CN108181125B - Machining center cutting fluid cooling system reliability test device - Google Patents

Abstract

The invention discloses a machining center cutting fluid cooling system reliability test device, which overcomes the problem that a laboratory reliability bench test aiming at a cooling system does not exist, and comprises a working condition simulation mechanism, a filtering mechanism, a cutting fluid conveying mechanism, a state monitoring alarm mechanism and an automatic control mechanism; the filtering mechanism comprises an electric control flow valve and a filter screen; the cutting fluid conveying mechanism comprises a cutting fluid water tank and a cutting fluid conveying pipe; the working condition simulation mechanism is positioned at the top end through the box body, the filtering mechanism is positioned below the working condition simulation mechanism, the cutting fluid conveying mechanism is positioned below the filtering mechanism, the filter screen is arranged on the box bottom of the box body, a pipeline connected with the electric control flow valve is inserted into the cutting fluid water tank, and the cutting fluid water tank is connected with the cutting fluid conveying pipe; the state monitoring and alarming mechanism is arranged in the working condition simulating mechanism, the filtering mechanism and the cutting fluid conveying mechanism, and the automatic control mechanism, the working condition simulating mechanism, the filtering mechanism, the cutting fluid conveying mechanism and the state monitoring and alarming mechanism are connected by signal lines.

Description

Machining center cutting fluid cooling system reliability test device

Technical Field

The invention relates to a testing device applied to the field of machining center cutting fluid cooling system reliability, in particular to a testing device for the machining center cutting fluid cooling system reliability.

Background

The processing center is basic manufacturing equipment for improving the national manufacturing level and equipment level, and is an important mark of the national industrial developed level and comprehensive national strength. The cutting fluid cooling system plays an important role in actual production as a commonly equipped device of a machining center. In the cutting process, the cutting fluid can cool the cutter and the workpiece, and reduce friction generated in cutting, so that the wear degree of the cutter is reduced, the surface quality of the workpiece is improved, and the effects of cooling, cleaning, lubricating and the like are achieved. In actual machining, the cutting fluid is generally recycled in order to reduce machining cost. The machining center is provided with a filtering system, a circulating system and a conveying system, so that the cutting fluid is conveyed to a water tank for continuous recycling after being subjected to deposition, filtration, oil-liquid separation and other processes after being used. However, in the machining process, due to reasons such as metal powder and impurities generated in the cutting process and lubricating oil on the surface of a workpiece, a circulating system is often blocked, so that the cutting fluid cannot be normally conveyed, and the normal use of a machining center is affected.

The small metal chips easily enter a circulating system along with cutting fluid, and if the small metal chips are not cleaned, the stability of equipment such as a water pump and the like is reduced, so that the filtering system generally has stronger filtering performance. If the diameter of the precipitated particles is very small, tiny metal powder can be continuously accumulated in a filtering system, and the viscosity of the cutting fluid is increased because the anti-rust oil coated on the surface of the processed workpiece blank is mixed in the cutting fluid under the flushing of the cutting fluid. When the cutting fluid passes through the filtering system, impurities such as oil stains and the like are bonded with tiny metal cuttings and are accumulated in the filtering system, so that a pipeline is blocked in time, the interruption of a circulating system is caused, and the whole machining center cannot work normally.

Because long-time use, many impurity can't be got rid of completely, simultaneously because high temperature, the not good reason of air permeability cause fungus such as mould to obtain good reproduction condition, and the cutting fluid has produced the dope, has increased its viscosity, causes key parts such as nozzle, pipeline, water pump to form and piles up, can continue to use after the light then mediation, and the heavy then leads to the pipeline to reveal, damages electron device, causes the serious trouble of complete machine.

So far, the reliability research on the cutting fluid cooling system of the machining center still stays in the stage of fault statistical analysis, and no corresponding bench test is carried out on the reliability research. Therefore, a device capable of simulating the working process of the cooling system is designed, and a scientific and reasonable reliability test on the device is very important.

Disclosure of Invention

The invention aims to solve the technical problem that a laboratory reliability bench test aiming at a cooling system is not available in the prior art, and provides a machining center cutting fluid cooling system reliability test device.

In order to solve the technical problems, the invention is realized by adopting the following technical scheme: the reliability test device for the cutting fluid cooling system of the machining center comprises a working condition simulation mechanism, a filtering mechanism, a cutting fluid conveying mechanism, a state monitoring alarm mechanism and an automatic control mechanism;

the working condition simulation mechanism comprises a box body;

the filtering mechanism comprises an electric control flow valve and a filter screen;

the cutting fluid conveying mechanism comprises a cutting fluid water tank and a cutting fluid conveying pipe;

the working condition simulation mechanism is arranged at the top end through the box body, the filtering mechanism is arranged below the working condition simulation mechanism, the cutting fluid conveying mechanism is arranged below the filtering mechanism, the filter screen is arranged on the bottom of the box body, a pipeline connected with the electric control flow valve is inserted into the cutting fluid water tank, and the cutting fluid water tank is connected with the lower end of the cutting fluid conveying pipe;

the state monitoring and alarming mechanism is arranged in the working condition simulation mechanism, the filtering mechanism and the cutting fluid conveying mechanism:

the state monitoring and alarming mechanism comprises a water pump temperature sensor, 6 cutting fluid pollution sensors with the same structure, 4 filtering device liquid level sensors with the same structure, a flow rate pressure gauge, an iron core temperature sensor, an intercepting water tank liquid level sensor, a cutting fluid water tank liquid level sensor, a liquid quality sensor and an alarm; the water pump temperature sensor is arranged on one side of a shell of the water pump in the cutting fluid conveying mechanism; 6 cutting fluid pollution sensors are respectively arranged in a first filtering device and a second filtering device in the filtering mechanism, 4 filtering device liquid level sensors with the same structure are respectively vertically arranged in the first filtering device and the second filtering device, one end of a flow pressure meter is connected with the top end of a cutting fluid conveying pipe, a connecting pipeline at the other end of the flow pressure meter is inserted into a box body, an iron core temperature sensor is arranged inside an iron core, an intercepting water tank liquid level sensor is arranged on one side wall of an intercepting water tank in the filtering mechanism, the cutting fluid tank liquid level sensor is arranged in a cutting fluid tank in the cutting fluid conveying mechanism, a liquid quality sensor is arranged at the bottom of the cutting fluid tank, and an alarm is arranged on a case of an upper industrial personal computer;

the automatic control mechanism, the working condition simulation mechanism, the filtering mechanism, the cutting fluid conveying mechanism and the state monitoring alarm mechanism are connected by signal lines:

the automatic control mechanism comprises an upper industrial personal computer, a data acquisition card, a lower programmable controller and an electromagnet controller; the upper industrial personal computer is connected with the data acquisition card, the upper industrial personal computer is connected with the lower programmable controller, and the upper industrial personal computer is connected with the electromagnet controller; a water pump temperature sensor, 6 cutting fluid pollution sensors with the same structure, 4 filtering device liquid level sensors with the same structure, a flow pressure gauge, an iron core temperature sensor, a cut-off water tank liquid level sensor and a cutting fluid water tank liquid level sensor in the data acquisition card and the state monitoring and alarming mechanism are connected with a liquid quality sensor by signal lines; the lower programmable controller, an electric control oil nozzle in the working condition simulation mechanism and an electric control flow valve in the filtering mechanism are connected with an alarm in the state monitoring alarm mechanism; and the electromagnet controller is connected with two ends of a coil in the working condition simulation mechanism.

The working condition simulation mechanism in the technical scheme comprises a cutting thermal simulation device, an oil stain simulation device and an impurity simulation device; the cutting thermal simulation device comprises 4 iron core support angle steels with the same structure, 4 coil support angle steels with the same structure and a coil shell assembly; the oil stain simulation device comprises an oil tank, an oil delivery pipe and an electric control oil nozzle; the impurity simulation device comprises scrap iron generated by dry cutting;

coil housing subassembly install in the box through 4 iron core support angle steel that the structure is the same and 4 coil support angle steel that the structure is the same, the oil tank is installed at the top of box left side tank wall, the oil-out direction of oil tank is down, the oil-out of oil tank is connected with defeated oil pipe's one end, defeated oil pipe's the other end passes the through-hole on the tank wall of box left side, and be connected with automatically controlled fuel sprayer, the iron core in the coil housing subassembly is aimed at to the shower nozzle of automatically controlled fuel sprayer, iron fillings are placed in the bottom of box, pile up highly for more than or equal to 10 cm.

According to the technical scheme, the box body is a square annular shell body with a cross section, the top of the box body is uncovered, two rectangular through holes used for installing a filter screen are symmetrically formed in the bottom of the box body, two layers of supporting structures with the same structure are welded on the periphery of the inner wall of the box body, each layer of supporting structure comprises 4 supporting angle steels with cross sections in an L shape, two circular through holes used for fixing coil supporting angle steels and iron core supporting angle steels are formed in the middle of each supporting angle steel, the 4 supporting angle steels are fixed in the horizontal plane of the same layer in a head-to-tail grounding mode, and the distance between the two layers of supporting structures formed by the supporting angle steels is 90 mm.

The coil shell assembly in the technical scheme comprises a coil, a coil shell, an outer ring waterproof gasket, an inner ring waterproof gasket, a coil shell cover and an iron core; the coil shell is a hollow structural member with an open cylindrical bottom end, threaded holes for fixing coil supporting angle steel are uniformly formed in the periphery of the top end of the coil shell, insulating paint is coated in the inner cavity of the coil shell, a coil is placed in the inner cavity of the coil shell, two ends of a coil wire extend out of two through holes in one side of the coil shell and are sealed by sealant, an inner ring waterproof gasket and an outer ring waterproof gasket are respectively installed on an inner ring and an outer ring of the bottom end of the coil shell, and a coil shell cover is fixed to the bottom end of the coil shell through bolts of the outer ring and bolts of the inner ring; the iron core is the cylindrical hollow structure of ring, and inside iron core temperature sensor of placing is peripheral being provided with the screw hole that is used for iron core and iron core support angle steel inner end to be connected uniformly in the iron core bottom, and the axis of iron core and the coincidence of coil casing's axis.

According to the technical scheme, the coil support angle steel and the iron core support angle steel are U-shaped steel, 1 pair of circular through holes and 1 pair of long through holes are respectively formed in two ends of the U-shaped steel, the inner end of the coil support angle steel is connected with a threaded hole in the top of a coil shell through the circular through holes by bolts, the outer end of the coil support angle steel is fixed with two through holes in the middle of L-shaped support angle steel welded on the inner wall of a box body through the long through holes by bolts, and the rotation axis of the coil shell is collinear with the symmetrical axis of; the inner end of the iron core support angle steel is connected with a threaded hole in the bottom position of the iron core through a circular through hole by a bolt, a long through hole in the outer end of the iron core support angle steel is connected with two through holes in the middle of the L-shaped support angle steel welded on the lower layer of the inner wall of the box body by a bolt, and the rotary axis of the iron core is collinear with that of the coil shell.

The filtering mechanism in the technical scheme further comprises an intercepting water tank, a first filtering device, 2 cutting fluid drainage devices with the same structure, a second filtering device and an electric control flow valve; 2 the same filter screen of structure be rectangle network structure spare, 2 the same filter screen of structure is installed in 2 the same rectangle through-holes of structure on the box bottom of the case, 2 the same cutting fluid drainage device of structure is installed below 2 the same filter screen of structure, 2 the same cutting fluid drainage device of structure install No. one filter equipment and No. two filter equipment from right to left under, the water tank that dams is installed under filter equipment and No. two filter equipment, No. one filter equipment and No. two filter equipment adopt the pipeline to insert respectively in the water tank that dams, automatically controlled flow valve installs on the bottom plate of water tank that dams.

The cutting fluid conveying mechanism in the technical scheme further comprises 3 low liquid level alarms, 3 high liquid level alarms and a water pump; cutting fluid water tank be rectangular bodily form's box spare, cutting fluid input pipe and cutting fluid conveyer pipe are installed respectively to the top of cutting fluid water tank, the water pump is installed in the left side of the cutting fluid conveyer pipe on cutting fluid water tank top, install 3 low liquid level alarms and 3 high liquid level alarms on the inner wall of cutting fluid water tank respectively, 3 low liquid level alarms are installed in the inner wall bottom of cutting fluid water tank on a parallel with same horizontal plane, 3 high liquid level alarms are installed in the inner wall top of cutting fluid water tank on a parallel with same horizontal plane, be equipped with the cutting fluid under the control of automatically controlled flow valve after filter mechanism filters in the cutting fluid water tank.

Compared with the prior art, the invention has the beneficial effects that:

1. the reliability test device for the cutting fluid cooling system of the machining center is based on the characteristics of the cutting fluid cooling system of the machining center, a laboratory bench test system is designed, independent reliability test can be carried out on the cutting fluid cooling system in a laboratory, corresponding test parameters are adjusted, the field environment of actual machining is simulated, weak links of the cutting fluid cooling system can be effectively found out, system parameters of the machining center can be optimized, and the use performance of the cutting fluid cooling system of the machining center is fully exerted.

2. The invention relates to a reliability test device of a cutting fluid cooling system of a machining center, which designs a working condition simulation mechanism according to the actual machining site environment, and comprises: the cutting heat simulation device, the oil stain simulation device and the impurity simulation device simulate the influence of cutting heat, oil stain, cutting scraps and the like generated in machining on a cooling system, and the accuracy and the authenticity of a test are guaranteed.

3. The reliability test device for the cutting fluid cooling system of the machining center can simultaneously test the reliability of two filtering systems, and embodies the flexibility and the universality of the device.

Drawings

The invention is further described with reference to the accompanying drawings in which:

FIG. 1 is a front view of the structural components of the device for testing the reliability of the cutting fluid cooling system of the machining center according to the present invention;

FIG. 2 is a perspective view of the simulation mechanism structure in the device for testing the reliability of the cutting fluid cooling system of the machining center according to the present invention;

FIG. 3 is a perspective view of the axial side of the structural components of the parts of the simulation mechanism in the device for testing the reliability of the cutting fluid cooling system of the machining center according to the present invention;

FIG. 4 is a perspective view of a half coil housing assembly structure in the device for testing reliability of a cutting fluid cooling system of a machining center according to the present invention;

FIG. 5 is a perspective view of the core structure of the device for testing the reliability of the cutting fluid cooling system of the machining center according to the present invention;

fig. 6 is a schematic diagram showing the structural components of a control mechanism in the device for testing the reliability of a cutting liquid cooling asahi system of a machining center according to the present invention.

In the figure: 1. a cutting fluid water tank, 2, a low liquid level alarm, 3, a high liquid level alarm, 4, a water pump, 5, a water pump temperature sensor, 6, a cutting fluid delivery pipe, 7, an intercepting water tank, 8, a cutting fluid pollution sensor, 9, a first filter device, 10, a filter device liquid level sensor, 11, a cutting fluid drainage device, 12, a box body, 13, an iron core support angle steel, 14, a coil support angle steel, 15, a flow pressure gauge, 16, an oil tank, 17, an oil delivery pipe, 18, an electric control oil nozzle, 19, a coil, 20, a coil shell, 21, an outer ring waterproof gasket, 22, an inner ring waterproof gasket, 23, a coil shell cover, 24, an iron core, 25, an iron core temperature sensor, 26, scrap iron, 27, a second filter device, 28, an intercepting water tank liquid level sensor, 29, an electric control flow valve, 30, a cutting fluid water tank liquid level sensor, 31, a, 32. cutting fluid, 33 supporting angle steel, 34 a filter screen, 35 an upper industrial personal computer, 36 a data acquisition card, 37 an alarm, 38 a lower programmable controller, 39 an electromagnet controller, 40 a signal line and 41 an embedded compact RIO controller.

Detailed Description

The invention is described in detail below with reference to the attached drawing figures:

the machining center cutting fluid cooling system reliability test device comprises a working condition simulation mechanism, a filtering mechanism, a cutting fluid conveying mechanism, a state monitoring alarm mechanism and an automatic control mechanism.

Working condition simulation mechanism

In the actual machining process, the metal chips often contain a large amount of metal powder with small particle size, which cannot be completely filtered by the primary filtering device of the machining center due to the small particle size of the metal powder. Therefore, the metal powder enters a secondary filtering system of the machining center after passing through the primary filtering device along with the flow of the cutting fluid, the metal powder is blocked in a water tank of the filtering system by a filter screen of the filtering device after being filtered by the secondary filtering system, and the filter screen of the filtering system is gradually covered by the tiny metal powder after being accumulated for a long time, so that the filter screen is failed, and finally, a circulation system is interrupted. In addition, since anticorrosive substances such as rust preventive oil, lubricating oil, and the like are applied to the surface of a part of the work blank, these substances are mixed into the cutting fluid under the flushing of the cutting fluid, thereby causing an increase in the viscosity of the cutting fluid. Dust, tiny metal particles and other impurities mixed in the cutting fluid are gradually bonded with each other, finally, sticky matters are formed and accumulated at a lower water gap, a water pump pipeline and a spray head, so that the pipeline is blocked, the cutting fluid cannot realize cooling circulation, the fault of a cutting fluid cooling system of a machining center is caused, and the machine must be stopped to carry out fault troubleshooting and dredge.

In summary, the working condition simulation mechanism provided by the invention considers the influence of various factors, and comprises a cutting thermal simulation device, an oil stain simulation device and an impurity simulation device.

The cutting thermal simulation device comprises a box body 12, 8 support angle steels 33, 4 iron core support angle steels 13 with the same structure, 4 coil support angle steels 14 with the same structure and a coil shell assembly.

The coil housing assembly comprises a coil 19, a coil housing 20, an outer ring waterproof gasket 21, an inner ring waterproof gasket 22, a coil housing cover 23 and an iron core 24.

The box body 12 is a shell part with a square cross section, the top of the box body is uncovered, the box body is fixed on a self-made foot rest and is placed at the highest position of the whole device, two rectangular through holes are symmetrically formed in the bottom of the box body, the edge of each through hole is in a step shape and used for fixing a filter screen 34, two layers of supporting structures with the same structure are welded around the inner wall of the box body 12, each layer of supporting structure comprises 4 supporting angle steels 33 with L-shaped cross sections, the middle of each supporting angle 33 is provided with two circular through holes and used for fixing a coil supporting angle steel 14 and an iron core supporting angle steel 13, the 4 supporting angle steels 33 are fixed in the same layer in an end-to-end mode, and the distance between the two layers of supporting;

the coil support angle steel 14 and the iron core support angle steel 13 are U-shaped steel, two ends of the U-shaped steel are respectively provided with 1 pair of circular through holes and 1 pair of long through holes, the inner end of the coil support angle steel 14 is connected with 8 threaded holes at the top of the coil shell 20 through the circular through holes by bolts, the outer end of the coil support angle steel 14 is fixed with two through holes in the middle of the L-shaped support angle steel 33 welded on the inner wall of the box body 12 through the long through holes by bolts, the relative positions of the 4 coil support angle steels 14 are adjusted through the long through holes of the coil support angle steel 14, so that the installation position of the coil shell 20 is adjusted, and the rotation axis of the coil shell 20 is collinear; the inner end of the iron core support angle steel 13 is connected with 8 threaded holes at the bottom of the iron core 24 through round through holes by bolts, a long through hole at the outer end of the iron core support angle steel 13 is connected with two through holes in the middle of the L-shaped support angle steel 33 welded on the lower layer of the inner wall of the box body 12 through bolts, and the relative position of the iron core support angle steel 13 is adjusted through the long through hole at the outer end of the iron core support angle steel 13, so that the relative position of the iron core 24 relative to the coil shell 20 is adjusted, and the rotation axis of the iron core 24 is coincided with the;

the coil shell 20 is a cylindrical hollow structural member, 8 threaded holes are formed in the periphery of the top end of the coil shell 20 and used for fixing the coil support angle steel 14, insulating paint is coated in the inner cavity of the coil shell 20, the coil 19 is placed in the inner cavity of the coil shell 20, the coil 19 is annular and formed by winding a copper core enameled wire, the outer diameter of the coil shell is equal to the outer diameter of the inner wall of the coil shell 20, the inner diameter of the inner wall of the coil shell 20 is equal to the inner diameter of the hollow inner wall of the coil shell 20, the height of the hollow inner wall of the coil shell 20 is equal to the height of the hollow inner wall of the coil shell 20, two ends of a lead of the coil 19 extend out of two through holes in one side of the coil shell 20 and are connected with an external electromagnet controller 39, the electromagnet controller 39 is connected with an upper industrial personal computer 35, the coil 19 is sealed by, the coil housing cover 23 is fixed at the bottom end of the coil housing 20 through 8 bolts of the outer ring and 4 bolts of the inner ring; the iron core 24 is the cylindrical hollow structure of ring, and the periphery of iron core 24 bottom is provided with 8 screw holes for being connected of iron core 24 and iron core support angle steel 13 inner end, the axis of iron core 24 and the coincidence of the axis of coil housing 20.

In order to ensure the stability of the device, the material of the parts of the cutting thermal simulation device is non-magnetic material, wherein the material of the coil shell 20 and the coil shell cover 23 is aluminum, the material of the bolt and the nut is white steel, the material of the coil support angle 14 and the iron core support angle 13 is 304 stainless steel, the material of the iron core 24 is pure iron, and the surface is subjected to rust-proof electroplating.

The working process of the cutting thermal simulation device is as follows: the electromagnet controller 39 outputs high-frequency alternating current under the control of the upper industrial personal computer 35, the coil 19 generates an alternating magnetic field inside the coil 19 under the action of the high-frequency alternating current, and the iron core 24 arranged in the middle of the coil 19 generates an eddy current effect under the condition of the alternating magnetic field, so that the iron core 24 generates heat to simulate cutting heat generated in actual processing. The adjustment of the heating quantity of the iron core 24 is realized by adjusting the current frequency and the current magnitude, so that the cutting heat under different working conditions is simulated.

The oil stain simulation device comprises an oil tank 16, an oil delivery pipe 17 and an electric control oil nozzle 18.

The oil tank 16 is a rectangular tank body, a mounting flange is arranged on one side of the rectangular tank body, the mounting flange is arranged at the uppermost end of the left side wall of the tank body 12 through 4 bolts, an oil outlet is arranged at the lower end of the oil tank 16 and faces downwards, the oil outlet is connected with one end of the oil delivery pipe 17, the oil delivery pipe 17 is a space circular bent pipe, the other end of the oil delivery pipe 17 penetrates through a through hole in the left side wall of the tank body 12 and is connected with the electric control oil nozzle 18, the electric control oil nozzle 18 is an ISDE electric control oil nozzle, a nozzle of the electric control oil nozzle 18 is aligned to the iron core 24, a control signal line of the electric control oil nozzle 18 is connected to an DQa output end of the lower programmable controller 38, the electric control oil nozzle 38 is connected with a USB port of the upper industrial personal computer 35 through an RS484 signal line, as the oil tank 16 is in an inverted state, oil can fully fill the oil, simulating a small amount of lubricating oil, rust-proof oil, etc. existing on the surface of a workpiece and the surface of a cutter in actual processing.

The impurity simulation device comprises scrap iron 26 and cutting fluid 32;

the impurity simulation device is scrap iron 26 placed at the bottom of the box body 12, the height of the scrap iron 26 stacked in the box body 12 is at least more than 10cm, the scrap iron 26 is required to be chips generated by dry cutting, and impurities remained in the scrap iron 26 can flow into the filtering device along with the cutting fluid 32 through the cutting fluid drainage device 11, so that the simulation that the impurities such as tiny metal particles and dust generated in the actual machining process are mixed into the cutting fluid 32 is realized.

Second, filtering mechanism

The filtering mechanism comprises a filter screen 34, 2 cutting fluid drainage devices 11 with the same structure, a first filtering device 9, a second filtering device 27, a cut-off water tank 7 and an electric control flow valve 29.

2 the same filter screen 34 of structure be rectangle network structure spare, the filtration mesh number of its filter screen 34 is 60 meshes, install in the rectangle through-hole of box 12 bottom, the rectangle through-hole edge of box 12 bottom is the dovetail groove, filter screen 34 is fixed a position by the dovetail groove, fix in the bottom of box 12, filter screen 34 is used for filtering impurity such as smear metal that processing produced, box 12's rectangle through-hole lower part welding cutting fluid drainage device 11, cutting fluid drainage device 11 is trapezoidal funnel, bottom through-hole welding has the rectangle steel pipe, be arranged in carrying cutting fluid 32 to filter equipment 9 and No. two filter equipment 27.

The first filtering device 9 and the second filtering device 27 are arranged on a self-made foot stand, and the height of the first filtering device and the height of the second filtering device are lower than the placing height of the box body 12 and higher than the height of the throttling water tank 7.

The intercepting water tank 7 is placed on a self-made foot stand, and the height of the intercepting water tank is lower than that of the first filtering device 9 and the second filtering device 27.

The filtering device in the filtering mechanism is a first filtering device 9 and a second filtering device 27, the filtering system of the first filtering device 9 and the second filtering device 27 is a second-stage filtering system, the device is a rectangular box body, two filtering screens are arranged in the box body and are respectively a first-stage filtering screen and a second-stage filtering screen, the box body is divided into 3 compartments, the mesh number of the first-stage filtering screen is 80 meshes, the mesh number of the second-stage filtering screen is 100 meshes, the filtered cutting fluid 32 flows into a first compartment in the second-stage filtering system from the box body 12 through a cutting fluid drainage device 11, flows into a second compartment through the filtering of the first-stage filtering screen, and then flows into a third compartment through the filtering of the second-stage filtering screen, a round hole is arranged at the lower end of the third compartment, the cutting fluid 32 enters a pipeline through the round hole and flows into a cut-off water tank 7, the cut-off water tank is a rectangular uncovered box body, an electric control flow valve 29 is installed at a water outlet at the lower end of the intercepting water tank 7, the model of the electric control flow valve 29 is a normally closed 2P025-06-08 electromagnetic valve, a control line of the electric control flow valve 29 is connected to an DQa output port of the lower programmable controller 38, and the lower programmable controller 38 controls the output flow of the electric control flow valve 29 under the control of the upper industrial personal computer 35;

the invention can simultaneously carry out reliability tests on the two filters, and the filters can be other types of filtering equipment, and can carry out corresponding reliability tests only by simply installing and debugging the filters.

Cutting fluid conveying mechanism

The cutting fluid conveying mechanism comprises a cutting fluid water tank 1, a low liquid level alarm 2, a high liquid level alarm 3, a water pump 4 and a cutting fluid conveying pipe 6.

The cutting fluid water tank 1 is a cuboid uncovered tank body part and is arranged at the bottommost layer of the whole device, the top end of the cutting fluid water tank 1 is respectively provided with a cutting fluid input pipe and a cutting fluid conveying pipe 6, the cutting fluid conveying pipe 6 is a circular pipe and penetrates through the cutting fluid water tank 1 to convey the cutting fluid to the inside of the water tank 12, a water pump 4 is arranged on one side of an output pipeline at the top end of the cutting fluid water tank 1, the water pump 4 is fixed with the cutting fluid water tank 1 through a mounting flange of the water pump 4 by 4 bolts, a water pump temperature sensor 5 is arranged on the side edge of the water pump 4 in an adhesive way, 3 low liquid level alarms 2 and 3 high liquid level alarms are respectively arranged on the inner wall of a cutting liquid water tank 1, the 3 low liquid level alarms 2 are arranged at the bottom end of the cutting liquid water tank 1 in parallel to the horizontal plane, and the 3 high liquid level alarms 3 are arranged at the top end of the inner wall of the cutting liquid water tank 1 in parallel to the horizontal plane; in operation, cutting fluid 32 is filtered by the filtering mechanism, flows into the intercepting water tank 7, is conveyed to the cutting fluid water tank 1 under the control of the electric control flow valve 29, is pumped out by the water pump 4, and is conveyed to the upper part of the iron core 24 through the cutting fluid conveying pipe 6.

The control line of the water pump 4 is connected to the DQa output port of the lower programmable controller 38, and the lower programmable controller 38 controls the working state of the water pump 4 under the control of the upper industrial personal computer 35

Owing to there are phenomenons such as leakage, evaporation, cutting fluid 32 loss is very fast when using, in order to prevent that cutting fluid 32 is too few, lead to the unable normal work of circulation system, install low liquid level alarm 2 in cutting fluid water tank 1, high liquid level alarm 3, in order to test the reliability of low liquid level alarm 2 and high liquid level alarm 3, 3 low liquid level alarms 2 and high liquid level alarm 3 of parallel mount in cutting fluid water tank 1 for 3 low liquid level alarms 2 of same liquid level or 3 high liquid level alarms 3 participate in the test simultaneously.

Fourth, state monitoring alarm mechanism

The state monitoring and alarming mechanism comprises a water pump temperature sensor 5, a cutting fluid pollution sensor 8 with the same structure, a filtering device liquid level sensor 10 with the same structure, a flow pressure gauge 15, an iron core temperature sensor 25, an intercepting water tank liquid level sensor 28, a cutting fluid water tank liquid level sensor 30, a liquid quality sensor 31, an alarm 37, a data acquisition card 36, a signal line 40 and an embedded compact RIO controller 41.

The water pump temperature sensor 5 is a patch type platinum resistor PT100 temperature sensor and is installed on one side of a shell of the water pump 4 in an adhesive mode, an acquisition port of the water pump temperature sensor 5 is connected with a data acquisition RTD interface of the data acquisition card 36 through a signal line 40, the type of the data acquisition card 36 is an NI compactRIO module, the type of the temperature acquisition card is NI9216, the data acquisition card 36 is a slot type acquisition card, a spring terminal on the data acquisition card 36 is fixed in a slot of the embedded compactRIO controller, and the embedded compactRIO controller is connected with an upper industrial personal computer through a USB (universal serial bus) to output data acquired by each data acquisition card 36.

The number of the cutting fluid pollution sensors 8 is 6, the model is OpcomiI, the cutting fluid pollution sensors are respectively arranged in a first filtering device 9 and a second filtering device 27, each filtering device is divided into 3 compartments by two filtering screens, 1 cutting fluid pollution sensor 8 is arranged on the wall of a box body which is 3cm away from the bottom in each compartment, a signal line of the cutting fluid pollution sensor 8 passes through the filtering device to be connected with an RTD interface of a data acquisition card, the cutting fluid pollution sensors 8 respectively test the concentration of impurity particles, the concentration of oil liquid and the like of the cutting fluid 32 in each compartment, the data acquisition card 36 is embedded into a clamping groove of an embedded compactRIO controller, the embedded compactRIO controller is connected with an upper industrial personal computer through a USB to carry out corresponding processing on signals and then transmits the signals to the upper industrial personal computer 35, the filtering performance of the filtering device and the cleanliness degree of the filtered cutting fluid 32 are obtained by comparing the data of the 3 cutting fluid pollution sensors 8 in each filtering device, the filtering performance of the two filtering devices can be compared by comparing the data of the water outlet cutting fluid pollution sensor 8 of the first filtering device 9 and the second filtering device 27.

The number of the filter device liquid level sensors 10 is 4, the type is star-shaped instrument CYW11 input type liquid level transmitter, the filter device liquid level sensors 10 are cylindrical, the measuring mode is input type, the liquid level sensors 10 are put into liquid, the measuring range of the liquid level sensors is higher than the height of a container of the filter device, the liquid level sensors are respectively and vertically arranged in three compartments of a first filter device 9 and a second filter device 27 which are divided by filter screens, the filter device liquid level sensors 10 are connected with RTD interfaces of a data acquisition card 36 through signal lines 40, when the liquid level of one of the filter device liquid level sensors 10 is too high, the filter screen at the position is blocked or the filtering performance of the filter screen is reduced, an upper industrial personal computer 35 controls a lower programmable controller 38 to sound an alarm 37, the lower programmable controller 38 is a Siemens S200 programmable controller, the lower programmable controller 38 is connected with the upper industrial personal computer through an RS484 data interface, the anode and the cathode of a power line of the alarm 37 are respectively connected with DQa0 and a DQA1L port of the lower programmable controller, and the lower programmable controller 38 controls the power on and off of a DQa0 port to control the alarm on and off of the alarm 37.

The flow pressure gauge 15 is an ND300 vortex flowmeter and is arranged at the top end of the cutting fluid conveying pipe 6 through a self-contained locking bolt to monitor the output flow and pressure of the cutting fluid 32 during work, data collected by the flow pressure gauge 15 is connected to an RTD input port of a data collection card 36 through a signal line 40, an embedded compact RIO controller is connected with an upper industrial personal computer through a USB to carry out corresponding processing on signals and then transmits the signals to the upper industrial personal computer 35, when the flow of the cutting fluid 32 measured by the flow pressure gauge 15 is reduced and the pressure is increased, the nozzle of the cutting fluid conveying pipe 6 is blocked, the upper industrial personal computer 35 sends signals, and an alarm 37 sounds;

the core temperature sensor 25 is a 10K NTC thermistor and is installed in a threaded hole in the core 24 through a self-threaded manner, the core temperature sensor 25 has a strong diamagnetic function, a data line of the core temperature sensor 25 is connected to an RTD input port of the data acquisition card 36, the data acquisition card 36 is embedded into a clamping groove of the embedded compactRIO controller, the acquired data is connected with an upper industrial personal computer through a USB by the embedded compactRIO controller, and when the temperature of the core 24 is too high, the cooling capacity of the cutting fluid 32 is reduced, and the output flow of the cutting fluid 32 is properly adjusted.

The intercepting water tank liquid level sensor 28 is a star instrument CYW11 throw-in type liquid level transmitter, the measuring mode is throw-in type, and the intercepting water tank liquid level sensor 28 can be thrown into liquid and thrown into one side of the intercepting water tank 7 to be used for monitoring the liquid level height of the intercepting water tank 7. The range measured by the cut-off tank level sensor 28 should be greater than the vessel height of the cut-off tank 7.

The cutting fluid water tank liquid level sensor 30 is a star instrument CYW11 throw-in type liquid level transmitter, the measuring mode is throw-in type, the cutting fluid water tank liquid level sensor 30 is thrown into liquid, and the cutting fluid water tank liquid level sensor is thrown into one side of the cutting fluid water tank 1 and used for monitoring the liquid level height of the cutting fluid water tank 1. The height range of the liquid level measured by the cutting fluid water tank liquid level sensor 30 is larger than the container height of the cutting fluid water tank 1. 8-liquid level sensor 10

The liquid quality sensor 31 with the model of OpcomiI is arranged at the bottom of the cutting fluid water tank 1 and used for monitoring the quality of the cutting fluid 32 in the cutting fluid water tank 1 and detecting whether the cutting fluid is deteriorated or not, the pollution degree and the like.

The alarm 37 is a rotary flashing alarm lamp with the model of LTE-1101J, the anode and the cathode of a power supply line of the alarm 37 are respectively connected to DQa0 ports and DQA1L ports of the lower programmable controller 38, and the lower programmable controller 38 controls the power on and off of the DQa0 ports to control the alarm of the alarm 37 to be turned on and off.

Each sensor is connected with an RTD input port of the data acquisition card 36 through a signal line 40, the data acquisition card 36 is embedded in a card slot of the embedded CompactRIO controller, the acquired data is connected with an upper industrial personal computer through a USB by the embedded CompactRIO controller, the upper industrial personal computer 35 is connected with a lower programmable controller 38 through an RS484 data line, and when a fault occurs, the upper industrial personal computer controls the start and stop of the lower programmable control alarm 37.

Automatic control mechanism

The automatic control mechanism comprises an upper industrial personal computer 35, a lower programmable controller 38 and an electromagnet controller (39).

The lower programmable controller 38 is Siemens S200 in model and is connected with the upper industrial personal computer 35 through an RS484 signal line.

The electromagnet controller (39) is connected with the upper industrial personal computer 35 through an RS232 data line, and the output end of the electromagnet controller 39 is connected with two wiring ends of the coil 19. The upper industrial personal computer 35 controls the electromagnet controller 39 to output current, thereby controlling the size of the magnetic field generated by the coil 19 and controlling the heat productivity of the iron core 24.

The reliability test device of the cutting fluid cooling system of the machining center is divided into 3 working states, namely a normal state, a low water level state of a water tank and a high water level state of the water tank.

The normal state is a stable test state, the water pump 4 normally works under rated power, the electric control oil spray nozzle 18 sprays oil regularly and quantitatively under the control of the lower programmable controller 38, the working condition simulation mechanism normally works, the flow of the electric control flow valve 29 is controlled by the upper industrial personal computer 35 to be equal to the flow measured by the flow pressure gauge 15, and the cutting fluid 32 is ensured to be in a stable circulation state.

In a normal state, the water level in the cutting fluid water tank 1 is in a normal state, the reading of each sensor is stable, and when the flow pressure gauge 15 displays that the flow is reduced or the pressure is increased, the nozzle of the cutting fluid conveying pipe 6 is blocked; when the temperature sensor 25 of the iron core displays temperature rise, the flow of the cutting fluid 32 is small, and the flow should be increased; when the temperature displayed by the iron core temperature sensor 25 is too low, the flow of the cutting fluid 32 is over-high, and the water pump 4 can be controlled by the upper industrial personal computer 35 to properly adjust the flow of the cutting fluid 32; when the liquid level sensor 10 of the filtering device displays that the liquid level is too high, the filtering device is indicated to be blocked, the lower programmable controller 38 controls the alarm 37 to work, the device is stopped, and faults are checked; in a normal state, because the output flow of the electric control flow valve 29 is equal to the output flow of the flow pressure gauge 15, the whole device is in a balanced state, when the liquid level of the intercepting water tank 7 is reduced and the liquid level of the cutting fluid water tank 1 is increased, the filtering device or a nozzle of the cutting fluid 32 is blocked, and the cutting fluid 32 cannot normally circulate; when the liquid level of the intercepting water tank 7 rises and the liquid level of the cutting fluid water tank 1 falls, the water pump 4 cannot pump water normally, and a nozzle of the filtering device or the cutting fluid conveying pipe 6 is blocked or has mechanical fault.

The low liquid level state of water tank for accelerating water pump 4 state of drawing water with higher speed, under this state, can test water pump 4's output capacity, filter equipment's the biggest filter performance and the alarm performance of the low liquid level alarm 2 in the cutting fluid water tank 1, in order to improve experimental quality, a plurality of low liquid level alarms 2 of installation in the water tank, every low liquid level alarm 2 is mutually independent, can test a plurality of low liquid level alarms 2's alarm performance simultaneously. In this state, the water pump 4 pumps water beyond the rated power, the output flow of the electric control flow valve 29 is kept unchanged, and the output flow is smaller than the output flow measured by the flow pressure gauge 15; under this state, the water level of the intercepting water tank 7 is increased, the water level of the cutting fluid water tank 1 is reduced, and when the cutting fluid water tank liquid level sensor 30 displays that the liquid level is too low, the low liquid level alarm 2 does not give an alarm, which indicates that the low liquid level alarm 2 has a fault.

The high liquid level state of water level for the warning performance of test high liquid level alarm 3, under this state, water pump 4 is in normal operating condition, automatically controlled flow valve 29 control output flow is the biggest, 7 water level reductions of shutoff water tank, 1 water level of cutting fluid water tank risees, when cutting fluid water tank level sensor 30 shows that the water level reachs the warning liquid level, high liquid level alarm 3 should begin to report to the police this moment, automatically controlled flow valve 29 closes, after the water level is in steady state, automatically controlled flow valve 29 outputs, it equals with flow pressure gauge 15 output flow to control automatically controlled flow valve 29 flow through upper industrial computer 35.

Claims (7)

1. A machining center cutting fluid cooling system reliability test device is characterized by comprising a working condition simulation mechanism, a filtering mechanism, a cutting fluid conveying mechanism, a state monitoring alarm mechanism and an automatic control mechanism;

the working condition simulation mechanism comprises a box body (12);

the filtering mechanism comprises an electric control flow valve (29) and a filter screen (34);

the cutting fluid conveying mechanism comprises a cutting fluid water tank (1) and a cutting fluid conveying pipe (6);

the working condition simulation mechanism is installed at the top end through a box body (12), the filtering mechanism is installed below the working condition simulation mechanism, the cutting fluid conveying mechanism is installed below the filtering mechanism, the filter screen (34) is installed on the bottom of the box body (12), a pipeline connected with the electric control flow valve (29) is inserted into the cutting fluid water tank (1), and the cutting fluid water tank (1) is connected with the lower end of the cutting fluid conveying pipe (6);

the state monitoring and alarming mechanism is arranged in the working condition simulation mechanism, the filtering mechanism and the cutting fluid conveying mechanism:

the state monitoring and alarming mechanism comprises a water pump temperature sensor (5), 6 cutting fluid pollution sensors (8) with the same structure, 4 filtering device liquid level sensors (10) with the same structure, a flow pressure gauge (15), an iron core temperature sensor (25), an intercepting water tank liquid level sensor (28), a cutting fluid water tank liquid level sensor (30), a liquid quality sensor (31) and an alarm (37);

the water pump temperature sensor (5) is arranged on one side of the shell of the water pump (4) in the cutting fluid conveying mechanism; 6 cutting fluid pollution sensors (8) are respectively arranged in a first filtering device (9) and a second filtering device (27) in a filtering mechanism, 4 filtering device liquid level sensors (10) with the same structure are respectively vertically arranged in the first filtering device (9) and the second filtering device (27), one end of a flow pressure meter (15) is connected with the top end of a cutting fluid conveying pipe (6), a connecting pipeline at the other end of the flow pressure meter (15) is inserted into a box body (12), an iron core temperature sensor (25) is arranged inside an iron core (24), an intercepting water tank liquid level sensor (28) is arranged on one side wall of an intercepting water tank (7) in the filtering mechanism, a cutting fluid water tank liquid level sensor (30) is arranged in a cutting fluid water tank (1) in the cutting fluid conveying mechanism, a liquid quality sensor (31) is arranged at the bottom of the cutting fluid water tank (1), the alarm (37) is arranged on a case of the upper industrial personal computer (35);

the automatic control mechanism, the working condition simulation mechanism, the filtering mechanism, the cutting fluid conveying mechanism and the state monitoring alarm mechanism are connected by a signal wire (40):

the automatic control mechanism comprises an upper industrial personal computer (35), a data acquisition card (36), a lower programmable controller (38) and an electromagnet controller (39);

the upper industrial personal computer (35) is connected with the data acquisition card (36), the upper industrial personal computer (35) is connected with the lower programmable controller (38), and the upper industrial personal computer (35) is connected with the electromagnet controller (39);

the data acquisition card (36) is connected with a water pump temperature sensor (5), 6 cutting fluid pollution sensors (8) with the same structure, 4 filtering device liquid level sensors (10) with the same structure, a flow pressure gauge (15), an iron core temperature sensor (25), an intercepting water tank liquid level sensor (28) and a cutting fluid water tank liquid level sensor (30) in the state monitoring and alarming mechanism through signal lines (40);

the lower programmable controller (38), an electric control fuel injection nozzle (18) in the working condition simulation mechanism and an electric control flow valve (29) in the filtering mechanism are connected with an alarm (37) in the state monitoring alarm mechanism;

and the electromagnet controller (39) is connected with two ends of a coil (19) in the working condition simulation mechanism.

2. The machining center cutting fluid cooling system reliability test device according to claim 1, wherein the working condition simulation mechanism comprises a cutting thermal simulation device, an oil stain simulation device and an impurity simulation device;

the cutting thermal simulation device comprises 4 iron core support angle steels (13) with the same structure, 4 coil support angle steels (14) with the same structure and a coil shell assembly;

the oil stain simulation device comprises an oil tank (16), an oil delivery pipe (17) and an electric control oil nozzle (18);

the impurity simulation device comprises scrap iron (26) generated by dry cutting;

the coil casing subassembly install in box (12) through 4 iron core support angle steel (13) that the structure is the same and 4 coil support angle steel (14) that the structure is the same, oil tank (16) are installed at the top of box (12) left side tank wall, the oil-out direction of oil tank (16) is down, the oil-out of oil tank (16) is connected with the one end of defeated oil pipe (17), the through-hole on the tank wall of box (12) left side is passed to the other end of defeated oil pipe (17), and be connected with automatically controlled oil nozzle (18), iron core (24) in the coil casing subassembly are aimed at to the shower nozzle of automatically controlled oil nozzle (18), iron fillings (26) are placed in the bottom of box (12), pile up highly for more than or equal to 10cm in box (12).

3. The machining center cutting fluid cooling system reliability test device according to claim 1 or 2, characterized in that the box body (12) is a shell member with a square annular cross section, the top is uncovered, two rectangular through holes for installing the filter screen (34) are symmetrically arranged on the bottom of the box, two layers of support structures with the same structure are welded around the inner wall of the box body (12), each layer of support structure comprises 4 support angle steels (33) with L-shaped cross sections, two circular through holes for fixing the coil support angle steels (14) and the iron core support angle steels (13) are arranged in the middle of each support angle steel (33), the 4 support angle steels (33) are fixed in the horizontal plane of the same layer in an end-to-end manner, and the distance between the two layers of support structures consisting of the support angle steels (33) is 90 mm.

4. The machining center cutting fluid cooling system reliability test device according to claim 2, wherein the coil housing assembly comprises a coil (19), a coil housing (20), an outer ring waterproof gasket (21), an inner ring waterproof gasket (22), a coil housing cover (23) and an iron core (24);

the coil shell (20) is a cylindrical hollow structural member with an open bottom end, threaded holes for fixing coil supporting angle steel (14) are uniformly formed in the periphery of the top end of the coil shell (20), insulating paint is coated in the inner cavity of the coil shell (20), a coil (19) is placed in the inner cavity of the coil shell (20), two ends of a wire of the coil (19) extend out of two through holes in one side of the coil shell (20) and are sealed by sealant, an inner ring waterproof gasket (22) and an outer ring waterproof gasket (21) are respectively installed on an inner ring and an outer ring of the bottom end of the coil shell (20), and a coil shell cover (23) is fixed to the bottom end of the coil shell (20) through bolts of the outer ring and bolts of the inner ring; iron core (24) are the cylindrical hollow structure of ring, and inside iron core temperature sensor (25) of placing, iron core (24) bottom periphery is provided with the screw hole that is used for iron core (24) and iron core support angle steel (13) inner end to be connected uniformly, and the axis of iron core (24) coincides with the axis of coil casing (20).

5. The machining center cutting fluid cooling system reliability test device according to claim 2, characterized in that the coil support angle (14) and the core support angle (13) are U-shaped steel, 1 pair of circular through holes and 1 pair of long through holes are respectively formed at two ends of the U-shaped steel, the inner end of the coil support angle (14) is connected with a threaded hole at the top of the coil housing (20) through the circular through holes by bolts, the outer end of the coil support angle (14) is fixed with two through holes in the middle of an L-shaped support angle (33) welded on the inner wall of the box body (12) through the long through holes by bolts, and the rotation axis of the coil housing (20) is collinear with the symmetry axis of the box body (12); the inner end of the iron core support angle steel (13) is connected with a threaded hole in the bottom position of the iron core (24) through a circular through hole by bolts, a long through hole in the outer end of the iron core support angle steel (13) is connected with two through holes in the middle of the L-shaped support angle steel (33) welded on the lower layer of the inner wall of the box body (12) by bolts, and the rotary axis of the iron core (24) is collinear with that of the coil shell (20).

6. The machining center cutting fluid cooling system reliability test device according to claim 1, wherein the filtering mechanism further comprises a cutoff water tank (7), a first filtering device (9), 2 cutting fluid drainage devices (11) with the same structure, a second filtering device (27) and an electric control flow valve (29);

2 filter screen (34) that the structure is the same are rectangle network structure spare, 2 filter screen (34) that the structure is the same are installed in 2 rectangle through-holes that the structure is the same on box (12) bottom of the case, 2 cutting fluid drainage device (11) that the structure is the same are installed below 2 filter screen (34) that the structure is the same, 2 cutting fluid drainage device (11) that the structure is the same are installed No. one filter equipment (9) and No. two filter equipment (27) from right to left under, shutoff water tank (7) are installed under filter equipment (9) and No. two filter equipment (27), No. one filter equipment (9) and No. two filter equipment (27) adopt the pipeline to insert respectively in shutoff water tank (7), automatically controlled flow valve (29) are installed on the bottom plate of water tank (7).

7. The machining center cutting fluid cooling system reliability test device according to claim 1, wherein the cutting fluid conveying mechanism further comprises 3 low liquid level alarms (2), 3 high liquid level alarms (3) and a water pump (4);

cutting fluid water tank (1) be rectangular bodily form's box spare, cutting fluid input tube and cutting fluid conveyer pipe (6) are installed respectively to the top of cutting fluid water tank (1), install water pump (4) in the left side of cutting fluid conveyer pipe (6) on cutting fluid water tank (1) top, install 3 low liquid level alarm (2) and 3 high liquid level alarm (3) respectively on the inner wall of cutting fluid water tank (1), install in the inner wall bottom of cutting fluid water tank (1) 3 low liquid level alarm (2) are on a parallel with same horizontal plane, install in the inner wall top of cutting fluid water tank (1) 3 high liquid level alarm (3) on a parallel with same horizontal plane, be equipped with cutting fluid (32) under electric control flow valve (29) control after filtering mechanism filters in cutting fluid water tank (1).

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