored three phase electric machine of three-phase operational amplification circuit simultaneously.Both relatively after, if sampling value greater than setting value, then the output state of comparator overturns, otherwise maintains the original state.These states output to the signal output wiring terminal of this torque overload supervising device bonnet correspondence respectively through load switching circuit and overload cut-out circuit.The state of signal is outwards to export with the form of " switch ", for example: when the overload of generation is not arranged, overload signal OL connects COM, be " opening state ", if transship, then OL disconnects COM, is " off state ", digital control system receives these states, just can judge the monitoring situation.
Sampled signal by the output of three-phase operational amplification circuit flows to detector self check and motor operating state observation circuit simultaneously, if the generation sampled signal has sudden change then might be that this torque overload supervising device self has fault, or the electric current phase shortage appears in monitored target motor, motor driver breaks down etc., behind electric motor starting, still there is not the sampled signal of receiving for another fruit, then might be that monitored target electric motor starting is malfunctioning, at this moment monitor output circuit output abnormality alarm signal A LM.
See also Fig. 2, this figure is the structure chart of display floater in the torque overload supervising device of the present invention.
Torque overload supervising device provided by the invention, display floater is divided into three parts by function, topmost portion is real-time torque value charactron display, can show the moment size variation situation of target to be monitored fast in real time, and the show value scope is 000～999; Mid portion is torque value monitoring setting area, set two parts by overload monitoring and setting and load monitoring and form, every part is formed by 3 bit digital toggle switch, and setting range is 000～999, the user can increase (pressing+key) to each dial-up position and subtract (pressing-key) setting according to applicable cases.The below is the condition prompting district, is made up of 3 indicator lamps, represents the overload of target to be monitored respectively, reaches load condition unusually.
When left side overload lamp is bright, show that target to be monitored has overload to take place, this torque overload supervising device sends " overload signal ", overload signal OL be normally closed signal (normally closed, often to open be the original hold mode of expression, normally closed is to keep connecting, often opening is to keep disconnecting, and the state of being switched on or switched off is for COM.The output wiring terminal of this torque overload supervising device, the terminal that 1 COM by name is arranged, be called the output signal common port, when output signal was connection, this signal terminal and COM connected, when output signal is disconnection, this signal terminal and COM disconnect, signal is that the form with " switch " transfers out), at this moment, the output state of this torque overload supervising device OL becomes disconnection from normally closed; When the most right-hand indicator lamp is bright, show that target to be monitored enters operating duty, load signal LD is for often opening signal, and at this moment, the LD output state of this torque overload supervising device becomes closure from often opening; When middle indicator lamp is bright, show the target to be monitored operation irregularity, the ALM output state of this torque overload supervising device becomes disconnection from normally closed; Abnormal alarm may be the inconsistent or phase shortage of three characteristics of the middle term electric current incoming direction; also may be because of target to be monitored (frequency converter, driver for brushless DC motor or motor servo driver) fault; make the undesired or sudden change of electric current cause that or this torque overload supervising device faults itself causes.This torque overload supervising device inside also disposes the unusual buzzer of reporting to the police, and when transshipping or occurring unusually, buzzer can send the tweeting sound warning.
Especially, the important role of load signal as if when dallying, be can be not out of order, and its controller provide airborne signals yet at the monitored motor of many occasions.But in actual the use, equipment can not worked during idle running, and this situation wastes energy exactly.Such as, ring mould drilling machine is holed and is added man-hour, and drill bit is disconnected suddenly, but occurs because of not having warning or fault, and its spindle motor can dally always, and lathe is also carried out processing action always.And this signal has been arranged, in the monitoring time section, if load signal exists always, explanation is empty brill state, can in time shut down, and provides caution signal, shortens the dry run time of equipment.
See also Fig. 3, this figure is the structure chart of the binding post in the torque overload supervising device of the present invention.
L, N binding post are that the alternating current 220V power supply inserts terminal, and the power supply of Jie Ruing is the working power of this torque overload of supply supervising device use herein.Signal OL, ALM and LD are respectively overload monitoring output, abnormal alarm lead-out terminal and the load monitoring lead-out terminal of this torque overload supervising device; be used for connecing the input port of master control system (as the numerical control system); for digital control system provides received signal; COM is the public terminal of output signal; master control system can in time be made response according to these signals and handle, and is not destroyed with the protection target to be monitored.U-, V-, W-connects the binding post of three phase mains (electrical source of power is come source interface, for example receive the three phase mains output of three-phase alternating current 380V power supply or frequency converter, motor servo driver), U+, V+, W+ is power access end (from here to the motor power supply) of the three-phase three phase electric machine of target to be monitored, E is a ground terminal, connects the shell of motor driver metal shell and target to be monitored three phase electric machine, receives on the ground wire then.
See also Fig. 4, this figure is the output state signal figure of torque overload supervising device of the present invention.
Output signal among the figure " high level part " is the output state that this signal of expression is in connection, and " low level part " is the output state that this signal of expression is in disconnection, and the state of being switched on or switched off is for COM.
Torque overload supervising device provided by the invention has the following advantages:
1, dual monitoring function
Can set in advance 2 monitoring values: be defined as load monitoring value and overload monitoring value respectively, if the monitored object moment of torsion exceeds the monitoring value of setting, control device is exported corresponding feedback signal immediately.Controller (as numerical control system, master controller etc.) signal whereby (for example: instant withdrawing is protected monitored object; feed velocity slows down; prompting user excessive tool wear must be changed cutter etc.); after setting the monitoring value; the user of service does not worry taking place as drill bit excessive wear or the breaking of rod and ignorant situation; can prevent the fracture of drill bit, saw blade, cutter, emery wheel and hurt sb.'s feelings; more can effectively avoid monitored object to be damaged, reduce that dry running time workpiece is done over again and the generation of waster rate.
2, the monitoring and protection value input function that need not convert
The real-time torque value 000～999 of the monitored target that display shows, be consistent with the equivalent of monitoring value loader (3 figure place code switch) input value 000～999, for example, when you are provided with input 100 monitoring value, then watch-dog just can show that the target torque value of survey in 100 o'clock monitors with display.So when the user in use recognizes the stressing conditions of target to be monitored by the real-time torsion show value of this device, can directly use the data that get from display, do not need to convert, operation is directly perceived.And if use frequency converter or servo-driver similarly to monitor, the value that then can not be directly shows with its display must be understood and convert as monitoring input value.
3, the direct input function of monitoring and protection value
The directly mode of input is adopted in the input operation of monitoring and protection value; the user only wants to import any numerical value; at any time directly import by digital loader on this device panel; do not need to enter or the functional switch conversion enters by menu conversion; and use frequency converter or servo-driver, then must carry out multistep operation conversion and just can import.
4, monitoring is worth real-time Presentation Function
Use digital toggle switch, the numeral that changes toggle switch has just changed the monitoring value of input, so digital toggle switch has Presentation Function simultaneously concurrently, promptly the user sees that the numeral on the digital toggle switch just knows how many monitoring values of current setting is.Just know what's what in user's use like this.And use frequency converter or servo-driver, and then can not show under the real-time torque condition, show the monitoring value that is provided with simultaneously again.
To the above-mentioned explanation of the disclosed embodiments, make this area professional and technical personnel can realize or use the present invention.Multiple modification to these embodiment will be conspicuous concerning those skilled in the art, and defined herein General Principle can realize under the situation that does not break away from the spirit or scope of the present invention in other embodiments.Therefore, the present invention will can not be restricted to these embodiment shown in this article, but will meet and principle disclosed herein and features of novelty the wideest corresponding to scope.
Claims (3)
1. torque overload supervising device, it is characterized in that, comprise that instrument input wires terminal, three-phase alternating current sample circuit, three-phase operational amplification circuit, load simulation amount comparator, overload analog quantity comparator, load switching circuit, overload cut-out circuit, load detection output circuit, overload detection output circuit, the 3rd analog to digital conversion circuit, motor torque show decoding, motor torque status displays, watch-dog self check and motor operating state observation circuit, monitoring output circuit and instrument output wiring terminal, wherein:
Described instrument input wires terminal, three-phase alternating current sample circuit, three-phase operational amplification circuit are connected in series successively;
Described three-phase operational amplification circuit, load simulation amount comparator, load switching circuit, load detection output circuit and described instrument output wiring terminal are connected in series successively;
Described three-phase operational amplification circuit, overload analog quantity comparator, overload cut-out circuit, overload detection output circuit and described instrument output wiring terminal are connected in series successively;
Described three-phase operational amplification circuit, watch-dog self check and motor operating state observation circuit, monitoring output circuit and described instrument output wiring terminal are connected in series successively;
Described instrument input wires terminal is connected with three phase electric machine with three-phase alternating-current supply respectively;
Described three-phase operational amplification circuit, the 3rd analog to digital conversion circuit, motor torque show that decoding and motor torque status displays are connected in series successively.
2. torque overload supervising device according to claim 1, it is characterized in that, also comprise load D/A converting circuit and load set digital switch, described load simulation amount comparator, load D/A converting circuit, load set digital switch are connected in series successively.
3. torque overload supervising device according to claim 1, it is characterized in that, also comprise overload D/A converting circuit and overload setting digital switch, described overload analog quantity comparator, overload D/A converting circuit, overload are set digital switch and are connected in series successively.
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| CN 201110077351 CN102166723A (en) | 2011-03-29 | 2011-03-29 | Torque overload monitoring device |
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| CN 201110077351 CN102166723A (en) | 2011-03-29 | 2011-03-29 | Torque overload monitoring device |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN105619178A (en) * | 2016-03-09 | 2016-06-01 | 华中科技大学 | Real-time detecting method of tool breakage of numerically-controlled machine tool |
| CN107144743A (en) * | 2017-05-08 | 2017-09-08 | 深圳市新益昌自动化设备有限公司 | Semiconductor packaging device linear motor driver method for detecting open phase |
| CN107272587A (en) * | 2017-06-07 | 2017-10-20 | 深圳市海浦蒙特科技有限公司 | The knife-breaking detecting method and frequency converter of engraving machine |
| TWI693982B (en) * | 2018-12-27 | 2020-05-21 | 聖杰國際股份有限公司 | Automatic tool changing mechanism of tool machine and its control method |
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| TWI693982B (en) * | 2018-12-27 | 2020-05-21 | 聖杰國際股份有限公司 | Automatic tool changing mechanism of tool machine and its control method |
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