CN103128661B - A kind of online anti-collision monitoring device of centerless internal grinder - Google Patents
A kind of online anti-collision monitoring device of centerless internal grinder Download PDFInfo
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- CN103128661B CN103128661B CN201110403886.0A CN201110403886A CN103128661B CN 103128661 B CN103128661 B CN 103128661B CN 201110403886 A CN201110403886 A CN 201110403886A CN 103128661 B CN103128661 B CN 103128661B
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Abstract
The invention discloses a kind of online anti-collision monitoring device of centerless internal grinder.The work mounting s of centreless grinding machine internal installs a sound emission (AE) sensor (1), and its output signal line is connected with preamplifier (2); Preamplifier (2) is connected with wave filter (3); Wave filter (3) is connected with A/D converter (4); A/D converter (4) is connected with DSP (5); DSP (5) is connected with PLC (6); DSP (5) is connected with PC host computer (8); PLC (6) is connected with display alarm system (7), PC host computer (8) and servo drive system (9) respectively; Wherein display alarm system (7) comprises touch display screen, alarm lamp and buzzer.The present invention when centreless grinding machine internal feed, can detect that the accident of emery wheel and workpiece is touched real-time and accurately, thus controls the feeding of servo-drive system stopping emery wheel in time, prevents pernicious collision, and on alarm display apparatus, shows relevant information and warning.
Description
Technical field
The present invention relates to a kind of online anti-collision monitoring device of centerless internal grinder.
Background technology
In modern grinding, automated system can complete feed and process automatically according to setting, can reduce extraneous the intervention like this, eliminates people because of error, improves the quality of intensely processed products.But owing to lacking on-line monitoring system, likely collide with workpiece during emery wheel feeding, not only create defective work like this, also can damage emery wheel or machine, and then cause the interruption of production.Particularly in miniature bearing Speed Grinding, because bearing aperture is smaller, the relative positioning of emery wheel and bearing requires more to increase; And in emery wheel High Rotation Speed, once collide, will be very serious to the damage of system.Therefore, need a kind of online anti-collision monitoring device of centerless internal grinder, emery wheel and workpiece meet accident contact time, monitor this activation signal in time, and determine whether collision, if collision then controls emery wheel rebound in time, stop the generation of pernicious collision, this supervising device must have very low False Rate simultaneously, to reduce unnecessary loss.
Sound emission (AE, AcousticEmission) detection technique is the Dynamic Non-Destruction Measurement technology that a kind of highly sensitive, Hz-KHz is wide, contain much information, and have in real time, the feature of online and whole detection.The characteristic parameter of the AE signal occurred when utilizing Materials Fracture or touch mill and change thereof can judge the generation and the intensity that rupture or touch mill.AE detection technique based on this principle has technical research widely and application in fields such as petrochemical industry, electric power, aviation, metallurgy, traffic, machineries.But due to the diversity in AE source and the complexity of noise jamming, the feature recognition and extraction of AE is a more scabrous problem.
In the prior art, CN88103673.0 patent of invention proposes a kind of acoustic emission detection system of product, and it utilizes impulse generator and time window measurement component to obtain acoustic emission signal; CN91233425.8 utility model patent proposes a kind of sound emission grinding contact detecting device, and it utilizes peakvalue's checking to judge the method that collision occurs; The signal processing of these methods is too simple, and its accuracy is difficult to the needs meeting Speed Grinding.And CN200780019078.6 patent of invention proposes a kind of for damaging the apparatus and method detected, collision detection can not be applicable to; Other collision monitoring device based on calibrate AE sensor some only by crest, amplitude as criterion judge collision, its accuracy and reliability lower, particularly under strong noise environment, be easy to judge by accident, cause the loss of time; And some does not propose the algorithm of concrete judgement collision, operability and practicality cannot be satisfactory; Also some is for the processing mode of other kinds, and the high speed centerless internal grinding for miniature bearing lasso has certain limitation.
Therefore, be necessary the online anti-collision monitoring device proposing a kind of like this centerless internal grinder, it can by judging whether can collide, prevent the generation of pernicious collision, and False Rate is dropped to minimum level to the monitoring of AE signal and machining state and analysis; And this supervising device can be applied in the high-speed grinding of miniature bearing lasso, and there is higher real-time and accuracy.
Summary of the invention
The object of the present invention is to provide a kind of centerless internal grinder, particularly in the Speed Grinding of miniature bearing, can monitor and prevent emery wheel and workpiece from colliding accurately and effectively, based on the online anti-collision monitoring device of sound emission.
In order to achieve the above object, the online anti-collision monitoring device of centerless internal grinder of the present invention comprises following several part: on the work mounting s of centreless grinding machine internal, install a sound emission (AE) sensor (1), its output signal line is connected with preamplifier (2); Preamplifier (2) is connected with wave filter (3); Wave filter (3) is connected with A/D converter (4); A/D converter (4) is connected with DSP (5); DSP (5) is connected with PLC (6); DSP (5) is connected with PC host computer (8); PLC (6) is connected with display alarm system (7), PC host computer (8) and servo drive system (9) respectively; Wherein display alarm system (7) comprises touch display screen, alarm lamp and buzzer.
Described calibrate AE sensor is arranged on the work mounting s of the work stage of miniature bearing lasso high speed grinding machine, towards grinding area, to collide between the acoustic emission signal produced when can receive emery wheel and absorption surface and other component or liquid, Noise and Interference signal that friction etc. produces.Its general incoming frequency is 100KHz-400KHz.
The vitals that described preamplifier (putting before abbreviation) is acoustic emission detection system, its Main Function, for improving signal to noise ratio, ensures high-gain and low noise.Due in miniature high-speed grinding system, acoustic emission detection is carried out usually in the environment of stronger mechanical noise (frequency band is usually less than 50KHz), liquid noise (the usual 100KHz-1MHz of frequency band) and electrical noise, also requires that preamplifier has certain strong anti-interference ability and the ability of restraint speckle.Before to put be analog circuit, be input as the voltage signal that calibrate AE sensor exports, export as the analog signal after amplifying.
Described wave filter is the bandpass filter that the acoustic emission signal of applicable emery wheel and absorption surface gathers, and the noise signal that mixes of the various Frequency and Amplitude in signal farthest can be rejected, and extracts certain band signal required for monitoring.
Described A/D converter is the device of the data signal analog signal of input being converted to output, and its data signal exported can input DSP and carry out signal transacting.
Described DSP (DigitalSignalProcessor, digital signal processor) is a kind of microprocessor with special construction, has powerful data-handling capacity and the high speed of service.In this device, rely on data processing and high-speed computation ability that DSP is powerful, the real-time digital signal processing algorithm of high speed can be realized to the data signal inputted from A/D converter, accurately extract the characteristic parameter judging collision, ensure good real-time.
Described PLC (ProgrammableLogicController, programmable logic controller (PLC)) is a kind of electronic control system of digital operation.This device PLC used is the control system PLC that this supervising device of application carries out the centreless grinding machine internal of online anticollision monitoring, and does not need to configure PLC separately, reduces cost.Described PLC is made up of CPU module, power module, digital input module, digital output module and communication module.Described digital input module is connected with DSP, receives the data signal that DSP sends; Described digital output module is connected with servo-driver, alarm lamp and buzzer; Described PLC is connected with touch display screen by communication module; Described PLC is connected with PC host computer by communication module.PLC receives the contact event handling result of DSP, again according to emery wheel feeding state flag bit, judge whether it is the accident contact event occurred in the process of emery wheel feeding, if so, then think and pernicious collision will occur, now PLC will send it back immediate skip to servo-drive system, and send display alarm instruction to display alarm system, meanwhile, PLC sends signal to PC, and PC will record detection signal and warning; Otherwise PLC will be failure to actuate.
Described servo-drive system is the servo-drive system that this supervising device of application carries out the control grinding wheel spindle feed motion of the centreless grinding machine internal of online anticollision monitoring.Described servo-drive system comprises servo-driver and servomotor.Described servomotor is connected with ball screw by decelerator, and ball screw is connected with grinding wheel spindle.PLC sends instruction to servo-driver, and servo-driver controls servomotor to be stopped, and through transmission system, controls grinding wheel spindle rebound in time, just can prevent emery wheel and workpiece from colliding in time.
Described display alarm system is the display alarm system that this supervising device of application carries out the centreless grinding machine internal of online anticollision monitoring.Described display alarm system comprises touch display screen, alarm lamp and buzzer.After described touch display screen receives the display alarm instruction of PLC, on touch display screen, display alarm content will remind operating personnel, described alarm lamp will glimmer until alarm release simultaneously, and described buzzer will pipe until alarm release always.
Described PC host computer is the PC host computer that this supervising device of application carries out the centreless grinding machine internal of online anticollision monitoring.Described PC host computer receives the signal that PLC sends, record monitoring result and warning message; Described PC host computer receives and stores the signal data of DSP collection; The alarm logging of storage and signal data are associated by described PC host computer.
The present invention is divided into signals collecting by workflow, analyzes judgement, controls to report to the police and record file four-stage.The operation principle in each stage is as follows.
Signals collecting: calibrate AE sensor is arranged on the work mounting s of work stage, towards grinding area, gathers the acoustic emission signal of grinding area always; The signal input preamplifier collected, increases signal strength signal intensity; Then input filter, removes most Noise and Interference, chooses the signal band of needs; The analog signal obtained input a/d converter again, is converted to data signal.
Analyze and judge: data signal input DSP, by predetermined time window by signal subsection, often obtain the signal segment of a full time window, calculate the energy value of this signal segment at once, try to achieve mean value divided by time window length again, obtain the Time Domain Processing result of this segment signal section; The threshold range (this threshold range is determined by experiment) of this result and setting is contrasted; If the result that continuous three signal segments (this is to prevent impulse disturbances) obtain all has exceeded the threshold range of setting, so illustrate and collected activation signal, now a certain digital signal input ports to PLC is sent high level signal by DSP, points out the generation of this situation; Otherwise DSP does not send signal to PLC.After the above-mentioned digital signal input ports of PLC receives the high level signal of DSP, the hardware interrupts OB40 triggered by the rising edge of this high level signal is triggered.In this interruption OB40, PLC checks the grinding wheel spindle feeding state flag bit of now grinding machine, if this contact event occurs when grinding wheel spindle feeding, then judges that there occurs emery wheel contacts with the accident of workpiece, and pernicious collision will occur; If occurred at other times, be then judged as normal contact, do not process.
Control to report to the police: this analyzes the judgement stage to judge to collide the working stage that Shi Caihui carries out.When judging to collide, the subprogram that the hardware interrupts OB40 that PLC is triggered will call for anticollision; On the one hand, PLC sends it back immediate skip to servo-driver, controls grinding wheel spindle rebound, prevents the generation of pernicious collision; On the other hand, PLC sends information to display alarm system, and touch display screen will show these abnormal conditions; Meanwhile, alarm lamp and buzzer is started.
Record files: this analyzes the judgement stage to judge to collide the working stage that Shi Caihui carries out.When judging to collide, PLC sends warning message to PC host computer, this warning message of PC host computer record.Meanwhile, data signal can be sent to PC host computer and be recorded as signal data by PC host computer by DSP.Warning message and signal data are associated file by PC host computer.
Compared with prior art, tool of the present invention has the following advantages:
1) Real-Time Monitoring, response rapidly
Calibrate AE sensor is always in running order, ceaselessly collection signal, and DSP computing at a high speed ensure that the real-time of signal transacting, once find the contact of grinding wheel spindle and workpiece, notice PLC makes a response at once.And when PLC receives the signal come in contact, after collision judgment, send instruction, pernicious collision of taking measures to prevent immediately to servo-drive system and display alarm system, and this is reported to the police to send information record to PC.Whole process full automation.
2) accuracy of judgement, False Rate is low
This device adopts calibrate AE sensor collection signal, is a kind of dynamic check method, very sensitive for dynamic defect.This method sets threshold range for the judgement of abnormal signal based on lot of experimental data, can obtain the judgement that accuracy is very high, coordinates the machining state auxiliary judgment of PLC, further reduces other contact interference, reduces False Rate.
3) with strong points, cost is lower
This device is for centreless grinding machine internal, designed by the high-speed grinding of particularly miniature bearing lasso, its sampling and analysis of signal determination methods also with this type grinding machine for experimental subjects, the data processing method be determined by experiment farthest improves the accuracy of judgement, is well applicable to this type grinding machine.And the control system assembly of this type grinding machine directly used by the assembly such as PLC, servo-drive system, PC host computer, touch display screen of this device, and fringe cost is lower.In addition, this device also can be transplanted in similar mechanical processing machine, needs to change signal characteristic abstraction parameter and threshold value setting etc., has certain portability.
4) waveform files, check analysis
The data that the acoustic emission signal of this device gathers can stored in PC host computer, so that experiment or the comparative analysis safeguarded, the record of warning message also facilitates supervision for workshop lathe and maintenance.
Accompanying drawing explanation
Fig. 1 is structural representation of the present invention;
Fig. 2 is that of the present invention not being in the mood for clamps and AE sensor set-point schematic diagram;
Fig. 3 is PLC wiring schematic diagram of the present invention;
Fig. 4 is interrupt routine schematic diagram of the present invention;
Fig. 5 is method flow schematic diagram of the present invention.
In Fig. 1: 1, sound emission (AE) sensor; 2, preamplifier; 3, wave filter; 4, A/D converter; 5, DSP; 6, PLC; 7, display alarm system; 8, PC host computer; 9, servo drive system; 10, servomotor; 11, ball screw; 12, grinding wheel spindle motor; 13, emery wheel; 14, workpiece; 15, left wheel; 16, work mounting s; 17, work stage.
In Fig. 2: 1, sound emission (AE) sensor; 13, emery wheel; 14, workpiece; 15, left wheel; 16, work mounting s; 17, work stage; 18, right roller; 19, road is expected; 20, charging ram; 21, backboard; 22, front apron.
Detailed description of the invention
The structural representation of the online anti-collision monitoring device of a kind of centerless internal grinder of the present invention as shown in Figure 1, in the apparatus, the work mounting s of centreless grinding machine internal installs a sound emission (AE) sensor (1), and its output signal line is connected with preamplifier (2); Preamplifier (2) is connected with wave filter (3); Wave filter (3) is connected with A/D converter (4); A/D converter (4) is connected with DSP (5); DSP (5) is connected with PLC (6); DSP (5) is connected with PC host computer (8); PLC (6) is connected with display alarm system (7), PC host computer (8) and servo drive system (9) respectively; Wherein display alarm system (7) comprises touch display screen, alarm lamp and buzzer.
The specific implementation method of each several part is as follows:
1) calibrate AE sensor, for measuring the stress wave that grinding area produces, can adopt SR150C type calibrate AE sensor.This sensor is of a size of φ 19 × 19.5, weight 28g, and sheathing material is stainless steel, and receiving surface is pottery, and interface position is in upper surface, and signal frequency range is 60 ~ 400KHz, resonant frequency 150KHz, and sensitivity is greater than-65dB.Acoustic emission signal after preamplifier and wave filter, exports A/D converter to successively.
2) preamplifier and wave filter: for carrying out filtering to grinding area acoustic emission signal and amplifying process, the PAI type wideband pre-amplifier supporting with SR150C type calibrate AE sensor can be adopted.The bandwidth of this wideband pre-amplifier is 10KHz ~ 2MHz, gain 40dB ± 1dB, dynamic range is greater than 74dB, undistorted output Vpp is greater than 13V, maximum output Vpp is greater than 20V, maximum input Vpp is greater than 200mV, and input impedance is greater than 50M Ω, output impedance 50 Ω, input mode is single ended input, power reguirements 28V direct current 100mA, quiescent current 20 ~ 25mA, transmitted pulse output amplitude-24V, transmitted pulse triggering-24V, physical dimension 116 × 36 × 30mm, sheathing material is cast aluminium, and interface type is BNC.Preamplifier comprises constrained input port, input port connecting acoustic emission sensor, and output port connects wave filter, the output access A/D converter of wave filter.
3) A/D converter: the analog signal for being picked out by wave filter is converted to data signal, and access DSP calculation process.The AD7952 type A/D converter that ADI company can be adopted to produce, voltage inputs, and input range is optional :+5V (10Vp-p) ,+10V (20Vp-p), ± 5V (20Vp-p), ± 10V (40Vp-p); ADC throughput rate is 1MSPS, and resolution ratio is 14-bit, and signal to noise ratio is 85dB2kHz, power consumption 235mW1MSPS and 10mW1kSPS, parallel 14 or 8 BITBUS network, and serial 5V or 3V interface, export DSP compatible, operating temperature-40 DEG C to+85 DEG C.A/D converter is connected with DSP with DSP compatibility interface.
4) DSP: for the data signal of calculation process A/D converter access, judge whether to come in contact, and export result to PLC.ADSP-2181 type DSP can be adopted, 16bit, instruction cycletime is 25ns, 20MHz crystal, 40MIPS duration performance, core voltage 5V, comprise the architecture of ADSP-2100 series and dual serial port, one 16 inner DMA ports, byte DMA port, a programmable interval timer etc., be integrated with the RAM of 80K byte, comprise 16K program RAM and 16K data RAM, have 4MB memory interface.
5) PLC: for receiving the contact prompting of DSP, and whether the pernicious collision of emery wheel and workpiece can be occurred by grinding wheel spindle feeding state flag bit auxiliary judgment, sending display alarm instruction and SERVO CONTROL instruction, and sending warning message to PC host computer.The control system PLC of centreless grinding machine internal can be adopted, as S7-300, CPU model is 312, and the instruction process time is bit instruction 0.1 μ s, word instruction 0.24 μ s, integer arithmetic 0.32 μ s, floating point arithmetic 1.1 μ s, digital quantity passage 256I/256O, analog quantity channel 64I/64O, internal memory 32kB, built-in RS485 interface.
6) touch display screen: for receiving the alarm command of PLC, display alarm information.The control system touch display screen of centreless grinding machine internal can be adopted, as SIMATICTP277, all-graphic 5.7 " TFT display screen; 256 looks, resolution ratio 320 × 240, user memory 4MB; integrated RS422/485 interface, USB interface and Ethernet interface, software clock, DC24V power supply.
Of the present invention be not in the mood for clamping and AE sensor set-point schematic diagram be installed on work mounting s (16) as Fig. 2, AE sensor (1), face workpiece grinding area.
PLC wiring schematic diagram of the present invention, as Fig. 3, shows in supervising device of the present invention, the connected mode of PLC and other equipment.As shown in the figure, PLC is connected with touch display screen and PC host computer by multipoint interface (MPI), and wherein, PC host computer needs MPI/PC adapter to connect; PLC is connected with DSP and servo-driver by input/output module.Wherein, be contact alarm signal from the signal of DSP input, namely can interrupt the high level signal of OB40 by trigger hardware; The signal exported to DSP removes alarm signal; The signal exported to servo-driver is startup, pulse, direction, stop signal; The signal inputted from servo-driver is Ready, fault, feedback signal.DSP is connected by RS485 and PLC.
Interrupt routine schematic diagram of the present invention is as Fig. 4, this is a hardware interrupts OB40 triggered by the rising edge signal of some digital signal input ports of PLC, the high level signal (namely contact alarm signal) of above-mentioned digital signal input ports for sending to PLC after receiving DSP and monitoring contact.In this hardware interrupts OB40, M7.0 is grinding wheel spindle feeding state flag bit, and 1 is just in feeding, and 0 for not having feeding; FB18 is emery wheel rebound subprogram; FB20 is display alarm subprogram.In PLC scan round process, when DSP sends high level signal to above-mentioned digital signal input ports, this hardware interrupts OB40 is triggered, if now M7.0=1, then calls FB18 and FB20, completes rebound and display alarm; If now M7.0=0, then never call FB18 and FB20; Exit hardware interrupts OB40, continue main program cycle scanning.
Method flow diagram of the present invention is as Fig. 5, and its job step is:
1) by AE sensor Real-time Collection grinding area acoustic emission signal, preamplifier is transported to;
2) carry out amplification by preamplifier to described signal to process, the above-mentioned signal after process is input to wave filter;
3) by wave filter, filtering process is carried out to described signal, the above-mentioned signal after process is input to A/D converter;
4) by A/D converter, described signal is converted to data signal, the above-mentioned signal after process is input to DSP;
5) by DSP, described signal is carried out Time Domain Piecewise process, often receive a complete signal segment, will calculate the signal energy mean value of this signal segment, and the result obtained be compared with threshold value, if exceed threshold value, then the number of times exceeding threshold value adds one; Otherwise the number of times exceeding threshold value resets;
6) whether the number of times exceeding threshold value described in DSP judges reaches three times, if so, then judge have contact event to occur, meanwhile, described in exceed threshold value number of times clearing; Otherwise, be failure to actuate;
7) when DSP judges have contact event to occur, DSP will send high level digital signal to a certain digital signal input ports of PLC;
8) when the above-mentioned digital signal input ports of PLC receives the described high level signal from DSP, the rising edge trigger hardware of this signal interrupts OB40, PLC scan round suspends, enter hardware interrupts OB40 program, now will check that whether current grinder wheel axle is in feeding, if so, PLC judges pernicious collision will occur, and performs rebound and warning subprogram; Otherwise PLC ignores the described high level signal from DSP;
9) when PLC performs rebound and warning subprogram, instruction will be sent respectively to servo drive system, touch display screen, alarm lamp, buzzer;
10) when servo drive system receives the rebound instruction of described PLC transmission, control servomotor is stopped and reversing, grinding wheel spindle is knock-oned, until alarm release;
11) when touch display screen receives the alarm command of described PLC transmission, by display alarm information, until alarm release;
12) when alarm lamp receives the alarm command of described PLC transmission, will glimmer, until alarm release always;
13) when buzzer receives the alarm command of described PLC transmission, will pipe, until alarm release always;
14) after warning starts, the data signal gathered when coming in contact event is delivered to PC host computer and stores by DSP;
15) after warning starts, PLC sends warning message and stores to PC host computer;
16) warning message that the described sound emission data signal that gathered by DSP and described PLC are sent is associated and files by PC host computer.
Claims (2)
1. the online anti-collision monitoring device of a centerless internal grinder, it is characterized in that being included in upper installation sound emission (AE) sensor (1) of work mounting s (16) of this centreless grinding machine internal, the output signal line of sound emission (AE) sensor (1) is connected with preamplifier (2), preamplifier (2) is connected with wave filter (3), wave filter (3) is connected with A/D converter (4), A/D converter (4) is connected with DSP (5), DSP (5) is connected with PLC (6), DSP (5) is connected with PC host computer (8), PLC (6) respectively with display alarm system (7), PC host computer (8) is connected with servo drive system (9), display alarm system (7) comprises touch display screen, alarm lamp and buzzer, its anticollision monitor procedure comprises the steps:
1) DSP gathers the data signal section in a time window;
2) average energy of all sampled points in above-mentioned time window is calculated;
3) more above-mentioned average energy result of calculation and threshold value, if result of calculation exceeds threshold range, then the number of times exceeding threshold value adds one; Otherwise the number of times exceeding threshold value resets;
4) if the above-mentioned number of times exceeding threshold value reaches a certain digital signal input ports transmission high level signal of 3, DSP to PLC; The number of times exceeding threshold value resets;
5) 1 is repeated) ~ 4);
6) if the above-mentioned digital signal input ports of PLC detects then enter hardware interrupts OB40 program by the rising edge that above-mentioned high level signal produces;
7) in above-mentioned OB40 program, if grinding wheel spindle feeding state flag bit is just in feeding, then rebound and warning subprogram is performed; Otherwise, stop interrupt routine OB40, continue scan round PLC main program.
2. use the online anti-collision monitoring device of a kind of centerless internal grinder described in claim 1, it is characterized in that the method that it controls grinding wheel spindle rebound comprises the steps:
1) PLC sends it back immediate skip to servo-driver;
2) servo-driver controls servomotor revolution certain hour;
3) servomotor makes grinding wheel spindle rebound certain displacement by the transmission of decelerator, ball screw.
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| CN105881120A (en) * | 2014-12-31 | 2016-08-24 | 无锡索立源机床制造有限公司 | Numerical control vertical internal grinding machine structure |
| CN109420939A (en) * | 2017-08-30 | 2019-03-05 | 南京锦冠汽车零部件有限公司 | A kind of automobile shafts processing automation equipment for grinding |
| TWI716849B (en) | 2019-04-10 | 2021-01-21 | 財團法人工業技術研究院 | Method and system for predicting collision detection of machining path |
| CN113909713B (en) * | 2021-11-05 | 2024-03-29 | 泰尔重工股份有限公司 | Anti-collision protection system and method for laser processing |
| CN115139169A (en) * | 2022-08-09 | 2022-10-04 | 肇庆高峰机械科技有限公司 | Control system for numerical control vertical single-side grinding machine for large square |
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| CN101670553A (en) * | 2009-09-28 | 2010-03-17 | 浙江大学 | External grinding multiparameter integrated quality monitoring device and method |
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