CN105234746A - Online tool wear monitoring system and detection method thereof - Google Patents
Online tool wear monitoring system and detection method thereof Download PDFInfo
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- CN105234746A CN105234746A CN201510828178.XA CN201510828178A CN105234746A CN 105234746 A CN105234746 A CN 105234746A CN 201510828178 A CN201510828178 A CN 201510828178A CN 105234746 A CN105234746 A CN 105234746A
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- Prior art keywords
- sensor
- monitoring system
- spindle motor
- tool wear
- signal processor
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
- B23Q17/0952—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
- B23Q17/0957—Detection of tool breakage
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
- B23Q17/0952—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
- B23Q17/0961—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining by measuring power, current or torque of a motor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
- B23Q17/0952—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
- B23Q17/0971—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining by measuring mechanical vibrations of parts of the machine
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Numerical Control (AREA)
Abstract
The invention discloses an online tool wear monitoring system and a detection method thereof. The online tool wear monitoring system comprises a current sensor, a voltage sensor, a vibration sensor, a sensor module, a signal processor and an industrial control all-in-one machine. The detection method comprises steps of hardware installation, system sampling and real-time monitoring. Under the premise that a machining cycle is not influenced, various failure modes including wear, tool rolling, chip clamping, tipping, damage, repeated machining, procedure missing, equipment aging and loading position errors of a tool and a machining technology are monitored online in real time, various product failures caused by the tool are prevented, shutdown detection is not needed, and the tool wear condition is monitored in real time in the machining process, so that the production efficiency is improved; meanwhile, by means of a wireless transmission module, a manager can confirm the machining state in real time in an office room, carries out remote control and sets various parameters of the monitoring system.
Description
Technical field
The present invention relates to Tool Wear Monitoring in machining, diagnosis and maintenance field, particularly relate to a kind of tool wear online monitoring system and detection method thereof.
Background technology
The mode of the plant equipment monitoring such as present lathe, milling machine, machining center, special machine comprises following several: 1, contact Tool Breakage Monitoring and infrared ray Tool Breakage Monitoring, this system can monitor drill bit, screw tap, milling cutter complete breakage but cannot monitor other tool failure, such as blade, cutterhead, reamer, lathe tool, hole boring cutter etc.And part tipping or wearing and tearing cannot monitor, most importantly increase process time, 2, operator is judged by the experience of oneself and determines whether are cutting-tool wear state and sustainable use, the method is without scientific basis, dangerous, 3, converted products method of counting (pressure tool changing) prevents tool failure, but the method can not guarantee each cutter, and (some cutter is long for service time service life, some stage property life-span is shorter), the waste cost of charp tool; 4, by checking that product size is prevented or judges cutter situation, but cannot 100% entirely to examine.
Summary of the invention
For solving the problems of the technologies described above, the present invention proposes a kind of tool wear online monitoring system, comprising
Current sensor: described current sensor is installed on machining spindle motor, for detecting the electric current in Spindle Motor running;
Voltage sensor: described voltage sensor is installed on machining spindle motor, for detecting the voltage in Spindle Motor running;
Shock sensor: described shock sensor is installed on machine spindle motor or product clamper, for the vibration frequency in real-time collecting Spindle Motor process;
Sensor assembly: described sensor assembly is connected with described current sensor, voltage sensor, shock sensor, for collected current, magnitude of voltage, automatic conversion relative load value, and the processing signal of reception and process equipment and cutter signal;
Signal processor: described signal processor is connected with described sensor assembly, for receiving and the data of analyte sensors module and the start and stop signal of equipment;
Industrial control all-in-one machine: described industrial control all-in-one machine is communicated with described signal processor, described industrial control all-in-one machine comprises display module and storage module, the signal received is converted to load chart by display module, monitored the various failure modes of cutter by setting margin line, storage module is for storing all process datas and fail data.
Preferably, described Spindle Motor is provided with u interface, V interface, W interface, and described voltage sensor is connected on u interface, V interface, W interface.
Preferably, described current sensor is connected on u interface.
Preferably, described industrial control all-in-one machine is also provided with wireless transport module, described wireless transmissions module by signal remote transmission on computer.
A detection method for tool wear online monitoring system, comprises the following steps:
1) hardware installation: the maximum service rating of record process equipment and minimum operating power, current sensor and voltage sensor are installed on Spindle Motor, sensor assembly is connected on current sensor and voltage sensor, be connected with signal processor by sensor assembly, signal processor is connected with industrial control all-in-one machine;
2) systematic sampling: get 2-3 sample and process, the data that current sensor and voltage sensor receive transfer to sensor assembly, calculate operating power, and be sent to signal processor, signal processor is sent to industrial control all-in-one machine after receiving power information and starting or stoping information, be compiled into load curve to show on display module, storage load curve data simultaneously, through repeated detection, the factors such as sample tool wear, choose in the data of record that load is reached the standard grade, rolled off the production line, acceptance line stores;
3) Real-Time Monitoring: decline according to the actual data that detect or rise, skew, extremely beat when causing encountering the margin line set, whether system will report to the police and point out and will shut down, and during selection "Yes", equipment will be shut down at once.
The tool wear online monitoring system that the present invention proposes and detection method thereof have following beneficial effect: the present invention is under the prerequisite not affecting the process-cycle, the various failure modes of real time and on line monitoring cutter and processing technology comprise wearing and tearing, volume cutter, folder bits, tipping, damaged, repeat processing, lose operation, ageing equipment, material loading positional fault, the various product failures that prevention cutter causes, detect without the need to shutting down, tool wear situation is monitored in real time in process, enhance productivity, simultaneously, make manager can in the various parameters of office's real-time confirmation machining state and Long-distance Control and setting monitoring system by wireless transport module.
Accompanying drawing explanation
In order to be illustrated more clearly in the technical scheme in the embodiment of the present invention, below the accompanying drawing used required in describing embodiment is briefly described.
Fig. 1 is the structural representation of the embodiment of the present invention 1;
Fig. 2 is the schematic diagram of embodiments of the invention 2;
Fig. 3 is the load curve schematic diagram under the present invention detects cutter normal mode;
Fig. 4 is the load curve schematic diagram that the present invention detects tool wear;
Fig. 5 is the load curve schematic diagram that the present invention detects tool failure;
Fig. 6 is M signal schematic representation of the present invention;
Wherein, 1-Spindle Motor, 2-current sensor, 3-voltage sensor, 4-shock sensor, 5-sensor assembly, 6-signal processor, 7-industrial control all-in-one machine, 8-M signal, 9-cutter head.
Detailed description of the invention
Below in conjunction with the accompanying drawing in the embodiment of the present invention, the technical scheme in the embodiment of the present invention is clearly and completely described.
Embodiment 1
As shown in Figure 1, a kind of tool wear online monitoring system, comprises current sensor 2: described current sensor 2 is installed on machining spindle motor 1, for detecting the electric current in Spindle Motor 1 running, voltage sensor 3: described voltage sensor 3 is installed on machining spindle motor 1, for detecting the voltage in Spindle Motor 1 running, wherein Spindle Motor 1 is provided with u interface, V interface, W interface, described voltage sensor 3 is connected to u interface, V interface, on W interface, for detecting the magnitude of voltage of motor in process, described current sensor 2 is connected on u interface, for detecting the current value of motor, sensor assembly 5 connects and accepts Current Voltage value, calculate and calculate relative value power according to Current Voltage change, pass to signal processor 6, signal processor 6 is that these data are sent to industrial control all-in-one machine 7, the data that industrial control all-in-one machine 7 receives each each cutter of product in real time convert load chart in real time according to software,
Signal processor 6: described signal processor 6 is connected with described sensor assembly 5, for receiving and the data of analyte sensors module 5 and the start and stop signal of equipment; Industrial control all-in-one machine 7: described industrial control all-in-one machine 7 is communicated with described signal processor 6, described industrial control all-in-one machine 7 comprises display module and storage module, the signal received is converted to load chart by display module, the various failure modes of cutter are monitored by setting margin line, storage module is for storing all process datas and fail data
Signal processor 6 also receives the M signal 8 that equipment sends, and M signal 8 being sent to industrial control all-in-one machine 7, M signal 8 is start to distinguish processing and terminate, and often cutter is started the signal processing and terminate processing, figure is as Fig. 6 in its signal analysis.
Get 2-3 sample processing, along with processing quantity rising cutter starts wearing and tearing, tool wear cutting resistance increases, the synthetic load of Spindle Motor 1 also rises thereupon, when load rises to and to a certain degree causes tool failure, canonical loading falls down quickly, repeat to add work hour load also will decline, also will give birth to or decline during raw material firmness change, reached the standard grade by this principle assumed load in system, roll off the production line, the margin lines such as acceptance line, and then the state such as the wearing and tearing of detection cutter and breakage, the normal mode load chart for cutter is as shown in Figure 3 schemed as a comparison, when worn, as Fig. 4, load line rises, as shown in Figure 5, when tool failure, load line moves down, when touching the warning line of setting, system alarm.
Load chart declines or rises, whether skew, extremely system when causing encountering the margin line set of beating will report to the police and point out and will shut down, and when selection is, equipment will be shut down at once.
Embodiment 2
On the basis of embodiment 1, as Fig. 2 has also set up shock sensor 4, described shock sensor 4 is installed on machine spindle motor 1 or product clamper, for the vibration frequency in real-time collecting Spindle Motor 1 process, as shown in Figure 1, be connected to processing work or cutter place, shock sensor 4 is in sensor assembly 5, sensor assembly 5 is connection signal processor 6 again, vibration signal is sent to industrial control all-in-one machine 7 by signal processor 6, convert the load curve of vibrations to, the power output of the variable effect motor of cutting resistance and audio frequency, by above-mentioned wearing and tearing or breakage because usually detecting cutter.
Embodiment 3
On the basis of embodiment 2, industrial control all-in-one machine 7 has set up wireless transport module, by wireless transport module by the Signal transmissions of all detections on computer, manager can in the various parameters of office's real-time confirmation machining state and Long-distance Control and setting monitoring system.
Embodiment 4
According to the detection method of a kind of tool wear online monitoring system of this structure, comprise the following steps:
1) hardware installation: the maximum service rating of record process equipment and minimum operating power, current sensor 2 and voltage sensor 3 are installed on Spindle Motor 1, sensor assembly 5 is connected to current sensor 2 with on voltage sensor 3, be connected with signal processor 6 by sensor assembly 5, signal processor 6 is connected with industrial control all-in-one machine 7;
2) systematic sampling: get 2-3 sample and process, the data that current sensor 2 and voltage sensor 3 receive transfer to sensor assembly 5, calculate operating power, and be sent to signal processor 6, signal processor 6 is sent to industrial control all-in-one machine 7 after receiving power information and starting or stoping information, be compiled into load curve to show on display module, storage load curve data simultaneously, through repeated detection, the factors such as sample tool wear, choose in the data of record that load is reached the standard grade, rolled off the production line, acceptance line stores;
3) Real-Time Monitoring: decline according to the actual data that detect or rise, skew, extremely beat when causing encountering the margin line set, whether system will report to the police and point out and will shut down, and during selection "Yes", equipment will be shut down at once.
To be apparent for those skilled in the art to the multiple amendment of embodiment, General Principle as defined herein can without departing from the spirit or scope of the present invention, realize in other embodiments.Therefore, the present invention can not be restricted to these embodiments shown in this article, but will meet the widest scope consistent with principle disclosed herein and features of novelty.
Claims (5)
1. a tool wear online monitoring system, is characterized in that, comprises
Current sensor: described current sensor is installed on machining spindle motor, for detecting the electric current in Spindle Motor running;
Voltage sensor: described voltage sensor is installed on machining spindle motor, for detecting the voltage in Spindle Motor running;
Shock sensor: described shock sensor is installed on machine spindle motor or product clamper, for the vibration frequency in real-time collecting Spindle Motor process;
Sensor assembly: described sensor assembly is connected with described current sensor, voltage sensor, shock sensor, for collected current, magnitude of voltage, automatic conversion relative load value, and the processing signal of reception and process equipment and cutter signal;
Signal processor: described signal processor is connected with described sensor assembly, for receiving and the data of analyte sensors module and the start and stop signal of equipment;
Industrial control all-in-one machine: described industrial control all-in-one machine is communicated with described signal processor, described industrial control all-in-one machine comprises display module and storage module, the signal received is converted to load chart by display module, monitored the various failure modes of cutter by setting margin line, storage module is for storing all process datas and fail data.
2. tool wear online monitoring system according to claim 1, is characterized in that, described Spindle Motor is provided with u interface, V interface, W interface, and described voltage sensor is connected on u interface, V interface, W interface.
3. tool wear online monitoring system according to claim 2, is characterized in that, described current sensor is connected on u interface.
4. tool wear online monitoring system according to claim 1, is characterized in that, described industrial control all-in-one machine is also provided with wireless transport module, described wireless transmissions module by signal remote transmission on computer.
5. a detection method for the tool wear online monitoring system as described in claim 1-3, is characterized in that, comprise the following steps:
S1: hardware installation: the maximum service rating of record process equipment and minimum operating power, current sensor and voltage sensor are installed on Spindle Motor, sensor assembly is connected on current sensor and voltage sensor, be connected with signal processor by sensor assembly, signal processor is connected with industrial control all-in-one machine;
S2: systematic sampling: get 2-3 sample and process, the data that current sensor and voltage sensor receive transfer to sensor assembly, calculate operating power, and be sent to signal processor, signal processor is sent to industrial control all-in-one machine after receiving power information and starting or stoping information, be compiled into load curve to show on display module, storage load curve data simultaneously, through repeated detection, the factors such as sample tool wear, choose in the data of record that load is reached the standard grade, rolled off the production line, acceptance line stores;
S3: Real-Time Monitoring: decline according to the actual data that detect or rise, skew, extremely beat when causing encountering the margin line set, whether system will report to the police and point out and will shut down, and during selection "Yes", equipment will be shut down at once.
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| CN201510828178.XA CN105234746A (en) | 2015-11-25 | 2015-11-25 | Online tool wear monitoring system and detection method thereof |
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|---|---|---|---|---|
| CN105834834A (en) * | 2016-04-21 | 2016-08-10 | 四川大学 | Milling cutter abrasion state monitoring method based on fruit fly optimization algorithm |
| CN106125667A (en) * | 2016-03-10 | 2016-11-16 | 上海永趋智能科技有限公司 | Digital control processing online monitoring system and method |
| CN107052903A (en) * | 2017-04-20 | 2017-08-18 | 南通国盛智能科技集团股份有限公司 | A kind of control method for ensureing processing constant load output |
| CN107363645A (en) * | 2017-08-21 | 2017-11-21 | 温州大学 | Milling machine process tool abrasion Forecasting Methodology based on power detection |
| CN108115206A (en) * | 2016-11-29 | 2018-06-05 | 日立汽车系统（中国）有限公司 | Method, control device and the system being processed using cutting tool to workpiece |
| CN108873814A (en) * | 2018-06-25 | 2018-11-23 | 深圳精匠云创科技有限公司 | Monitoring system, monitoring method and storage equipment |
| CN109129016A (en) * | 2018-10-22 | 2019-01-04 | 深圳大学 | A kind of knife-breaking detecting method and detection system of numerically-controlled machine tool |
| CN109352416A (en) * | 2018-12-05 | 2019-02-19 | 上海交通大学 | A kind of machine tool chief axis folder bits and/or cutter twine the alarm method and device of bits |
| CN109732405A (en) * | 2018-12-30 | 2019-05-10 | 深圳市五湖智联实业有限公司 | A kind of cutting tool for CNC machine side member calculates wear monitoring control system and method |
| CN110712066A (en) * | 2019-10-22 | 2020-01-21 | 湖南工学院 | Method suitable for monitoring cutter state in deep hole internal thread machining |
| CN111009103A (en) * | 2019-12-02 | 2020-04-14 | 上海道基环保科技有限公司 | Monitoring and alarming system and method for monitoring cutter head fracture condition in cutter drum on line |
| TWI704974B (en) * | 2019-10-30 | 2020-09-21 | 彭炘烽 | On-line processing measuring device for processing machine |
| CN111774932A (en) * | 2020-06-30 | 2020-10-16 | 华中科技大学无锡研究院 | Cutter health condition online monitoring method, device and system |
| CN111774933A (en) * | 2020-06-30 | 2020-10-16 | 华中科技大学无锡研究院 | Method for monitoring machine tool cutter in real time and automatically replacing backup cutter and real-time monitoring system for machine tool cutter |
| CN111774934A (en) * | 2020-06-30 | 2020-10-16 | 华中科技大学无锡研究院 | Cutter health condition monitoring method, device and system based on end-to-end model |
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| CN105834834A (en) * | 2016-04-21 | 2016-08-10 | 四川大学 | Milling cutter abrasion state monitoring method based on fruit fly optimization algorithm |
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| CN108873814A (en) * | 2018-06-25 | 2018-11-23 | 深圳精匠云创科技有限公司 | Monitoring system, monitoring method and storage equipment |
| CN109129016A (en) * | 2018-10-22 | 2019-01-04 | 深圳大学 | A kind of knife-breaking detecting method and detection system of numerically-controlled machine tool |
| CN109352416A (en) * | 2018-12-05 | 2019-02-19 | 上海交通大学 | A kind of machine tool chief axis folder bits and/or cutter twine the alarm method and device of bits |
| CN109352416B (en) * | 2018-12-05 | 2019-12-27 | 上海交通大学 | Alarming method and device for clamping chips of machine tool spindle and/or winding chips of cutter |
| CN109732405A (en) * | 2018-12-30 | 2019-05-10 | 深圳市五湖智联实业有限公司 | A kind of cutting tool for CNC machine side member calculates wear monitoring control system and method |
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| CN110712066A (en) * | 2019-10-22 | 2020-01-21 | 湖南工学院 | Method suitable for monitoring cutter state in deep hole internal thread machining |
| TWI704974B (en) * | 2019-10-30 | 2020-09-21 | 彭炘烽 | On-line processing measuring device for processing machine |
| CN111009103A (en) * | 2019-12-02 | 2020-04-14 | 上海道基环保科技有限公司 | Monitoring and alarming system and method for monitoring cutter head fracture condition in cutter drum on line |
| CN111774932A (en) * | 2020-06-30 | 2020-10-16 | 华中科技大学无锡研究院 | Cutter health condition online monitoring method, device and system |
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