CN102520672B - 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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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 monitoring method and the system of a kind of plastic history and defect, the method and systematically discussed multidimensional sensor and the application of signal collection and analysis method, utilize the impact shock response signal that digital correlation causes plastic deformation force to analyze, obtain the whether normal information of judgement plastic yield duty.
Background technology
Plastic yield is a complicated dynamic process, the motion of device drives mould causes the plastic yield of material (plate or derby), mould and equipment and workpiece also can produce a certain amount of elastic deformation simultaneously, in forming process, the cumulative processes of these elastic deformations, and moulding finish after these elastic deformations 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 impact briquetting process from the angle of power both at home and abroad, and the theoretical question of forming process monitoring, from the angle of acceleration vibration, do not study.Vibration is that masterpiece is used in the unit interval change in displacement rate producing on certain mass and natural frequency material, and general quantity turns to acceleration of gravity unit.It is not only relevant with workpiece blank and forming shape, also relevant with the state of equipment and mold.Therefore it more can reflect the variation of the variation of technological parameter of plastic forming process and mould, equipment working state all sidedly.The method and system of Chinese patent 01810063.5(on-line monitoring punching course) on July 6th, 2003, disclose a kind of application process and the system of stamping press in gap-framepress punching press monitoring of measuring by strain transducer, international monopoly (WO1992007711) DIE CUSHION DEVICE OF PRESS MACHINE disclosed 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 stamping quality monitoring; US Patent No. 006114965A (System for monitoring the dynamic tooling shutheight deflection activity within a press machine) discloses a kind of system of utilizing a plurality of acceleration transducer monitoring multi-station molds on September 5th, 2000, but it is that acceleration signal is changed into bottom dead centre displacement, and then using bottom dead centre displacement to the sensitivity of equipment and mold state as pilot signal, judge duty; US Patent No. 006209400B2 (Portable press vibration severity monitoring system and method) discloses a kind of portable pressing machine vibration monitoring instrument and using method April 3 calendar year 2001, it is a kind of monitoring system that adopts hardware integration circuit to realize, and cannot adapt to the on-line monitoring of various different technology conditions; US Patent No. 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 pressing machine monitoring on March 10th, 1998, as pressure, speed, load, temperature etc., but do not relate to vibration, especially Multidimensional acceleration vibration signal; A kind of US Patent No. 06481295B1 (Method and system for monitoring peak compressive and tensile process severity levels of a press machine using acceleration data) discloses detected pressures machine acceleration peak value method on October 18th, 2000 is for judging the load-carrying ability rank of pressing machine, but not for monitoring, the method is only considered peak value simultaneously; United States Patent (USP) 04692857(Method and apparatus for protecting press from being damaged by overload conditions) a kind of device and method that utilizes rotary encoder and hydraulic load protection pressing machine to be no more than load curve allowable was disclosed on September 8th, 1987; United States Patent (USP) 05339665(Die-cushion apparatus of press machine) on August 23rd, 1994, disclose a kind of hydraulic pressure overload protective device protection mould that utilizes and avoided the device damaging; United States Patent (USP) 006820026B1(Console mounted vibration severity monitor) a kind of duty of utilizing acceleration transducer, speed pickup and displacement transducer to carry out monitoring pressure machine was disclosed on January 19th, 2000, but the method is only calculated its effective value (RMS), signal waveform is not carried out to further signal processing, do not obtain the eigenwert relevant to technique or defect.In addition also have some other document to relate to the description of pressing machine monitoring, but all belong to theoretical research, fail to propose effective means for engineering practice.Or the aspect such as oil of monitor force machine, gas, liquid, electricity, machinery, reckon without moulded manufacturability problem.
When plastic forming process, it is a complicated dynamic process that press, mould, blank interact.To be stamped into example, no matter be separation circuit or molding procedure, punching press effective travel generally completes in hundreds of milliseconds tens, and forming force has violent variation, shows the feature of impact, correspondingly on the relevant parts of mould and press, produces impact shock.
Summary of the invention
The invention provides monitoring method and the system of a kind of plastic history and defect, it is mainly the multiple degrees of freedom that is conceived to vibration, adopt multidimensional sensor to carry out the duty of watch-dog and mould, and Applied Digital correlation method differentiates the unusual fluctuation of the signature waveform in different process stage, thereby identify stage and the reason that defect produces.
Technical conceive of the present invention is: its principle is to utilize the vibration signal that impulsive force that in plastic history, equipment and mould are subject to produces to comprise equipment, the information that 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, determine in vibration signal, comprise and equipment, mould, work status changes relevant characteristic information, according to the molding character time period, carry out computing cross-correlation with normal signal, carry out correlativity and mistiming comparison, thereby there is problem in which that judgement is technological process in stage, opertaing device sends information in time, the action of control lathe.
Technical scheme of the present invention is:
(1) a plurality of acceleration vibration transducers are installed in the position of the acceleration vibration sensing that, variation causes to forming force on equipment and mold;
(2), gather the acceleration vibration signal of equipment and mold under idle condition stored record; Gather the acceleration vibration signal of equipment and mold under normal condition, and stored record; The acceleration vibration signal that in collecting work process, on-line monitoring gathers, and stored record;
(3), the acceleration vibration signal gathering is carried out to digital signal processing, extract the acceleration change waveform in each feature stage of forming process, carry out digital correlation analysis calculating with normal vibration waveform, according to cross-correlation calculation result, determine that normally whether technique;
(4), according to result, show that data also control lathe action.
Further restriction to such scheme: plastic history mainly comprises punching press, forging, upsetting squeeze or shearing.
Further restriction to such scheme: described collection, refers to the synchronous acquisition of a plurality of sensors that start from a certain key phase position.
Further restriction to such scheme: described signal, refers to and bear the parts of slide block hitting power or the parts of other and its mechanical attachment on equipment top shoe or equipment rack with respect to the acceleration vibration signal of equipment worktable or base.
Further restriction to such scheme: the described feature stage refers to each stage relevant to moulding process feature, acceleration signal between each stage can obviously be distinguished, mainly comprise the initial contact phase of mould and workpiece, workpiece and stablize plastic period, dead stage of bottom dead centre upsetting, equipment elasticity and reply touching the mill stage of frame vibration stage, patrix return and workpiece, and patrix leaves the vibration recovery stage after workpiece.
Further restriction to such scheme: when described digital correlation analysis refers to normal moulding, each stage signal of each stage signal and institute's monitor procedure carries out the calculating of digital cross-correlation function, calculates simple crosscorrelation extreme value or time offset.
Realize a kind of monitoring system of said method: by acceleration vibration transducer, signals collecting and storage, digital signal processing, visualization model, control module or telecommunication module, formed.
Beneficial effect:
This method and system adopt acceleration vibration transducer, have easy installation, the feature that susceptibility is high; A plurality of sensor acceleration of system acquisition vibration signal, comprises the signal of the multiple directions dimension component of the acceleration of X/Y/Z direction or the combination in any of XY/YZ/ZX axial angle acceleration, can distinguish the variation different condition of multiple directions; The signal of system acquisition is to be subject to the position of forming force with respect to the acceleration of base, and the deviation of effectively having avoided equipment vibration in addition to cause, as the vibration of other equipment in workshop is rejected by the sensor signal of base.
Accompanying drawing explanation
Fig. 1 is system principle diagram.
Fig. 2 is that acceleration vibration transducer is arranged on the schematic diagram on equipment crossbeam, column and base.
Fig. 3 is the schematic diagram that acceleration vibration transducer is arranged on press ram, guide rail, patrix, guide pin bushing and counterdie.
Fig. 4 is the vibration mode that press and mould moving component may occur.
Slide block and table base Z-direction vibration typical waveform when Fig. 5 is punching press.
Fig. 6 is that on equipment, certain point accelerates each molding character stage corresponding to typical waveform with respect to the vibration of base.
Fig. 7 be on equipment certain point at after-stage BBC with respect to the contrast (normally) of base vibrational waveform.
Fig. 8 be on equipment certain point at after-stage BBC the cross-correlation analysis eigenwert (normally) with respect to base vibration.
Fig. 9 be on equipment certain point at after-stage BBC with respect to the contrast (extremely) of base vibrational waveform.
Figure 10 be on equipment certain point at after-stage BBC the cross-correlation analysis eigenwert (extremely) with respect to base vibration.
Figure 11 is that on equipment, certain point leaves piece stage with respect to the contrast (extremely) of base vibrational waveform at patrix.
Figure 12 is that on equipment, certain point leaves piece stage with respect to the cross-correlation analysis eigenwert (extremely) of base vibration at patrix.
Shown in 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 as shown in Figure 1, as shown in Figure 1, realizes a kind of monitoring system of the present invention, mainly acceleration vibration transducer, signals collecting and storage, digital signal processing, visualization model, control module or telecommunication module, consists of.
Exemplary embodiments as shown in Figure 2,3, degree of will speed up vibration transducer 1 is arranged 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, installation site is according to different press equipments, the position that selection is the most responsive to technique, may there is degree of freedom vibration as shown in Figure 4 in these parts, therefore will carry out settling signal collection with being no less than 2 acceleration transducers.In order to gather the effective plastic working stage, use key phase sensor 5 and key phase trigger 12 to determine a fixing reference position, triggering collection makes each sensor synchronous acquisition (synchronous acquisitions of a plurality of sensors that start from a certain key phase position) simultaneously.
The general signal that first gathers the operation of several times empty-load device, at this moment, owing to there is no forming force, the vibration of equipment is only caused by the gap between motor and moving component, friction etc., presents a kind of background noise.These background noises still present when normal punching press, as shown in the curve of base Z axis in accompanying drawing 5, therefore, in order farthest to eliminate it, need to first record the local noise of several times with the Changing Pattern of press no load movement, so that later stage signal is eliminated it while processing.Due to equipment support, may be subject near the impact of other formers simultaneously, the sensor signal of therefore installing on support will be carried out differential mode processing with other position sensor signals, prevents the impact of other vibration interference that sensor that column, crossbeam, slide block etc. are located is subject to transmitting from support.Its result as shown in Figure 6.
The key phase sensor pair being contained on guide rail and slide block plays a part 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 by light, magnetic, electricity, machinery etc., in circuit, produce a pulse signal, pulse signal triggering collection system, realize the synchronous acquisition of all passages, record storage system and complete high speed storing.After collecting the signal of certain hour or quantity, acquisition system stops gathering, and starts image data to process, until key phase sensor triggers again during 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 is directly mutually related, and these positions are mainly to consider the impact of mechanic transmission clearance on synchronous key phase position accuracy.
After testing and measuring technology and frock are normal, gather each sensor signal under several times normal process and machine condition.The Z-direction vibration signal of typical case's punching course as shown in Figure 6.Here process is divided into 6 stages: the initial contact region of patrix and workpiece, workpiece plastic period, bottom dead centre upsetting dead band, equipment elasticity are replied touching the mill stage of frame oscillation section, patrix return and workpiece, and patrix leaves the vibration recovery stage after workpiece.With respect to power---stroke (or time) curve, the boundary of acceleration oscillating curve is very obvious, has facilitated the extraction of feature identification and the characteristic quantity in each stage.
The signal more than detecting will be processed by filtering, and find meet technology characteristics rule sign mutation point (as above-mentioned 6 the whole story in stage point), traditional wavelet analysis is similarly being difficult to play a role in non-stationary signal.And forge, the plastic yield such as pressure-sizing, cold-heading shows as impact, this impact is similar with the characteristic of Laplace small echo, by carrying out cross-correlation calculation with 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, be judged to forming defect, there is technology trouble.
Fig. 7 has showed two stages of key in forming process---the signature waveform of dead stage of bottom dead centre upsetting and equipment elasticity reply frame oscillation section.Normal forming process shown in figure, relatively its difference is very little with reference waveform, by digital correlation analysis, obtains the curve shown in Fig. 8, and its maximum related value is 0.966629, by the mistiming after key signal alignment, in order to be compared 0.4 millisecond of signal lag, waveform symmetry is good.
And abnormality as shown in Figure 9, its different wave shape is larger, after digital correlation analysis as shown in figure 10, maximum related value only 0.422502,1.2 milliseconds of time leads, and waveform symmetry is very poor, the forming process that therefore can judge accompanying drawing 9 has occurred leading abnormal with respect to normal condition, waveform similarity is very poor, and workpiece is described.Further from five-stage patrix, leave touching mill and replying waveform of workpiece, the tested waveform reference waveform that seriously lags behind, as shown in Figure 11, correlation computations waveform as shown in Figure 12, its symmetry is fair, calculate 27 milliseconds of time lags, but acceleration amplitude is far longer than normal condition, devices illustrated bottom dead centre is too low.
In general, related coefficient is less than 0.7, and waveform correlation is asymmetric, and correlativity is poor, and related coefficient to be greater than 0.9 be just height correlation.In plastic history, employing power---stroke (or time) curve is difficult to obtain effective comparative result with digital correlation analysis, and acceleration vibration is more responsive for technique, therefore adopt the digital correlation analysis of Acceleration pulse to be very easy to the various defective workmanships of explanation.
Complicacy due to process conditions, selected be used for judging characteristic signal or the eigenwert that whether normal technique is, can realize and calculating and judgement by software, can also in system operation interface, by user's man-machine interactively, be selected, to meet the demand of different process.
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, for showing historical data or current data.Display mode can adopt bar chart conventional in software, histogram, radar map, curve map, color cloud picture etc., allow inquiry, printing etc., these need to adopt the pattern of virtual instrument to complete based on computer system, also Ethernet easy to use or other bus systems are carried out communication simultaneously, allow an a series of pressure group of planes carry out Centralized Monitoring by communication.
Claims (7)
1. a monitoring method for plastic history and defect, is characterized in that:
(1) a plurality of acceleration vibration transducers are installed in the position of the Relative Vibration displacement that, variation causes to forming force on equipment and mold;
(2), gather the acceleration vibration signal of equipment and mold under idle condition stored record; Gather the acceleration vibration signal of equipment and mold under normal condition, and stored record; The acceleration vibration signal that in collecting work process, on-line monitoring gathers, and stored record;
(3), calculate the signal difference between slide block or stressed member and base, carry out digital signal processing, according to cross-correlation calculation result judgement technique normally whether the acceleration change waveform that extracts each feature stage of forming process, carries out digital correlation analysis calculating with normal vibration waveform;
(4), according to result, show that data also control lathe action.
2. the monitoring method of a kind of plastic history as claimed in claim 1 and defect, is characterized in that: described collection, refers to the synchronous acquisition of a plurality of sensors that start from a certain key phase position.
3. the monitoring method of a kind of plastic history as claimed in claim 1 and defect, it is characterized in that: described signal, refers to and on equipment top shoe or equipment rack, bear the parts of slide block hitting power or the parts of other and its mechanical attachment with respect to the acceleration vibration signal of equipment worktable or base.
4. the monitoring method of a kind of plastic history as claimed in claim 1 and defect, it is characterized in that: the described feature stage refers to the stage relevant to moulding process feature, acceleration signal between each stage can obviously be distinguished, mainly comprise the initial contact phase of mould and workpiece, workpiece and stablize plastic period, dead stage of bottom dead centre upsetting, equipment elasticity and reply touching the mill stage of frame vibration stage, patrix return and workpiece, and patrix leaves the vibration recovery stage after workpiece.
5. the monitoring method of a kind of plastic history as claimed in claim 4 and defect, is characterized in that: the described feature stage adopts digital signal processing method to identify, 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 defect, it is characterized in that: when described digital correlation analysis refers to normal moulding, each stage signal or preset specific template signal and each stage signal of institute's monitor procedure carry out the calculating of digital cross-correlation function, calculate simple crosscorrelation extreme value or time offset.
7. the monitoring method of a kind of plastic history as claimed in claim 1 and defect, is characterized in that: the result that digital correlation analysis calculates is the foundation of judgement, is mainly the time offset according to relevant extreme value or extreme value.
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| CN107756867B (en) * | 2017-11-27 | 2023-12-29 | 吕言 | An intelligent control device of a press machine method and press system |
| JP7134652B2 (en) * | 2018-03-12 | 2022-09-12 | 曙ブレーキ工業株式会社 | Anomaly detection method and anomaly detection device |
| 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 |
| CN111037987B (en) * | 2019-12-28 | 2022-03-01 | 西安交通大学 | State monitoring signal processing method for multi-link mechanism of large mechanical press |
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| US5488872A (en) * | 1993-06-17 | 1996-02-06 | Eoa Systems, Inc. | System and method for load sensing |
| CN1430721A (en) * | 2001-12-14 | 2003-07-16 | 香港中文大学 | Method and system of in-line monitoring punching procedure |
| CN101073924A (en) * | 2007-06-15 | 2007-11-21 | 西安交通大学 | Transmission system of servo-driven double-angle lever mechanical press of switch magnetic reluctant motor |
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Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5488872A (en) * | 1993-06-17 | 1996-02-06 | Eoa Systems, Inc. | System and method for load sensing |
| CN1430721A (en) * | 2001-12-14 | 2003-07-16 | 香港中文大学 | Method and system of in-line monitoring punching procedure |
| CN101073924A (en) * | 2007-06-15 | 2007-11-21 | 西安交通大学 | Transmission system of servo-driven double-angle lever mechanical press of switch magnetic reluctant motor |
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