CN108196514A - A kind of numerically-controlled machine tool operating status long-distance monitoring method - Google Patents
A kind of numerically-controlled machine tool operating status long-distance monitoring method Download PDFInfo
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- CN108196514A CN108196514A CN201810273603.7A CN201810273603A CN108196514A CN 108196514 A CN108196514 A CN 108196514A CN 201810273603 A CN201810273603 A CN 201810273603A CN 108196514 A CN108196514 A CN 108196514A
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- lathe
- machine tool
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/406—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by monitoring or safety
- G05B19/4065—Monitoring tool breakage, life or condition
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/37—Measurements
- G05B2219/37616—Use same monitoring tools to monitor tool and workpiece
Abstract
Numerically-controlled machine tool operating status long-distance monitoring method provided by the invention, includes the following steps：S1 sensor, on-line checking and acquisition lathe status data) are arranged in lathe main portions；The main portions refer to machine tool chief axis, spindle box, knife rest, spindle motor, feeding guide rail；S2) collected status data feeding microcontroller is handled, then passes to communication module；S3) data are uploaded to remote server by communication module by router again；S4) server analyzes and processes status data and fault statistics.The present invention can make administrative staff quickly control the process information of numerically-controlled machine tool in time, timely adjust the generation of machined parameters, trouble saving, reduce the shutdown loss of user, have great importance to the promotion for realizing processing efficiency and productivity effect.
Description
Technical field
The present invention relates to a set of systems for being used to implement lathe operating status remote monitoring, are to be related to one kind specifically
The multi-faceted online active remote monitoring system of lathe operating status.
Background technology
Lathe is because with advantages such as high precision machining, high degree of automation, productivity height, it has also become manufacturing enterprise of China
Main production equipments.How more and more machine tooling equipment, improve existing workshop management pattern in enterprise, with
The real-time remote monitoring of operation conditions during realization workshop machine tooling, to improving the utilization of productivity and enterprise's process equipment
Rate, reinforcement enterprise are significant to the management of process and the market competitiveness of enhancing enterprise.
Invention content
The technical problems to be solved by the invention are：A kind of numerically-controlled machine tool operating status long-distance monitoring method, the party are provided
Principal states data when method can run lathe are acquired processing, transmission and analysis displaying, facilitate manager to lathe
Operating status is monitored.
The present invention solves its technical problem and uses following technical solution：
Numerically-controlled machine tool operating status long-distance monitoring method provided by the invention, includes the following steps：
S1 sensor, on-line checking and acquisition lathe status data) are arranged in lathe main portions；The main portions
Refer to machine tool chief axis, spindle box, knife rest, spindle motor, feeding guide rail；
S2) collected status data feeding microcontroller is handled, then passes to communication module；
S3) data are uploaded to remote server by communication module by router again；
S4) server analyzes and processes status data and fault statistics.
In the above method, the status data that the step S1 is acquired includes temperature information, machine vibration information, main shaft electricity
Acc power and lathe operation data itself.
In the above method, the step S1 is specifically included in the method for lathe main portions placement sensor：
S11) the orientation situation influenced according to the structure of numerically-controlled machine tool, heat source distribution and Thermal Error on workpiece accuracy, will be warm
Sensor arrangement is spent at lathe key point position, including spindle box, X-axis guide rail, cutter and motor；When arranging temperature sensor,
Temperature sensor is close to heat source, and its quantity is more than the quantity of numerically controlled lathe heat source；Lathe is obtained finally by temperature sensor
Temperature information；
S12) using 2 non-contact electric eddy vibrating sensors, X, the Y-direction of machine tool chief axis are separately mounted to, is obtained
Machine vibration information；
S13 it) is connected on the three phase electric machine of lathe using Hall-type Three Phase Power Sensor, obtains spindle motor of machine tool work(
Rate.
In the above method, step S2 is specifically included：Microcontroller circuit and communication module circuitry are chosen, the two is connected,
Wherein communication module need to embed ICP/IP protocol stack；Microcontroller obtains conditions of machine tool by amplifying circuit and analog to digital conversion circuit
It after data, then is instructed by AT and establishes communication link with communication module, microcontroller will finally by transmission-transmission logic serial ports
Conditions of machine tool data are sent to communication module；Then communication module carries out network transmission with router again.
In the above method, the communication module of step S2 is using the chip comprising radio network functions, the router of step S3
Accessing wirelessly dot pattern is operated in, is communicatively coupled by communication module by wireless network and routing, router passes through net again
Network transfers data to server.
In the above method, step S4 is specifically included：Lathe running state data is obtained by server and is analyzed and processed
Afterwards, then by lathe running state information recognition methods data exception point is obtained, is then described and based on event by phenomenon of the failure
The Trouble Match of fault tree analysis obtains incipient fault collection with extracting method, is commented finally by the state based on Multi-information acquisition theory
The method of estimating determines fault set.
In the above method, the method that server analyzes and processes lathe running state data includes：At zero averaging
Reason, wavelet analysis, time-domain analysis, frequency-domain analysis and transient analysis.
In the above method, the method for obtaining incipient fault collection specifically includes：Pass through the data exception point and failure identified
Phenomenon describes, and is matched from the fault message storehouse of foundation using the method for calculating similarity and extraction obtains incipient fault
Collection.
In the above method, the state evaluating method based on Multi-information acquisition theory specifically includes：In the form of confidence interval
Typical sample is reference data, calculate temperature sensor, electric vortex vibrating sensor, Three Phase Power Sensor evidence potential
Reliability density in fault set, and it is normalized to obtain the belief function distribution of each sensing data, Ran Houtong
It crosses D-S evidence theory and is determined fault set.
The technological merit of the present invention includes：With the depth integration of emerging information technology and traditional manufacture, Yi Jizhi
The promotion of development strategy can be manufactured, industrial circle has welcome primary new deep reform.Numerically-controlled machine tool is used as and is obtained in manufacturing
To widely applied mechanical industry equipment, the present invention is mainly acquired the running state data of lathe, developing intellectual resource hardware
Module can be wirelessly transferred to collecting data, be uploaded onto the server, compared to traditional numerically controlled machine remote monitoring system
Mostly by the way of internet or intranet accesses, both modes are required for being laid with private cable or optical fiber, cost compared with
High and inconvenient, Intelligent hardware module of the invention carries out the long-range prison of numerically-controlled machine tool operating status using public wireless network
Control, it is of low cost and conveniently.Then it is carried out to data except dry filtering is cleaned, most using zero averaging processing, wavelet analysis method
Time frequency analysis is carried out afterwards, transient state analyzing method carries out lathe remote dynamic monitoring, while can carry out early warning to the failure of lathe
And judgement, such as certain the moment numerically-controlled machine tool monitoring data of table 1 for the present invention (wherein temperature point position is shown in attached drawing 6).The present invention
Using the Diagnostic Strategy of multi-sensor information fusion and D-S evidence theory, the fast and accurately early warning of machine failure can be realized
And diagnosis, administrative staff can be made quickly to control the process information of numerically-controlled machine tool in time, timely adjust machined parameters, is pre-
The generation of fail-safe reduces the shutdown loss of user, has great importance to the promotion for realizing processing efficiency and productivity effect.
Certain the moment numerically-controlled machine tool monitoring data of table 1
Description of the drawings
Overall flow schematic diagram of the attached drawing 1 for the present invention.
Data acquisition transmission schematic diagram of the attached drawing 2 for the present invention.
TCP data segment schematic diagram of the attached drawing 3 for the present invention.
Data processing schematic diagram of the attached drawing 4 for the present invention.
Fault diagnosis model frame of the attached drawing 5 for the present invention.
Numerically-controlled machine tool temperature point layout drawing of the attached drawing 6 for the present invention.
Specific embodiment
With reference to embodiment, the invention will be further described, but does not limit the present invention.
A kind of lathe modernization machinery very high as the degree of automation, has the characteristics that versatility and complexity, produces
Raw failure also becomes more intricate.In order to accurately grasp the operating status of lathe in real time, the present invention realizes
Acquisition, processing, transmission and the displaying of principal states data when lathe is run, facilitate manager can be to the operating status of lathe
It is monitored.
Lathe operating status remote monitoring is made of three parts, and respectively the acquisition of status data, data are transmitted, counted
According to processing and long-range display.
The acquisition of status data is to be directed to reflect that machine tool motion state and the main signal of process state are supervised
It surveys, which is connect by electrical adaptable interface (including signal condition part) with sensor, these sensors are directly installed on
Lathe main portions (components such as such as main shaft/feed shaft, cutter), direct-on-line detect the key message at these positions, acquire number
According to object for machine tool chief axis, feed shaft, cutter, machine body etc., the signal of status monitoring includes power, vibration and temperature
Deng.It for vibration signal, is obtained using current vortex sensor, power obtains after being converted by electric current, voltage signal, and temperature is using temperature
Sensor is spent to obtain.Lathe self-operating data are obtained by numerically-controlled machine tool RS-232 (telecommunications proposed standard 232) serial line interface.
The transmission section of data includes STM32F103 controller designs, sensor data acquisition, WiFi module and router
Setting.As shown in Figure 1, STM32F103 controllers are mainly used for parsing the control routine of host computer, place overall system architecture
The data of reason analyte sensors acquisition simultaneously control WiFi module that sensing data is uploaded to server by serial ports.WiFi moulds
Block embeds ICP/IP protocol, can realize the data transfer transmission between serial ports, WiFi, which is operated in STA
Under (Station, wireless site) station mode, router (need to access internet) is AP (Access Point, accessing points) mould
Formula, WiFi module can be connected into Internet (Global Internet) by router, so as to fulfill remote monitoring.
Data processing module is for different signal characteristics, can carry out time-domain analysis (dimensionless index, probability to signal
Density, auto-correlation function, cross-correlation function), frequency-domain analysis (power spectrum, cepstrum), time frequency analysis and transient analysis (baud
Figure, polar diagram), it can also carry out various trend analyses and forecast.And the data most handled well at last are shown in page end, make pipe
Reason person can realize the operating status of online long-range monitoring lathe.
The present invention is further illustrated below in conjunction with the accompanying drawings.
Numerically-controlled machine tool operating status long-distance monitoring method provided by the invention is divided into three parts, wherein：First part is
Data acquire, and second part is data transmission, and Part III is Data Analysis Services.
The part of data acquisition of the present invention includes multiple sensors, and part of data acquisition main working process is as follows.(1) it adopts
With platinum resistance Pt100 temperature sensors, the side influenced according to the structure of numerically-controlled machine tool, heat source distribution and Thermal Error on workpiece accuracy
Situations such as position, temperature sensor is arranged in the key points such as spindle box, X-axis guide rail, cutter and motor position.Arrange temperature sensing
During device, temperature sensor should be close to heat source, and its quantity should be more than the quantity of numerically controlled lathe heat source.Thermal resistance collection
Signal ADC (analog-to-digital conversion) channel into microcontroller is followed by by amplifying circuit enhanced processing, by after analog-to-digital conversion
To digital quantity, so as to processing and transmission later.(2) it using 2 non-contact electric eddy vibrating sensors, is separately mounted to lead
The X of axis, Y-direction are amplified signal by preamplifier, and obtaining voltage signal by transmitter later accesses microcontroller
ADC channel.(3) power of spindle motor is measured using Hall current sensor, it is single to obtain voltage signal access by transmitter
Piece machine ADC channel.(4) numerically-controlled machine tool itself operation data, such as rotating speed pass through the standard RS-232 serial communications of digital control system
After interface is by serial port level conversion core piece MAX3232, the UART (universal asynchronous receiving-transmitting transmitter) of microcontroller is accessed.It is all
Data (1)~(4) are ultimately delivered to microcontroller STM32F103.
The TCP data segment of the present invention is using a high-performance low-power-consumption WiFi chip ESP8266, embeds TCP and (passes
Transport control protocol is discussed)/IP (Internet protocol) agreement.Using PCB (printed circuit board) antenna, by matched design, under spacious environment
Transmission range can reach 400m or so, and all I/O (input/output) mouths are drawn, and band metal shielding passes through the FCC＆CE (U.S.
Federal Communications Committee and European Union) certification.The main function of WiFi module is connection remote server, completes rs 232 serial interface signal and nothing
The conversion of line signal ensures the data transmit-receive of microprocessor.Microcontroller STM32F103 instructs that (Attention is used for by AT
Establish communication link) it communicates with WiFi chip, the data come from sensor acquisition are passed through TTL (transmission-transmission logic) serial ports
It is transmitted to WiFi module (pin 8 of Fig. 3 chips U1), module is as STA (Station) by data transparent transmission (chip U1
Pin 7) to AP (Access Point routers, pattern be wireless access point), data are sent out after AP accesses Internet
Database server is given, that is, accesses Cloud Server, host computer (database server) is then connected to by Cloud Server again.
As shown in figure 3, chip U1 is ESP8266, pin 1 and pin 16 are power supply foot, using 3.3V direct current supplys；
Its pin 7 and pin 8 send and receive foot for serial data, for WIFI and microcomputer series interface communication, while microcontroller with
The common GND of WIFI module；Pin 9 resets foot for chip, and low level is effective, and VCC3.3V is pulled to by resistance R2, then with microcontroller
One I/O port is connected, and drags down I/O port resetting WIFI chips；11 chips of pin enable foot, and high level is effective, are pulled up with resistance R1
To VCC3.3.
The Data Analysis Services of the present invention for different signal characteristics, signal can be carried out time-domain analysis, frequency-domain analysis,
Time frequency analysis (wavelet transformation) and transient analysis (Bode diagram, polar diagram), monitor the operating status of lathe in real time,
That is the numerically-controlled machine tool running state data of state analysis prediction and Fig. 4 in Fig. 1.Meanwhile the various data to receiving utilize
Multi-information acquisition theory carries out status assessment and fault tree ID Technology and carries out fault diagnosis, i.e. fault statistics in Fig. 1
Analysis.
As shown in figure 4, the flow of Data Management Analysis is：Lathe is digitally controlled by database server (sql server)
After running state data and processing, then must by lathe running state information recognition methods (threshold values of setting conditions of machine tool data)
To data exception point, then described by phenomenon of the failure and the Trouble Match based on failure tree analysis (FTA) (is used and counted with extracting method
The method for calculating similarity is matched from the fault message storehouse of foundation and extraction obtains incipient fault collection) obtain incipient fault
Collection, fault set is determined finally by the state evaluating method based on Multi-information acquisition theory.(the typical sample in the form of confidence interval
This for reference data, calculate temperature sensor, electric vortex vibrating sensor, Three Phase Power Sensor evidence in incipient fault collection
In reliability density, and be normalized to obtain the belief function distribution of each sensing data to it, then demonstrate,proved by D-S
Fault set is determined according to theory).
Claims (9)
1. a kind of numerically-controlled machine tool operating status long-distance monitoring method, it is characterised in that including：
S1 sensor, on-line checking and acquisition lathe status data) are arranged in lathe main portions；The main portions refer to
Machine tool chief axis, spindle box, knife rest, spindle motor, feeding guide rail；
S2) collected status data feeding microcontroller is handled, then passes to communication module；
S3) data are uploaded to remote server by communication module by router again；
S4) server analyzes and processes status data and fault statistics.
2. monitoring method according to claim 1, it is characterised in that：The status data that the step S1 is acquired includes temperature
Spend information, machine vibration information, spindle motor power and lathe operation data itself.
3. monitoring method according to claim 2, which is characterized in that the step S1 is arranged in lathe main portions and sensed
The method of device specifically includes：
S11) the orientation situation influenced according to the structure of numerically-controlled machine tool, heat source distribution and Thermal Error on workpiece accuracy, temperature is passed
Sensor is arranged in lathe key point position, including spindle box, X-axis guide rail, cutter and motor；When arranging temperature sensor, temperature
Sensor is close to heat source, and its quantity is more than the quantity of numerically controlled lathe heat source；Lathe temperature is obtained finally by temperature sensor
Information；
S12) using 2 non-contact electric eddy vibrating sensors, X, the Y-direction of machine tool chief axis are separately mounted to, obtains lathe
Vibration information；
S13 it) is connected on the three phase electric machine of lathe using Hall-type Three Phase Power Sensor, obtains spindle motor of machine tool power.
4. monitoring method according to claim 1, which is characterized in that step S2 is specifically included：Choose microcontroller circuit
And communication module circuitry, the two is connected, wherein communication module need to embed ICP/IP protocol stack；Microcontroller passes through amplifying circuit
After obtaining conditions of machine tool data with analog to digital conversion circuit, then instructed by AT and establish communication link, microcontroller with communication module
Conditions of machine tool data are sent to communication module finally by transmission-transmission logic serial ports；Then communication module again with router
Carry out network transmission.
5. monitoring method according to claim 4, it is characterised in that：The communication module of step S2 uses and includes wireless network
The chip of function, the router of step S3 are operated in accessing wirelessly dot pattern, by communication module by wireless network and route into
Row communication connection, router transfer data to server by network again.
6. monitoring method according to claim 1, which is characterized in that step S4 is specifically included：Lathe is obtained by server
Running state data and after being analyzed and processed, then data exception point is obtained by lathe running state information recognition methods, so
It is described afterwards by phenomenon of the failure and the Trouble Match based on failure tree analysis (FTA) obtains incipient fault collection with extracting method, finally by
Fault set is determined based on the state evaluating method of Multi-information acquisition theory.
7. monitoring method according to claim 6, which is characterized in that server analyzes lathe running state data
The method of processing includes：Zero averaging processing, wavelet analysis, time-domain analysis, frequency-domain analysis and transient analysis.
8. monitoring method according to claim 6, which is characterized in that the method for obtaining incipient fault collection specifically includes：It is logical
Cross the data exception point identified and phenomenon of the failure description, using calculate similarity method from the fault message storehouse of foundation into
Row matching and extraction obtain incipient fault collection.
9. monitoring method according to claim 6, which is characterized in that the state evaluating method based on Multi-information acquisition theory
It specifically includes：Typical sample in the form of confidence interval is reference data, calculate temperature sensor, electric vortex vibrating sensor,
The reliability density that the evidence of Three Phase Power Sensor is concentrated in incipient fault, and it is normalized to obtain each sensor
The belief function distribution of data, is then determined fault set by D-S evidence theory.
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| CN109064725A (en) * | 2018-07-19 | 2018-12-21 | 大族激光科技产业集团股份有限公司 | Laser cutting device management method, device, system, medium and computer equipment |
| CN109581968A (en) * | 2018-12-18 | 2019-04-05 | 广东原点智能技术有限公司 | A kind of numerically-controlled machine tool real-time monitoring system and its implementation |
| CN110045679A (en) * | 2019-04-17 | 2019-07-23 | 北京天泽智云科技有限公司 | The acquisition of lathe multi-source data and Data Quality Assessment Methodology based on edge calculations |
| CN110109420A (en) * | 2019-03-27 | 2019-08-09 | 苏州艾米妮娜工业智能技术有限公司 | A kind of cloud Intelligent Machining equipment |
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