CN102520672A - Method and system for monitoring plastic deformation process and defects - Google Patents
Method and system for monitoring plastic deformation process and defects Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 63
- 238000012544 monitoring process Methods 0.000 title claims abstract description 34
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- 238000005516 engineering process Methods 0.000 claims description 14
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- 238000004364 calculation method Methods 0.000 claims description 6
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- 238000005314 correlation function Methods 0.000 claims description 2
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- 238000004891 communication Methods 0.000 abstract description 3
- 238000004458 analytical method Methods 0.000 abstract description 2
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- 230000005489 elastic deformation Effects 0.000 description 3
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Abstract
The invention provides a method and system for monitoring a plastic deformation process and defects. The method comprises the following steps of: a plurality of acceleration vibration sensors are mounted at positions of relative vibration displacements arising from the change of a forming force, on equipment or a die; the signal characteristics of the vibrations of the equipment and the die arising from the impact generated by deformation under a normal state is determined through acquiring signals from the sensors under normal circumstances and carrying out signal analysis; and when the working state of the die or the equipment changes, the signal characteristics of pressing vibration signals can also change, the correlation change between the signal characteristics and waveforms under a normal process state occurs, which can be recognized by using a digital correlation method, the system is led to control a pressing machine to carry out corresponding protective operation, and meanwhile, information on the defects is displayed on a display interface of the system. The system implementing the method mainly consists of the acceleration vibration sensors, a signal acquisition and storage device, a digital signal processor, a visible module and a control unit or a remote communication module.
Description
Technical field
The invention provides the monitoring method and the system of a kind of plastic history and defective; These method and system have been set forth the application of multidimensional sensor and signals collecting and analytical approach; Utilize digital correlation that the impact shock response signal that plastic deformation force causes is analyzed, obtain to judge the whether normal information of plastic yield duty.
Background technology
Plastic yield is a complex dynamic process, and the motion of device drives mould causes the plastic yield of material (plate or derby), and mould and equipment and workpiece also can produce a certain amount of elastic deformation simultaneously; In forming process; Be the process that these elastic deformations add up, and these elastic deformations of moulding end back can discharge, therefore; Variation because of forming force on mould and equipment causes corresponding vibration, and it has reflected the state of mould and equipment and even Workpiece shaping quality.Many scholars have studied the impact briquetting process from the angle of power both at home and abroad, and the theoretical question of forming process monitoring, do not study from the angle of vibration acceleration.Vibration is that masterpiece is used in the unit interval change in displacement rate that produces on certain mass and the natural frequency material, and general quantity turns to acceleration of gravity unit.It is not only relevant with workpiece blank and shaping form, and is also relevant with the state of equipment and mold.Therefore it more can reflect variation and the mould of the technological parameter of plastic forming process, the variation of equipment working state all sidedly.Chinese patent 01810063.5 (method and system of on-line monitoring punching course) disclosed a kind of application process and the system of stamping press in gap-framepress punching press monitoring of measuring through strain transducer on July 6th, 2003, and international monopoly (WO 1,992 007711) DIE CUSHION DEVICE OF PRESS MACHINE discloses a kind of method and apparatus that utilizes the motor-driven work of hydraulic system pressure monitor force on May 14th, 1992; International monopoly (WO2009078237) CONTROL DEVICE AND CONTROL METHOD FOR DIE-CUSHION DEVICE discloses a kind of monitoring on June 25th, 2009 and has drawn the method that method that whether pad hydraulic cylinder liquid flow velocity exist unusual fluctuations to change realizes the stamping quality monitoring; U.S. Pat 006114965A (System for monitoring the dynamic tooling shutheight deflection activity within a press machine) discloses a kind of system that utilizes a plurality of acceleration transducer monitoring multistation moulds on September 5th, 2000; But it is to change acceleration signal into the bottom dead centre displacement; And then the bottom dead centre displacement to the sensitivity of equipment and mold state as pilot signal, come the judgment task state; U.S. Pat 006209400B2 (Portable press vibration severity monitoring system and method) discloses a kind of portable pressing machine vibration monitoring instrument and method of application April 3 calendar year 2001; It is a kind of monitoring system that adopts the hardware integrated circuit to realize, can't adapt to the on-line monitoring of various different technology conditions; U.S. Pat 05724843A (Method of diagnosing pressing machine based on detected physical value as compared with reference) discloses a kind of method of utilizing multiple magnitude of physical quantity to carry out the pressing machine monitoring on March 10th, 1998; Like pressure, speed, load, temperature etc.; But do not relate to vibration, especially multidimensional acceleration vibration signal; U.S. Pat 06481295B1 (the Method and system for monitoring peak compressive and tensile process severity levels of a press machine using acceleration data) method that discloses a kind of detected pressures machine acceleration peak value on October 18th, 2000 is used to judge the load-carrying ability rank of pressing machine; But not being used for monitoring, this method is only considered peak value simultaneously; United States Patent (USP) 04692857 (Method and apparatus for protecting press from being damaged by overload conditions) discloses a kind of device and method that utilizes rotary encoder and hydraulic load protection pressing machine to be no more than load curve allowable on September 8th, 1987; United States Patent (USP) 05339665 (Die-cushion apparatus of press machine) discloses a kind of hydraulic pressure overload protective device protection mould that utilizes on August 23rd, 1994 and has avoided the device that damages; United States Patent (USP) 006820026B1 (Console mounted vibration severity monitor) discloses a kind of duty of utilizing acceleration transducer, speed pickup and displacement transducer to come the monitoring pressure machine on January 19th, 2000; But this method is only calculated its effective value (RMS); Signal waveform is not carried out further signal Processing, do not obtain the eigenwert relevant with technology or defective.Also have some other document to relate to the description of pressing machine monitoring in addition, but all belong to theoretical research, fail to propose effective means and be used for engineering practice.Or aspect such as oil of monitor force machine, gas, liquid, electricity, machinery, reckon without forming technology property problem.
When the plastic forming process, it is a complex dynamic process that press, mould, blank interact.To be stamped into example, no matter be separation circuit or forming process, the punching press effective travel is generally accomplished in hundreds of milliseconds tens, and plastic force has violent variation, shows the characteristic of impact, correspondingly on the relevant parts of mould and press, produces impact shock.
Summary of the invention
The present invention provides the monitoring method and the system of a kind of plastic history and defective; It mainly is the multiple degrees of freedom that is conceived to vibrate; The duty that adopts multidimensional sensor to come watch-dog and mould; And the Applied Digital correlation method differentiates the unusual fluctuation of the signature waveform in different process stage, thereby identifies stage and reason that defective produces.
Technical conceive of the present invention is: its principle is to utilize the vibration signal that impulsive force produced that equipment and mould receive in the plastic history to comprise the information that equipment, mould and work status change; Utilize a plurality of acceleration vibration transducers to detect the signal of all directions dimension component; Pass through digital signal processing; That confirms in the vibration signal to be comprised changes relevant characteristic information with equipment, mould, work status, according to the formed features time period, carries out computing cross-correlation with normal signal; Carry out correlativity and mistiming relatively; Thereby judge it is which of technological process problem to have occurred, opertaing device in time sends information, the action of control lathe in stage.
Technical scheme of the present invention is:
A plurality of acceleration vibration transducers are installed in the position of the acceleration vibration sensing that (1), variation causes to forming force on equipment or mould;
(2), gather the acceleration vibration signal of equipment and mold under the idle condition and stored record; Gather the acceleration vibration signal of equipment and mold under the normal condition, and stored record; The acceleration vibration signal that on-line monitoring is gathered in the collecting work process, and stored record;
(3), the acceleration vibration signal of gathering is carried out digital signal processing, extract the acceleration change waveform in each characteristic stage of forming process, carry out the digital correlation analytical calculation, confirm that according to the cross-correlation calculation result normally whether technology with the normal vibration waveform;
(4), according to the result, video data is also controlled the lathe action.
Further qualification to such scheme: plastic history mainly comprises punching press, forging, upsetting squeeze or shears.
Further qualification to such scheme: described collection is meant the synchronous acquisition of a plurality of sensors that begin from a certain key phase position.
Further qualification to such scheme: described signal is meant the vibration acceleration signal of the parts of the parts that bear the slide block hitting power on equipment top shoe or the equipment rack or other and its mechanical attachment with respect to equipment work platform or base.
Further qualification to such scheme: the described characteristic stage is meant each stage relevant with the forming technology characteristic; Acceleration signal between each stage can obviously be distinguished; Mainly comprise the initial contact phase of mould and workpiece, workpiece and stablize upset dead stage, equipment elasticity of plastic yield stage, bottom dead centre and reply bumping the mill stage of frame vibration stage, patrix return and workpiece, and patrix leaves the vibration recovery stage behind the workpiece.
Further qualification to such scheme: each stage signal of each stage signal and institute's monitor procedure carried out digital cross correlation function calculating when described digital correlation analysis was meant normal the shaping, calculated simple crosscorrelation extreme value or time offset.
Realize a kind of monitoring system of said method: form by acceleration vibration transducer, signals collecting and storage, digital signal processing, visualization model, control module or telecommunication module.
Beneficial effect:
This method and system adopt the acceleration vibration transducer, have easy mounting, the characteristics that susceptibility is high; The a plurality of sensor acceleration of system acquisition vibration signal comprises the signal of a plurality of direction dimension components of combination in any of acceleration or the XY/YZ/ZX axial angle acceleration of X/Y/Z direction, can distinguish the variation different condition of a plurality of directions; The signal of system acquisition is to receive the acceleration of the position of forming force with respect to base, and the deviation of having avoided the vibration beyond the equipment to cause is effectively rejected by the sensor signal of base like the vibration of other equipment in the workshop.
Description of drawings
Fig. 1 is a system principle diagram.
Fig. 2 is that the acceleration vibration transducer is installed in the synoptic diagram on equipment crossbeam, column and the base.
Fig. 3 is the synoptic diagram that the acceleration vibration transducer is installed in press ram, guide rail, patrix, guide pin bushing and counterdie.
Fig. 4 is the vibration mode that press and mould moving component possibly occur.
Slide block and table base Z were to the vibration typical waveform when Fig. 5 was punching press.
Fig. 6 is that certain point quickens each corresponding formed features stage of typical waveform with respect to the vibration of base on the equipment.
Fig. 7 be on the equipment certain point at after-stage BBC with respect to the contrast (normally) of base vibrational waveform.
Fig. 8 be on the equipment certain point in the cross-correlation analysis eigenwert (normally) of after-stage BBC with respect to the base vibration.
Fig. 9 be on the equipment certain point at after-stage BBC with respect to the contrast (unusually) of base vibrational waveform.
Figure 10 be on the equipment certain point in the cross-correlation analysis eigenwert (unusually) of after-stage BBC with respect to the base vibration.
Figure 11 is that certain point leaves the contrast (unusually) of piece stage with respect to the base vibrational waveform at patrix on the equipment.
Figure 12 is that certain point leaves the cross-correlation analysis eigenwert (unusually) of piece stage with respect to the base vibration at patrix on the equipment.
Shown in the figure: 1. acceleration vibration transducer, 2. pressing machine column, 3. press crown, 4. pressing machine lower bottom base, 5. key phase sensor; 6. guide rail of press machine, 7. guide-post of die-set, 8. blank holder, 9. counterdie; 10. guide pin bushing, 11. patrixes, 12. key phase triggers, 13. press rams.
Embodiment
System principle diagram is as shown in Figure 1, can be known by Fig. 1, realizes a kind of monitoring system of the present invention, mainly is made up of acceleration vibration transducer, signals collecting and storage, digital signal processing, visualization model, control module or telecommunication module.
Exemplary embodiments is like Fig. 2, shown in 3; Degree of will speed up vibration transducer 1 is installed on the parts such as the column 2, entablature 3, slide block 13, base 4, patrix 11, counterdie 9, guide pin bushing 10, blank holder 8, guide rail of press machine 6, guide-post of die-set 7 of press; The installation site is according to different press equipments; Degree of freedom vibration shown in accompanying drawing 4 possibly appear in the position that selection is the most responsive to technology, these parts, therefore will use to be no less than 2 acceleration transducers and to accomplish signals collecting.Simultaneously in order to gather the effective plastic working stage, use key phase sensor 5 and key mutually trigger 12 confirm a reference position of fixing, triggering collection makes each sensor synchronous acquisition (synchronous acquisition of a plurality of sensors that begin from a certain key phase position).
The general signal of gathering the operation of several times empty-load device earlier, at this moment owing to there is not forming force, the vibration of equipment is only caused by the gap between motor and the moving component, friction etc., presents a kind of background noise.These background noises still appear when normal punching press; Shown in the curve of base Z axle in the accompanying drawing 5, therefore, in order farthest to eliminate it; Need earlier the local noise of record several times with the Changing Pattern of press no load movement, so that the later stage is eliminated it during signal Processing.Simultaneously because the equipment support possibly receive near the influence of other formers; The sensor signal of therefore on support, installing will be carried out differential mode with other position sensor signals and handled, and prevents that sensor that column, crossbeam, slide block etc. are located from receiving the influence of other vibration interference that transmit from support.Its result is as shown in Figure 6.
Be contained on guide rail and the slide block key mutually the sensor pair play a part the synchronous acquisition trigger pip.Key phase sensor pair can adopt photoelectric sensor, electromagnetic eddy induction or Hall element etc.; When slide block down arrives certain position; Key phase trigger 11 causes key phase sensor 5 to trigger through light, magnetic, electricity, machinery etc., in circuit, produces a pulse signal, pulse signal triggering collection system; Realize the synchronous acquisition of all passages, the record storage system is accomplished high speed storing.Behind the signal that collects certain hour or quantity, acquisition system stops to gather, and begins image data is handled, and key phase sensor triggers once more when moulding next time.
Key phase sensor pair also can be contained in flywheel, bent axle of equipment etc. and the slide block movement position that directly is mutually related, and these positions mainly are to consider the influence of mechanical drive gap to synchronous key phase position accuracy.
After testing and measuring technology and frock are normal, gather each sensor signal under several times normal process and the machine condition.Typical case punching course Z to vibration signal shown in accompanying drawing 6.Here be divided into 6 stages to process: bumping the mill stage of frame oscillation section, patrix return and workpiece replied in the initial contact region of patrix and workpiece, workpiece plastic yield stage, bottom dead centre rammer dead band, equipment elasticity, and patrix leaves the vibration recovery stage behind the workpiece.With respect to power---stroke (or time) curve, the boundary of vibration acceleration curve is very obvious, has made things convenient for the feature identification and the features extraction in each stage.
More than detected signal to pass through Filtering Processing, and find meet technology characteristics regularity signals catastrophe point (as above-mentioned 6 the whole story in stage point), traditional wavelet analysis similarly is being difficult to play a role in the non-stationary signal.And forge, plastic yield such as pressure-sizing, cold-heading shows as impact; This impact is similar with the characteristic of Laplace small echo; Through carrying out cross-correlation calculation with the Laplace small echo, and waveform carries out cross-correlation calculation during with normal operating conditions, can obtain the waveform of related function; From its peak value, time offset, zoom factor, symmetry, periodically, obtain the characteristic that state of the art changes.If it has exceeded the eigenwert of normal condition, then be judged to forming defect, there is technology trouble.
Fig. 7 has showed two crucial in forming process stages---the upset signature waveform of dead stage and equipment elasticity answer frame oscillation section of bottom dead centre.Normal forming process shown in the figure, relatively its difference is very little with reference waveform, obtains curve shown in Figure 8 through the digital correlation analysis, and its maximum related value does
0.966629, afterwards the mistiming is to be lagged behind by comparison signal by the key signal alignment
0.4Millisecond, waveform symmetry property is good.
And ERST is as shown in Figure 9, and its different wave shape is bigger, and is shown in figure 10 after the digital correlation analysis, and maximum related value only
0.422502, time lead
1.2Millisecond, and waveform symmetry property is very poor, and the forming process that therefore can judge accompanying drawing 9 has taken place leading unusual with respect to normal condition, and waveform similarity property is very poor, and workpiece is described.Further leave bumping mill and replying waveform of workpiece from the five-stage patrix; The tested waveform reference waveform that seriously lags behind, shown in accompanying drawing 11, the correlation computations waveform is shown in accompanying drawing 12; Its symmetry is fair; Calculate 27 milliseconds of time lags, but acceleration amplitude is far longer than normal condition, the devices illustrated bottom dead centre is low excessively.
In general, related coefficient less than
0.7, and waveform correlation is asymmetric, then correlativity is relatively poor, and related coefficient greater than
0.9Be height correlation just.In the plastic history; Employing power---stroke (or time) curve is difficult to obtain effective comparative result with the digital correlation analysis; And vibration acceleration is more responsive for technology, therefore adopts the digital correlation analysis of acceleration waveform then to be very easy to the various defective workmanships of explanation.
Because the complicacy of process conditions; That is selected for use is used for judging characteristic signal or the eigenwert that whether normal technology is; Can realize calculating and judgement by software, can also in the system operation interface, select, to satisfy the demand of different process by user's man-machine interactively.
The operation of system is arranged in pairs or groups with showing employing dot matrix graphic alphanumeric display or LED light, can adopt keyboard operation, push-botton operation or touch screen operation, is used to show historical data or current data.Display mode can adopt bar chart commonly used in the software, histogram, radar map, curve map, color cloud picture etc.; Allow inquiry, printing etc.; These need adopt the pattern of virtual instrument to accomplish based on computer system; Also convenient simultaneously use Ethernet or other bus systems are come communication, let an a series of pressure group of planes carry out Centralized Monitoring through communication.
Claims (8)
1. the monitoring method of plastic history and defective is characterized in that:
A plurality of acceleration vibration transducers are installed in the position of the relative vibration displacement that (1), variation causes to forming force on equipment or mould;
(2), gather the acceleration vibration signal of equipment and mold under the idle condition and stored record; Gather the acceleration vibration signal of equipment and mold under the normal condition, and stored record; The acceleration vibration signal that on-line monitoring is gathered in the collecting work process, and stored record;
(3), the signal difference between calculating slide block or stressed member and the base; Carry out digital signal processing; Extract the acceleration change waveform in each characteristic stage of forming process, carry out the digital correlation analytical calculation, judge that according to the cross-correlation calculation result normally whether technology with the normal vibration waveform;
(4), according to the result, video data is also controlled the lathe action.
2. the monitoring method of a kind of plastic history as claimed in claim 1 and defective is characterized in that: described collection is meant the synchronous acquisition of a plurality of sensors that begin from a certain key phase position.
3. the monitoring method of a kind of plastic history as claimed in claim 1 and defective; It is characterized in that: described signal; Be meant on equipment top shoe or the equipment rack and bear slide block that the parts of the parts of hitting power or other and its mechanical attachment are with respect to the vibration acceleration signal of equipment work platform or base.
4. the monitoring method of a kind of plastic history as claimed in claim 1 and defective; It is characterized in that: the described characteristic stage is meant the stage relevant with the forming technology characteristic; Acceleration signal between each stage can obviously be distinguished; Mainly comprise the initial contact phase of mould and workpiece, workpiece and stablize upset dead stage, equipment elasticity of plastic yield stage, bottom dead centre and reply bumping the mill stage of frame vibration stage, patrix return and workpiece, and patrix leaves the vibration recovery stage behind the workpiece.
5. the monitoring method of a kind of plastic history as claimed in claim 4 and defective is characterized in that: the described characteristic stage adopts digital signal processing method to discern, and mainly comprises Laplace small echo or digital cross-correlation analysis.
6. the monitoring method of a kind of plastic history as claimed in claim 1 and defective; It is characterized in that: each stage signal of each stage signal or the specific template signal that presets and institute's monitor procedure carried out digital cross correlation function calculating when described digital correlation analysis was meant normal the shaping, calculated simple crosscorrelation extreme value or time offset.
7. the monitoring method of a kind of plastic history as claimed in claim 1 and defective is characterized in that: the digital correlation result calculated is the foundation of judging, mainly is the time offset according to relevant extreme value or extreme value.
8. the monitoring system of plastic history and defective is characterized in that: mainly be made up of acceleration vibration transducer, signals collecting and storage, digital signal processing, visualization model, control module or telecommunication module.
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Cited By (9)
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| CN107756867A (en) * | 2017-11-27 | 2018-03-06 | 吕言 | Forcing press intelligent controlling device, method and press machine system |
| CN108072401A (en) * | 2016-11-14 | 2018-05-25 | 山东理工大学 | A kind of press force energy parametric measurement device and method |
| CN110252851A (en) * | 2018-03-12 | 2019-09-20 | 曙制动器工业株式会社 | Method for detecting abnormality and abnormal detector in punch process |
| CN110695134A (en) * | 2019-10-28 | 2020-01-17 | 威海华邦精冲科技股份有限公司 | Offset load online measuring device and evaluation method for fine blanking progressive die |
| CN111037987A (en) * | 2019-12-28 | 2020-04-21 | 西安交通大学 | State monitoring signal processing method for multi-link mechanism of large mechanical press |
| CN111050998A (en) * | 2017-10-12 | 2020-04-21 | 西铁城时计株式会社 | Abnormality detection device and machine tool provided with abnormality detection device |
| CN112720539A (en) * | 2021-01-26 | 2021-04-30 | 郑州轻工业大学 | Thin-wall fragile piece internal-supporting type grabbing manipulator operation impact and transfer process experiment system |
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| CN108072401A (en) * | 2016-11-14 | 2018-05-25 | 山东理工大学 | A kind of press force energy parametric measurement device and method |
| CN111050998A (en) * | 2017-10-12 | 2020-04-21 | 西铁城时计株式会社 | Abnormality detection device and machine tool provided with abnormality detection device |
| KR20200062187A (en) * | 2017-10-12 | 2020-06-03 | 시티즌 도케이 가부시키가이샤 | Machine tool equipped with an abnormality detection device and an abnormality detection device |
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| KR102632038B1 (en) * | 2017-10-12 | 2024-02-01 | 시티즌 도케이 가부시키가이샤 | Anomaly detection device and machine tool equipped with anomaly detection device |
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| CN107756867A (en) * | 2017-11-27 | 2018-03-06 | 吕言 | Forcing press intelligent controlling device, method and press machine system |
| CN110252851A (en) * | 2018-03-12 | 2019-09-20 | 曙制动器工业株式会社 | Method for detecting abnormality and abnormal detector in punch process |
| CN110695134A (en) * | 2019-10-28 | 2020-01-17 | 威海华邦精冲科技股份有限公司 | Offset load online measuring device and evaluation method for fine blanking progressive die |
| CN110695134B (en) * | 2019-10-28 | 2024-03-15 | 威海华邦精密工业股份有限公司 | Unbalanced load assessment method using unbalanced load online measurement device oriented to fine blanking progressive die |
| CN111037987A (en) * | 2019-12-28 | 2020-04-21 | 西安交通大学 | State monitoring signal processing method for multi-link mechanism of large mechanical press |
| CN112720539A (en) * | 2021-01-26 | 2021-04-30 | 郑州轻工业大学 | Thin-wall fragile piece internal-supporting type grabbing manipulator operation impact and transfer process experiment system |
| CN114633446A (en) * | 2022-03-03 | 2022-06-17 | 天津市久跃科技有限公司 | Injection mold online operation monitoring method |
| CN117380813A (en) * | 2023-10-26 | 2024-01-12 | 江苏瑞金装备科技有限公司 | Forming and stamping process for side beams of front floor of automobile |
| CN117380813B (en) * | 2023-10-26 | 2024-04-05 | 江苏瑞金装备科技有限公司 | Forming and stamping process for side beams of front floor of automobile |
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|---|---|
| CN102520672B (en) | 2014-04-09 |
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Effective date of registration: 20190118 Address after: 442500 Changling Development Zone, Yunxian County, Shiyan City, Hubei Province (ASEAN Industrial Park) Patentee after: Shiyan Dewo Auto Parts Co.,Ltd. Address before: 442002 West Road, Shiyan City, Hubei Province, No. 167 Patentee before: Hubei University of Automobile Technology |
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