CN103048951A - Test method for assessing reliability of numerical control system - Google Patents
Test method for assessing reliability of numerical control system Download PDFInfo
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Abstract
The invention provides a test method for assessing the reliability of a numerical control system. The method comprises the following steps of: carrying out tail tests on finite samples of the numerical control system (comprising a spindle motor and a feed motor) in a non-substituted mode at regular time under same actual measurement physical environments, monitoring the test process of long-term massive running, collecting running data, failure data, maintenance data and the like, acquiring the accurate and comparable site running data of the numerical control system in twenty thousand hours and above under the condition of same running environments, and establishing a typical actual measurement database of the numerical control system. Processing analysis and comparison analysis are carried out on a large quantity of collected data information in the real measurement database of the numerical control system, such as mean time between failures (MTBF), failure phenomena, diagnosis process and running statuses. Acquired failure time, failure characters, failure distribution, product quality mapping and other conditions are obtained by further processing, and the reliability data characters, the failure features, the mode classification, the influence analysis and the like of the numerical control system are further researched.
Description
Technical field
The present invention relates to a kind of test method for assessment of the digital control system reliability, specifically set up identical actual measurement physical environment, the tested digital control system of finite sample is carried out Censoring free of discontinuities continuous service test without alternative patterns, carry out long-time mass running test process monitoring, gather service data, fault data and service data etc., carry out fault mode, impact and criticality analysis (FMECA), calculate the data such as mean time between failures (MTBF), Mean Time To Repair according to the acquisition data.
Background technology
The reliability level of digital control system and numerically-controlled machine has vital effect for the normal operation of numerical control equipment and numerical control production firm raising product competitiveness.The test of digital control system fail-test is under the reliability engineering theoretical direction, by relevant national standard and standard, combining with digital control machine tool applications characteristics are obtained the data such as mean time between failures MTBF, failure message and running status that reflect digital control system reliability level by the actual tests test.In order fully to test and Experimental Comparison, except at processing site digital control system being carried out the record of reliability, in the laboratory finite sample is carried out the continuous running experiment of indoor free of discontinuities.
Digital control system reliability measured data is that Modern NC Machine Tool is designed and developed, the key foundation data of performance evaluation and production application.Research and solve digital control system reliability theory, testing evaluation method and gordian technique, accurately, objective acquisition has the firsthand data of the domestic numerical control system reliability of comparability, analyze Reliability status and the influence factor of domestic numerical control system and equipment, for the reliability growth that realizes digital control system and numerically-controlled machine, solve the not high common problem of domestic numerical control product reliability, promote China NC Machine technical merit, the capacity of R﹠D and production application level, improve the competitive power of equipment manufacture, have great importance.
For reaching tens of different manufacturers, the digital control system performance test of different model, consider that digital control system is highly reliable, small sample, the characteristics such as long operational time, set up identical actual measurement physical environment, these tested digital control systems are carried out Censoring free of discontinuities continuous service test without alternative patterns, carry out long-time mass running test process monitoring, gather service data, fault data and service data etc. are carried out fault mode according to the acquisition data, impact and criticality analysis (FMECA), calculate the mean time between failures (MTBF), the data such as Mean Time To Repair.
Summary of the invention
The object of the invention is to set up a kind of test method for assessment of the digital control system reliability, the characteristics such as, small sample highly reliable for digital control system, long operational time, assurance is set up unified experimental situation to different digital control systems and is carried out Censoring free of discontinuities continuous service test without alternative patterns, in order to contrast with estimate each digital control system performance.
The present invention is a kind of method of testing, the method requires under identical actual measurement physical environment, carry out the Censoring free of discontinuities continuous service test without alternative patterns of the digital control system of finite sample, carry out long-time mass running test process monitoring, gather service data, fault data and service data etc., obtained 20,000 hours and above equal running environment condition under accurate, comparable digital control system on-the-spot service data, and set up typical digital control system measured data storehouse.
The technical solution used in the present invention is: a kind of test method for assessment of the digital control system reliability, and the method step is as follows:
On-test, apply electric stress to digital control system, keeps energising in the whole circulation.
After the energising digital control system is carried out key testing.In 0 ~ 360s, finish key testing.
Behind the 360s digital control system is carried out no load test.Do not add any load, from 360s to 365s, 5s inner main axis rotating speed is by the zero rated speed that accelerates to forward, move 300s under rated speed, from 665s to 675s, 10s inner main axis rotating speed decelerates to zero by rated speed, again by the zero rated speed that accelerates to counter-rotating, move 300s under rated speed, from 975s to 980s, 5s inner main axis rotating speed decelerates to zero by rated speed.
Behind the 980s digital control system is carried out the main shaft accelerated test.From 980s to 990s, 10s inner main axis rotating speed by zero accelerate to forward very fast 90%, under this speed, move 5s.
Behind the 995s digital control system is carried out the very fast test of main shaft.From 995s to 1000s, 5s inner main axis rotating speed by forward very fast 90% to accelerate to forward very fast, at very fast lower operation 5s, from 1005s to 1010s, 5s inner main axis rotating speed decelerates to very fast 90% by very fast.
Behind the 1010s digital control system is carried out main shaft deceleration test.At 90% very fast lower operation 5s, from 1015s to 1025s, 10s inner main axis rotating speed decelerates to zero by very fast 90%.
Behind the 1025s digital control system is carried out the main shaft accelerated test.From 1025s to 1035s, 10s inner main axis rotating speed by zero accelerate to counter-rotating very fast 90%, under this speed, move 5s.
Behind the 1040s digital control system is carried out the very fast test of main shaft.From 1040s to 1045s, it is very fast that 5s inner main axis rotating speed accelerates to counter-rotating by counter-rotating very fast 90%, and at very fast lower operation 5s, from 1050s to 1055s, 5s inner main axis rotating speed decelerates to very fast 90% by very fast.
Behind the 1055s digital control system is carried out main shaft deceleration test.At counter-rotating 90% very fast lower operation 5s, from 1060s to 1070s, 10s inner main axis rotating speed decelerates to zero by counter-rotating very fast 90%.
Behind the 1070s digital control system is carried out linear interpolation exercise test in the XY face.From 1070s to 1670s, X, Y diaxon from initial point, move to simultaneously respectively separately 90% place of stroke under rated speed, and then former road are returned simultaneously in the 600s.
Behind the 1670s digital control system is carried out linear interpolation exercise test in the XZ face.From 1670s to 2270s, X, Z diaxon from initial point, move to simultaneously respectively separately 90% place of stroke under rated speed, and then former road are returned simultaneously in the 600s.
Behind the 2270s digital control system is carried out linear interpolation exercise test in the YZ face.From 2270s to 2870s, Y, Z diaxon from initial point, move to simultaneously respectively separately 90% place of stroke under rated speed, and then former road are returned simultaneously in the 600s.
Behind the 2870s digital control system is carried out circular interpolation exercise test in the XY face.From 2870s to 3470s, X, Y diaxon are done in the XY plane clockwise and each week of counterclockwise arc moving interpolation under rated speed in the 600s.
Behind the 3470s digital control system is carried out circular interpolation exercise test in the ZX face.From 3470s to 4070s, Z, X diaxon are done in the ZX plane clockwise and each week of counterclockwise arc moving interpolation under rated speed in the 600s.
Behind the 4070s digital control system is carried out circular interpolation exercise test in the YZ face.From 4070s to 4670s, Y, Z diaxon are done in the YZ plane clockwise and each week of counterclockwise arc moving interpolation under rated speed in the 600s.
Behind the 4670s digital control system is carried out load testing.In the nominal load situation, from 4670s to 5270s, X, Y diaxon are done the linear interpolation motion in the 600s; From 5270s to 5870s, X, Z diaxon are done the linear interpolation motion in the 600s; From 5870s to 6470s, Y, Z diaxon are done the linear interpolation motion in the 600s; From 6470s to 7070s, X, Y diaxon are done the circular interpolation motion in the 600s; From 7070s to 7670s, Z, X diaxon are done the circular interpolation motion in the 600s; From 7670s to 8270s, Y, Z diaxon are done the circular interpolation motion in the 600s.
Test constantly circulation until when moving 30000, test finishes.
The inventive method uses the method for field test data and usage data to compare following advantage with other:
1, be different from over to the test sample book point that exists in the numerical control Reliability evaluation less, the deficiency such as the test duration is short, test environment is different, the present invention carries out the experiment of long-time continuous free of discontinuities Censoring;
2, long-time nothing of carrying out bulk article in identical test environment of the present invention is replaced the fixed time test method, can guarantee objectivity and the comparability of test data.
Description of drawings
Fig. 1 test macro topological diagram;
Fig. 2 video acquisition system synoptic diagram;
Fig. 3 system topology figure;
Fig. 4 network transmission system structural drawing;
Fig. 5 signal acquiring system schematic diagram;
Fig. 6 test box equipment synoptic diagram;
Fig. 7 data-storage system tentative programme design drawing;
Fig. 8 is operation test loop flow process.
Embodiment
The present invention includes data acquisition system (DAS), data access and display systems, three modules of data storage system as shown in Figure 1.
1, data acquisition system (DAS)
Data acquisition system (DAS) comprises video acquisition module and status data acquisition module.
1) video acquisition module
Video acquisition module mainly is comprised of three parts, is respectively: front network video camera (IPC), network transmission system, video management control system.System architecture synoptic diagram and system topology figure are respectively shown in accompanying drawing 2, accompanying drawing 3;
For each serial digital control system of different manufacturers, all be furnished with the leading portion web camera, other is furnished with a plurality of panoramic monitoring cameras, selects the hemisphere machine of supporting infrared photography, to guarantee uninterrupted monitoring in 24 hours.The network transmission system structural drawing adopts double-core switch (supporting the POE function) to access all IPC and server and storage system as shown in Figure 4, has guaranteed the safe reliability of transmission of video.The video management control system adopts (SuSE) Linux OS, has the ability of opposing virus and illegal invasion, supports the 7*24 continuous throughout the twenty-four hour24, possesses the two-node cluster hot backup function, possesses off-line arrangement, quick backup configuration file and system configuration quick restoring mechanism; Support that large-capacity video is transmitted, large-capacity video storage program request, frame flag and business support information management function; Has perfect rights management ability, multistage right assignment mechanism; Storage is supported according to temporal scalability, supports stream storage and general file storage; Built-in Web Server can support two kinds of access modes of CLIENT and WEB; Possess high stability, support the mistake proofing redundant configuration.
2) status data acquisition module
The status data acquisition module comprises that mainly numerical control system running status signals collecting and ambient signal gather two aspects.Select the EtherCAT Industrial Ethernet to have bandwidth up to 100Mb/s, the standard ethernet Frame is adopted in data communication, can realize easily interconnected with Ethernet having good compatibility, is particularly useful for distributed data acquisition at a high speed.Basic schematic diagram directly causes the EtherCAT module from the PLC of digital control system with the signal of needs collection as shown in Figure 5.But in the digital control system of reality, digital control system is processed, the digital control system signal of needs collection is become and digital control system signal passive contact one to one by adding relay, so just can very easily signal be caused the EtherCAT module.
In order to understand digital control system from the ruuning situation of the whole process of end of run that brings into operation, therefore just need to carry out data acquisition to the signal that can represent the digital control system operation conditions.Need the signal of the digital control system of collection mainly to comprise: NC power supply, NC prepare, 24V connects, system moves pulse output, main shaft is prepared/rotated, axis servomotor (XYZ) is prepared/rotation; Digital control system for each producer's different series designs separately, has made a cover test box, as shown in Figure 6.
In the process to numerical control System Reliability Test test data collection, mainly use 3 class EtherCAT modules, be respectively EL1008, EL2004, EL3064, the specific works principle of each module is as follows:
EL1008:8 passage digital-quantity input terminal 24V DC, 3ms; Its digital-quantity input terminal obtains binary control signal from field level, and the signal form that data are isolated with electricity is transferred to more high-rise automation cell.EL100x series digit amount input terminal has a 3ms input filter; Each terminal can show its state by a LED.
EL2004:4 passage digital quantity lead-out terminal 24V DC, 0.5A; The binary control signal that the signal form that its digital output terminal is isolated with electricity transmits the robotization key-course passes to the topworks of mechanical floor.
EL3064:4 tunnels analogy amount input terminal module 0 ... 10V is single-ended, 12 analog quantitys; Its input terminal module is for the treatment of the signal in the 0-10V scope.Resolution after electric current is digitized is 12, and is sent to the upper level automation equipment under the state of electricity isolation.In terminal module EL3064,4 single-ended is input as 2 line systems, and a public internal interface earth potential is arranged.Each power contact of terminal module is connected to each other; The benchmark earth point of all input ends is the 0V power contact.
The signal of tested digital control system links to each other with 2 " signal integration modules " of parallel redundancy, two signal integration modules are contacted with the EtherCAT agreement by twisted-pair feeder, and link to each other with the PLC2-TWINCAT data gather computer with PLC1-TWINCAT respectively, form redundant two paths of signals acquisition system.PLC1-TWINCAT and PLC2-TWINCAT are with the collection of 1 minute collection period realization data-signal, and the data communication device that collects is crossed computer network and is stored in the data-storage system.
For the collection of ambient signal, need to increase in addition a humiture transducer, when the temperature around the transmitter, when Humidity Generator changes, acquisition module can be with the temperature that collects, real-time the showing of situation of change of humidity.
2, data-storage system (IPSAN)
Data-storage system design, system adopt IPSAN to carry out centralized stores, and adopt the universal document system storage, support filing management.Consider the redundant safety factor, select 1.2 times total volume of capacity as calculated to support the data storage of video acquisition module and state acquisition module.The IPSAN storage system has used that RAID5+ is hot standby, disk size is forced the technology such as coupling, distributed metadata store, so that storage system has energy-conservation, data storage security advantages of higher.As shown in Figure 7, comprise 3 modules: data memory module, data backup module and data management module, the ultimate principle of each module is as follows respectively:
1) data memory module:
This module comprises 2 database servers, 2 storage switch and 6 cover disk arrays.Database server is obtained data from data acquisition, and mode and two storage switch cross connections by two-node cluster hot backup deposit data in disk array, to guarantee the safe reliability of data storage;
2) data backup module:
This module comprises exterior storage medium and 1 PC.PC is connected to database server by the network switch, and then by database server with the data importing exterior storage medium in the disk array, after importing is finished, exterior storage medium and database server can be disconnected, separately storage, the rear loss of data in case disk array breaks down;
3) data management module:
This module comprises 2 PCs.PC can be connected to database server by the network switch, and calls the data that are stored in the disk array by database server, to finish the operations such as the checking of fault data, analysis;
3, data access and display systems:
This system comprises network display module and video display module.
1) 1) network display module
The network display module comprises 1 Web server, 1 application server, 1 certificate server and the fire wall with VPN.When external user is applied for visit data by Internet, at first by the fire wall with VPN, afterwards behind the authenticated server authentication, at last by application server processes access application.Web server provides the network connection support.
2) 2) video display module
Video display module adopts liquid crystal display tiled display scheme, carries out the control that video shows by VMX specialty image mosaic controller.VMX specialty image mosaic controller has that the data operation ability is powerful, edge shield technology, RGB and the Video window can be roamed arbitrarily, stack, convergent-divergent and support Dan Ping to cut apart and the function such as multi-screen splicing, can guarantee display system clear, smooth finish the video display function.
The present invention adopts method of testing to test being subjected to test system to carry out combined stress, and combined stress comprises: temperature, humidity, electric stress and working stress etc.Temperature and humidity stress adopts the natural environmental condition of testing ground, does Real-Time Monitoring and record in the process of the test.Test profile is seen accompanying drawing 8, and process of the test is as follows:
On-test, apply electric stress to digital control system, keeps energising in the whole circulation.
After the energising digital control system is carried out key testing.In 0 ~ 360s, finish key testing.
Behind the 360s digital control system is carried out no load test.Do not add any load, from 360s to 365s, 5s inner main axis rotating speed is by the zero rated speed that accelerates to forward, move 300s under rated speed, from 665s to 675s, 10s inner main axis rotating speed decelerates to zero by rated speed, again by the zero rated speed that accelerates to counter-rotating, move 300s under rated speed, from 975s to 980s, 5s inner main axis rotating speed decelerates to zero by rated speed.
Behind the 980s digital control system is carried out the main shaft accelerated test.From 980s to 990s, 10s inner main axis rotating speed by zero accelerate to forward very fast 90%, under this speed, move 5s.
Behind the 995s digital control system is carried out the very fast test of main shaft.From 995s to 1000s, 5s inner main axis rotating speed by forward very fast 90% to accelerate to forward very fast, at very fast lower operation 5s, from 1005s to 1010s, 5s inner main axis rotating speed decelerates to very fast 90% by very fast.
Behind the 1010s digital control system is carried out main shaft deceleration test.At 90% very fast lower operation 5s, from 1015s to 1025s, 10s inner main axis rotating speed decelerates to zero by very fast 90%.
Behind the 1025s digital control system is carried out the main shaft accelerated test.From 1025s to 1035s, 10s inner main axis rotating speed by zero accelerate to counter-rotating very fast 90%, under this speed, move 5s.
Behind the 1040s digital control system is carried out the very fast test of main shaft.From 1040s to 1045s, it is very fast that 5s inner main axis rotating speed accelerates to counter-rotating by counter-rotating very fast 90%, and at very fast lower operation 5s, from 1050s to 1055s, 5s inner main axis rotating speed decelerates to very fast 90% by very fast.
Behind the 1055s digital control system is carried out main shaft deceleration test.At counter-rotating 90% very fast lower operation 5s, from 1060s to 1070s, 10s inner main axis rotating speed decelerates to zero by counter-rotating very fast 90%.
Behind the 1070s digital control system is carried out linear interpolation exercise test in the XY face.From 1070s to 1670s, X, Y diaxon from initial point, move to simultaneously respectively separately 90% place of stroke under rated speed, and then former road are returned simultaneously in the 600s.
Behind the 1670s digital control system is carried out linear interpolation exercise test in the XZ face.From 1670s to 2270s, X, Z diaxon from initial point, move to simultaneously respectively separately 90% place of stroke under rated speed, and then former road are returned simultaneously in the 600s.
Behind the 2270s digital control system is carried out linear interpolation exercise test in the YZ face.From 2270s to 2870s, Y, Z diaxon from initial point, move to simultaneously respectively separately 90% place of stroke under rated speed, and then former road are returned simultaneously in the 600s.
Behind the 2870s digital control system is carried out circular interpolation exercise test in the XY face.From 2870s to 3470s, X, Y diaxon are done in the XY plane clockwise and each week of counterclockwise arc moving interpolation under rated speed in the 600s.
Behind the 3470s digital control system is carried out circular interpolation exercise test in the ZX face.From 3470s to 4070s, Z, X diaxon are done in the ZX plane clockwise and each week of counterclockwise arc moving interpolation under rated speed in the 600s.
Behind the 4070s digital control system is carried out circular interpolation exercise test in the YZ face.From 4070s to 4670s, Y, Z diaxon are done in the YZ plane clockwise and each week of counterclockwise arc moving interpolation under rated speed in the 600s.
Behind the 4670s digital control system is carried out load testing.In the nominal load situation, from 4670s to 5270s, X, Y diaxon are done the linear interpolation motion in the 600s; From 5270s to 5870s, X, Z diaxon are done the linear interpolation motion in the 600s; From 5870s to 6470s, Y, Z diaxon are done the linear interpolation motion in the 600s; From 6470s to 7070s, X, Y diaxon are done the circular interpolation motion in the 600s; From 7070s to 7670s, Z, X diaxon are done the circular interpolation motion in the 600s; From 7670s to 8270s, Y, Z diaxon are done the circular interpolation motion in the 600s.
Test constantly circulation until 30000 the time test finish.The part that the present invention does not elaborate belongs to techniques well known.
Claims (1)
1. test method for assessment of the digital control system reliability, it is characterized in that: the method step is as follows:
On-test, apply electric stress to digital control system, keeps energising in the whole circulation;
After the energising digital control system is carried out key testing, in 0 ~ 360s, finish key testing;
Behind the 360s digital control system is carried out no load test, do not add any load, from 360s to 365s, 5s inner main axis rotating speed moves 300s by the zero rated speed that accelerates to forward under rated speed, from 665s to 675s, 10s inner main axis rotating speed decelerates to zero by rated speed, by the zero rated speed that accelerates to counter-rotating, moves 300s under rated speed again, from 975s to 980s, 5s inner main axis rotating speed decelerates to zero by rated speed;
Behind the 980s digital control system is carried out the main shaft accelerated test, from 980s to 990s, 10s inner main axis rotating speed by zero accelerate to forward very fast 90%, under this speed, move 5s;
Behind the 995s digital control system is carried out the very fast test of main shaft, from 995s to 1000s, 5s inner main axis rotating speed by forward very fast 90% to accelerate to forward very fast, at very fast lower operation 5s, from 1005s to 1010s, 5s inner main axis rotating speed decelerates to very fast 90% by very fast;
Behind the 1010s digital control system is carried out the main shaft test of slowing down, at 90% very fast lower operation 5s, from 1015s to 1025s, 10s inner main axis rotating speed decelerates to zero by very fast 90%;
Behind the 1025s digital control system is carried out the main shaft accelerated test, from 1025s to 1035s, 10s inner main axis rotating speed by zero accelerate to counter-rotating very fast 90%, under this speed, move 5s;
Behind the 1040s digital control system is carried out the very fast test of main shaft, from 1040s to 1045s, it is very fast that 5s inner main axis rotating speed accelerates to counter-rotating by counter-rotating very fast 90%, and at very fast lower operation 5s, from 1050s to 1055s, 5s inner main axis rotating speed decelerates to very fast 90% by very fast;
Behind the 1055s digital control system is carried out the main shaft test of slowing down, at counter-rotating 90% very fast lower operation 5s, from 1060s to 1070s, 10s inner main axis rotating speed by counter-rotating very fast 90% decelerate to zero;
Behind the 1070s digital control system is carried out linear interpolation exercise test in the XY face, from 1070s to 1670s, X, Y diaxon from initial point, move to simultaneously respectively separately 90% place of stroke under rated speed, and then former road are returned simultaneously in the 600s;
Behind the 1670s digital control system is carried out linear interpolation exercise test in the XZ face, from 1670s to 2270s, X, Z diaxon from initial point, move to simultaneously respectively separately 90% place of stroke under rated speed, and then former road are returned simultaneously in the 600s;
Behind the 2270s digital control system is carried out linear interpolation exercise test in the YZ face, from 2270s to 2870s, Y, Z diaxon from initial point, move to simultaneously respectively separately 90% place of stroke under rated speed, and then former road are returned simultaneously in the 600s;
Behind the 2870s digital control system is carried out circular interpolation exercise test in the XY face, from 2870s to 3470s, X, Y diaxon are done in the XY plane clockwise and each week of counterclockwise arc moving interpolation under rated speed in the 600s;
Behind the 3470s digital control system is carried out circular interpolation exercise test in the ZX face, from 3470s to 4070s, Z, X diaxon are done in the ZX plane clockwise and each week of counterclockwise arc moving interpolation under rated speed in the 600s;
Behind the 4070s digital control system is carried out circular interpolation exercise test in the YZ face, from 4070s to 4670s, Y, Z diaxon are done in the YZ plane clockwise and each week of counterclockwise arc moving interpolation under rated speed in the 600s;
Behind the 4670s digital control system is carried out load testing, in the nominal load situation, from 4670s to 5270s, X, Y diaxon are done the linear interpolation motion in the 600s; From 5270s to 5870s, X, Z diaxon are done the linear interpolation motion in the 600s; From 5870s to 6470s, Y, Z diaxon are done the linear interpolation motion in the 600s; From 6470s to 7070s, X, Y diaxon are done the circular interpolation motion in the 600s; From 7070s to 7670s, Z, X diaxon are done the circular interpolation motion in the 600s; From 7670s to 8270s, Y, Z diaxon are done the circular interpolation motion in the 600s;
Test constantly circulation until when moving 30000, test finishes.
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| CN108536094A (en) * | 2017-03-01 | 2018-09-14 | 沈机（上海）智能系统研发设计有限公司 | Machine tool capability detecting system, method and numerically-controlled machine tool |
| CN109656196A (en) * | 2018-12-27 | 2019-04-19 | 西安交通大学 | Digital control system all-round property testing method and apparatus |
| CN111291486A (en) * | 2020-02-09 | 2020-06-16 | 吉林大学 | Reliability evaluation method for system component of numerical control machine tool |
| CN116880359A (en) * | 2023-09-07 | 2023-10-13 | 天津艺仕机床有限公司 | Test method and system of trusted numerical control system |
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