CN109739183B - Large-scale digit control machine tool fault monitoring system based on multisensor - Google Patents
Large-scale digit control machine tool fault monitoring system based on multisensor Download PDFInfo
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Abstract
The invention discloses a large-scale numerical control machine tool fault monitoring system based on multiple sensors, which comprises a sensor module, a data acquisition module, a summarizing module, a data analysis module, an information monitoring module, a controller, a data interconnection module, a storage module, a data processing module, an emergency stop button, an alarm, a data calculation module and a warning lamp, wherein the data acquisition module is connected with the data acquisition module; according to the tool wear detection system, the data analysis module transmits Ti and Yi to the information monitoring module after acquiring the Ti and the Yi, the information monitoring module compares the Ti and the Yi with preset values t and y respectively to generate a maintenance signal and a replacement signal, the maintenance signal and the replacement signal are transmitted to the data interconnection module together through the controller, and the data interconnection module displays the received maintenance signal and the received replacement signal on a mobile phone of a worker, so that the worker can know the tool wear condition within a period of time conveniently, and the tool with large wear degree can be maintained and replaced.
Description
Technical Field
The invention relates to the technical field of fault monitoring systems, in particular to a large-scale numerical control machine tool fault monitoring system based on multiple sensors.
Background
The numerical control machine tool is a digital control machine tool for short, and is an automatic machine tool provided with a program control system. The numerical control machine can process the program with control code or other symbol instruction, and decode it, and use coded digital representation, then input the numerical control device through the information carrier, and after the operation processing, the numerical control device can give out various control signals to control the action of the machine tool, and according to the shape and size required by the drawing, the part can be automatically machined. And a large number of sensors and travel switches are arranged in the numerical control machine tool, and the safety and accurate operation of the numerical control machine tool are monitored by combining a fault monitoring system.
In the existing fault monitoring system of the numerical control machine tool, the abrasion condition of the tool in a period of time is difficult to monitor and analyze, and further the processing effect and the service life of the tool are easily influenced; the rotating speed condition of the main shaft cannot be monitored and calculated in real time, and corresponding reminding can be timely given, so that the machining precision of the numerical control machine tool is easily influenced; meanwhile, the cutter changing condition of the numerical control machine tool is difficult to judge in real time so as to improve the motion precision of the cutter disc.
In order to solve the above-mentioned drawbacks, a technical solution is now provided.
Disclosure of Invention
The invention aims to provide a fault monitoring system of a large numerical control machine tool based on multiple sensors.
The technical problems to be solved by the invention are as follows:
(1) how to monitor and analyze the wear of the tool over a period of time in an effective manner;
(2) how to monitor and calculate the rotating speed condition of the main shaft in real time and make corresponding prompt in time;
(3) how to judge the tool changing condition of the numerical control machine tool in real time so as to improve the motion precision of the cutter disc.
The purpose of the invention can be realized by the following technical scheme:
a large-scale numerical control machine tool fault monitoring system based on multiple sensors comprises a sensor module, a data acquisition module, a summarizing module, a data analysis module, an information monitoring module, a controller, a data interconnection module, a storage module, a data processing module, an emergency stop button, an alarm, a data calculation module and a warning lamp;
the sensor module is used for collecting data information by a sensor, the sensor comprises a temperature sensor, a rotating speed sensor and a voltage sensor, and the sensor module is used for transmitting the collected data information to the summarizing module; the data acquisition module is used for acquiring the working information of the numerical control machine tool, the working information comprises the working time of a cutter, the using times of the cutter, the cutter changing time of a cutter disc and the number of the cutters which pass by the cutter disc during cutter changing, and the data acquisition module is used for transmitting the acquired working information to the summarizing module; the summarizing module is used for receiving data information transmitted in the sensor module and working information transmitted in the data acquisition module, the summarizing module is used for generating analysis signals together with the working time of the cutter and the using times of the cutter in the working information from the data information and transmitting the analysis signals to the data analysis module, and the data collected by the temperature sensor is the working temperature of the cutter; after receiving the analysis signal, the data analysis module starts to perform analysis operation, and the method specifically comprises the following steps:
the method comprises the following steps: acquiring the highest temperature of each cutter in daily work within a period of time, and calibrating the highest temperature as Qij, i is 1.. n, j is 1.. m, and when i is 1, Q1j represents the highest temperature of the first cutter in daily work within the period of time;
step two: acquiring the working duration of each cutter per day in a period of time, and calibrating the working duration as Wij, i is 1.. n, j is 1.. m, and Qij corresponds to Wij one to one, and when i is 1, W1j represents the working duration of the first cutter per day in a period of time;
step three: acquiring the number of times of use of each cutter per day in a period of time, and calibrating the number of times of use as Eij, i is 1.. n, j is 1.. m, and Qij, Wij and Eij correspond to each other one by one, and when i is 1, E1j represents the number of times of use of the first cutter per day in the period of time;
step four: carrying out weight distribution on the influence ratios of Qij, Wij and Eij in the first step to the third step on the service life of the cutter, sequentially distributing the weight ratios to preset values q, w and e, wherein q is greater than e, and obtaining the wear coefficient of each cutter in each day according to a formula Rij Qij q + Wij w + Eij, wherein when i is 1, R1j represents the wear coefficient of the first cutter in each day in a period of time;
step five: firstly according to the formula
N, calculating the average wear coefficient of each cutter in each day in a period of time, and then calculating the average wear coefficient according to a formula
N, calculating the discrete degree of the wear coefficient of each cutter in each day in a period of time;
the data analysis module transmits the Ti and the Yi to the information monitoring module after acquiring the Ti and the Yi; the information monitoring module compares the received Ti and Yi with preset values t and y respectively, when the Ti is larger than the preset value t and the Yi is larger than the preset value y, a maintenance signal is generated by the cutter corresponding to the Ti or Yi, when the Ti is larger than the preset value t and the Yi is smaller than or equal to the preset value y, a replacement signal is generated by the cutter corresponding to the Ti or Yi, the maintenance signal and the replacement signal are transmitted to the controller, and under other conditions, no signal is generated for transmission; the controller transmits the overhaul signal and the replacement signal to the data interconnection module when receiving the overhaul signal and the replacement signal; the data interconnection module is used for receiving the overhaul signal and the replacement signal and displaying the overhaul signal and the replacement signal on a mobile phone of a worker, so that the worker can overhaul and replace the cutter with high abrasion degree in a period of time conveniently, and the data interconnection module is in communication connection with the mobile phone of the worker; the controller is also used for transmitting the maintenance signal to the storage module, and the storage module generates a maintenance registration table for storage after receiving the maintenance signal, so that a worker can conveniently check and analyze the cutters recorded in the maintenance registration table in the future;
the summarizing module is used for receiving data information transmitted in the sensor module and working information transmitted in the data acquisition module, and is also used for generating processing signals together with data collected by the rotating speed sensor and data collected by the voltage sensor in the data information and transmitting the processing signals to the data processing module, wherein the data collected by the rotating speed sensor is the rotating speed of the main shaft, and the data collected by the voltage sensor is the output voltage of the main shaft; after receiving the processing signal, the data processing module starts to perform processing operation, and the specific steps are as follows:
the method comprises the following steps: acquiring the rotation speed difference between the maximum rotation speed and the minimum rotation speed of a main shaft within each minute except the first minute and the last minute in the machining process of the machine tool in real time, and calibrating the rotation speed difference as Ui, wherein i is 1.. n;
step two: acquiring the voltage difference between the maximum output voltage and the minimum output voltage of the spindle within each minute except the first minute and the last minute in the machining process of the machine tool in real time, and calibrating the voltage difference as Ii, i being 1.. n;
step three: firstly according to the formula
The real-time average rotating speed difference of the main shaft in every minute except the first minute and the last minute in the machining process of the machine tool is obtained according to a formula
The discrete degree of the real-time rotation speed difference of the main shaft in every minute except the first minute and the last minute in the machining process of the machine tool is obtained;
step four: firstly according to the formula
To obtain the real-time average voltage difference of the main shaft in every minute except the first minute and the last minute during the machining process of the machine tool, and then according to the formula
The discrete degree of the real-time voltage difference of the main shaft in every minute except the first minute and the last minute in the machining process of the machine tool is obtained;
the data processing module transmits O, P, A and S to the information monitoring module after acquiring the data; when receiving O, P, A and S, the information monitoring module compares the signals with preset values O, P, a and S respectively to avoid the influence on the rotation speed of the spindle due to unstable output voltage of the spindle and reduce the error in judgment, when A is less than the preset value a, S is less than the preset value S, O is greater than the preset value O, and P is less than the preset value P, a stop signal is generated, when A is less than the preset value a, S is less than the preset value S, O is greater than the preset value O, and P is greater than or equal to the preset value P, an inspection signal is generated and transmitted to the controller, and in other cases, no signal is generated for transmission; when the controller receives a stop signal, the controller controls an emergency stop button of the numerical control machine tool to be started and an alarm to give an alarm, and the controller is electrically connected with the emergency stop button and the alarm; the controller transmits the inspection signal to the data interconnection module when receiving the inspection signal; the data interconnection module is also used for receiving the inspection signal and displaying the inspection signal on a mobile phone of a worker so as to timely remind the worker to overhaul the spindle of the numerical control machine tool after the machining, and the data interconnection module is in communication connection with the mobile phone of the worker;
the summarizing module is used for receiving data information transmitted in the sensor module and working information transmitted in the data acquisition module, and the summarizing module is also used for generating a calculation signal together with the tool changing time of the tool disc and the number of tools moved by the tool disc during tool changing in the working information and transmitting the calculation signal to the data calculation module; after receiving the calculation signal, the data calculation module starts to perform calculation operation, and the specific steps are as follows:
the method comprises the following steps: acquiring the tool changing duration of a tool disc every time in the machining process of a machine tool in real time, and calibrating the tool changing duration as Di, wherein i is 1.
Step two: acquiring the number of tools which pass through a tool disc every time the tool disc changes in the machining process of the machine tool in real time, and calibrating the number as Fi, wherein i is 1.
Step three: according to the formula
N, calculating the time for changing one cutter each time when the cutter disc changes the cutter in the machining process of the machine tool;
step four: firstly according to the formula
The mean value of the time spent by changing one knife every time the cutter disc changes the knife in the machining process of the machine tool is obtained, and the pole difference coefficient of the longest time spent by changing one knife and the shortest time spent by changing one knife in each time the cutter disc changes the knife in the machining process of the machine tool is obtained according to the formula J ═ Gi (Max) -Gi (Min);
after acquiring H and J, the data calculation module transmits the H and J to the information monitoring module; the information monitoring module respectively combines the H and the J with rated values H and J when receiving the H and the J, compares the H and the J with preset values k and l respectively, and when receiving the H and the J, the information monitoring module respectively combines the H and the J with the rated values H and the J, compares the H and the J with the preset values k and the l
Is greater than the preset value k and is,
when the signal is less than the preset value l, generating a detection signal and transmitting the detection signal to the controller, and otherwise, generating no signal for transmission; when receiving the detection signal, the controller controls the emergency stop button of the numerical control machine to be started and the warning lamp to flicker, so that after the numerical control machine is machined, the operator can be prompted timely, and the controller is electrically connected with the emergency stop button and the warning lamp.
Further, the tool changing duration of the tool disc is defined as the time consumed by the tool disc in the process of replacing other tools for machining, and is recorded by a timer.
Further, the period of time is defined as the interval time between the first day of the previous month to the first day of the present month.
The invention has the beneficial effects that:
1. the data analysis module starts analysis operation after receiving an analysis signal, and transmits Ti and Yi to the information monitoring module after obtaining the Ti and Yi, the information monitoring module compares the Ti and Yi with preset values t and y respectively, when the Ti is larger than the preset value t and the Yi is larger than the preset value y, a maintenance signal is generated by a cutter corresponding to the Ti or Yi, when the Ti is larger than the preset value t and the Yi is smaller than or equal to the preset value y, a replacement signal is generated by the cutter corresponding to the Ti or Yi, the maintenance signal and the replacement signal are transmitted to the controller, when the controller receives the maintenance signal and the replacement signal, the controller transmits the maintenance signal and the replacement signal to the data interconnection module, the data interconnection module displays the received maintenance signal and the received replacement signal on a mobile phone of a worker, so that the worker can know the wear condition of the cutter within a period of time, the controller is also used for transmitting the maintenance signal to the storage module, and the storage module generates a maintenance registration table for storage after receiving the maintenance signal so as to facilitate later checking and checking;
2. the data processing module starts processing operation after receiving a processing signal and transmits O, P, A and S to the information monitoring module after obtaining the processing signal, the information monitoring module compares O, P, A and S with preset values O, P, a and S respectively, generates a stop signal when A is less than a preset value a, S is less than a preset value S, O is greater than a preset value O and P is less than a preset value P, generates a check signal when A is less than a preset value a, S is less than a preset value S, O is greater than a preset value O and P is greater than or equal to a preset value P, and simultaneously transmits the stop signal or the check signal to the controller, the controller immediately controls an emergency stop button of the numerical control machine to be started and an alarm to give an alarm when receiving the stop signal, and transmits the check signal to the data interconnection module when receiving the check signal, the data interconnection module can display the received inspection signal on a mobile phone of a worker, so that the rotation speed condition of the spindle can be monitored and calculated in real time conveniently, and the worker can be reminded of maintaining the spindle of the numerical control machine tool in time so as to avoid influencing the machining precision of the numerical control machine tool;
3. the data calculation module starts to perform calculation operation after receiving the calculation signal, transmits H and J to the information monitoring module after acquiring the H and the J, and the information monitoring module is firstly combined with rated values H and J respectively and then compared with preset values k and l respectively when receiving the H and the J, and when receiving the H and the J, the information monitoring module compares the H and the J with preset values k and l respectively
Is greater than the preset value k and is,
when being less than default l, generate the detected signal and transmit to the controller, the controller is when receiving detected signal, and the scram button of control digit control machine tool is opened and the warning light scintillation immediately to real-time understanding the tool changing condition of this digit control machine tool, and timely indicate the staff, with the motion accuracy that improves the cutter dish and the processingquality of part.
Drawings
In order to facilitate understanding for those skilled in the art, the present invention will be further described with reference to the accompanying drawings.
FIG. 1 is a block diagram of the system of the present invention.
Detailed Description
As shown in fig. 1, a fault monitoring system for a large-scale numerical control machine based on multiple sensors comprises a sensor module, a data acquisition module, a summary module, a data analysis module, an information monitoring module, a controller, a data interconnection module, a storage module, a data processing module, an emergency stop button, an alarm, a data calculation module and a warning light;
the sensor module is used for collecting data information by a sensor, the sensor comprises a temperature sensor, a rotating speed sensor and a voltage sensor, and the sensor module is used for transmitting the collected data information to the summarizing module; the data acquisition module is used for acquiring the working information of the numerical control machine tool, the working information comprises the working time of a cutter, the using times of the cutter, the cutter changing time of a cutter disc and the number of the cutters which pass by the cutter disc during cutter changing, and the data acquisition module is used for transmitting the acquired working information to the summarizing module; the summarizing module is used for receiving data information transmitted in the sensor module and working information transmitted in the data acquisition module, the summarizing module is used for generating analysis signals together with the working time of the cutter and the using times of the cutter in the working information from the data information and transmitting the analysis signals to the data analysis module, and the data collected by the temperature sensor is the working temperature of the cutter; after receiving the analysis signal, the data analysis module starts to perform analysis operation, and the method specifically comprises the following steps:
the method comprises the following steps: acquiring the highest temperature of each cutter in daily work within a period of time, and calibrating the highest temperature as Qij, i is 1.. n, j is 1.. m, and when i is 1, Q1j represents the highest temperature of the first cutter in daily work within the period of time;
step two: acquiring the working duration of each cutter per day in a period of time, and calibrating the working duration as Wij, i is 1.. n, j is 1.. m, and Qij corresponds to Wij one to one, and when i is 1, W1j represents the working duration of the first cutter per day in a period of time;
step three: acquiring the number of times of use of each cutter per day in a period of time, and calibrating the number of times of use as Eij, i is 1.. n, j is 1.. m, and Qij, Wij and Eij correspond to each other one by one, and when i is 1, E1j represents the number of times of use of the first cutter per day in the period of time;
step four: carrying out weight distribution on the influence ratios of Qij, Wij and Eij in the first step to the third step on the service life of the cutter, sequentially distributing the weight ratios to preset values q, w and e, wherein q is greater than e, and obtaining the wear coefficient of each cutter in each day according to a formula Rij Qij q + Wij w + Eij, wherein when i is 1, R1j represents the wear coefficient of the first cutter in each day in a period of time;
step five: firstly according to the formula
N, calculating the average wear coefficient of each cutter in each day in a period of time, and then calculating the average wear coefficient according to a formula
N, calculating the discrete degree of the wear coefficient of each cutter in each day in a period of time;
the data analysis module transmits the Ti and the Yi to the information monitoring module after acquiring the Ti and the Yi; the information monitoring module compares the received Ti and Yi with preset values t and y respectively, when the Ti is larger than the preset value t and the Yi is larger than the preset value y, a maintenance signal is generated by the cutter corresponding to the Ti or Yi, when the Ti is larger than the preset value t and the Yi is smaller than or equal to the preset value y, a replacement signal is generated by the cutter corresponding to the Ti or Yi, the maintenance signal and the replacement signal are transmitted to the controller, and under other conditions, no signal is generated for transmission; the controller transmits the overhaul signal and the replacement signal to the data interconnection module when receiving the overhaul signal and the replacement signal; the data interconnection module is used for receiving the overhaul signal and the replacement signal and displaying the overhaul signal and the replacement signal on a mobile phone of a worker, so that the worker can overhaul and replace the cutter with high abrasion degree in a period of time conveniently, and the data interconnection module is in communication connection with the mobile phone of the worker; the controller is also used for transmitting the maintenance signal to the storage module, and the storage module generates a maintenance registration table for storage after receiving the maintenance signal, so that a worker can conveniently check and analyze the cutters recorded in the maintenance registration table in the future;
the summarizing module is used for receiving data information transmitted in the sensor module and working information transmitted in the data acquisition module, and is also used for generating processing signals together with data collected by the rotating speed sensor and data collected by the voltage sensor in the data information and transmitting the processing signals to the data processing module, wherein the data collected by the rotating speed sensor is the rotating speed of the main shaft, and the data collected by the voltage sensor is the output voltage of the main shaft; after receiving the processing signal, the data processing module starts to perform processing operation, and the specific steps are as follows:
the method comprises the following steps: acquiring the rotation speed difference between the maximum rotation speed and the minimum rotation speed of a main shaft within each minute except the first minute and the last minute in the machining process of the machine tool in real time, and calibrating the rotation speed difference as Ui, wherein i is 1.. n;
step two: acquiring the voltage difference between the maximum output voltage and the minimum output voltage of the spindle within each minute except the first minute and the last minute in the machining process of the machine tool in real time, and calibrating the voltage difference as Ii, i being 1.. n;
step three: firstly according to the formula
The real-time average rotating speed difference of the main shaft in every minute except the first minute and the last minute in the machining process of the machine tool is obtained according to a formula
The discrete degree of the real-time rotation speed difference of the main shaft in every minute except the first minute and the last minute in the machining process of the machine tool is obtained;
step four: firstly according to the formula
To obtain the real-time average voltage difference of the main shaft in every minute except the first minute and the last minute during the machining process of the machine tool, and then according to the formula
The discrete degree of the real-time voltage difference of the main shaft in every minute except the first minute and the last minute in the machining process of the machine tool is obtained;
the data processing module transmits O, P, A and S to the information monitoring module after acquiring the data; when receiving O, P, A and S, the information monitoring module compares the signals with preset values O, P, a and S respectively to avoid the influence on the rotation speed of the spindle due to unstable output voltage of the spindle and reduce the error in judgment, when A is less than the preset value a, S is less than the preset value S, O is greater than the preset value O, and P is less than the preset value P, a stop signal is generated, when A is less than the preset value a, S is less than the preset value S, O is greater than the preset value O, and P is greater than or equal to the preset value P, an inspection signal is generated and transmitted to the controller, and in other cases, no signal is generated for transmission; when the controller receives a stop signal, the controller controls an emergency stop button of the numerical control machine tool to be started and an alarm to give an alarm, and the controller is electrically connected with the emergency stop button and the alarm; the controller transmits the inspection signal to the data interconnection module when receiving the inspection signal; the data interconnection module is also used for receiving the inspection signal and displaying the inspection signal on a mobile phone of a worker so as to timely remind the worker to overhaul the spindle of the numerical control machine tool after the machining, and the data interconnection module is in communication connection with the mobile phone of the worker;
the summarizing module is used for receiving data information transmitted in the sensor module and working information transmitted in the data acquisition module, and the summarizing module is also used for generating a calculation signal together with the tool changing time of the tool disc and the number of tools moved by the tool disc during tool changing in the working information and transmitting the calculation signal to the data calculation module; after receiving the calculation signal, the data calculation module starts to perform calculation operation, and the specific steps are as follows:
the method comprises the following steps: acquiring the tool changing duration of a tool disc every time in the machining process of a machine tool in real time, and calibrating the tool changing duration as Di, wherein i is 1.
Step two: acquiring the number of tools which pass through a tool disc every time the tool disc changes in the machining process of the machine tool in real time, and calibrating the number as Fi, wherein i is 1.
Step three: according to the formula
N, calculating the time for changing one cutter each time when the cutter disc changes the cutter in the machining process of the machine tool;
step four: firstly according to the formula
The mean value of the time spent by changing one knife every time the cutter disc changes the knife in the machining process of the machine tool is obtained, and the pole difference coefficient of the longest time spent by changing one knife and the shortest time spent by changing one knife in each time the cutter disc changes the knife in the machining process of the machine tool is obtained according to the formula J ═ Gi (Max) -Gi (Min);
after acquiring H and J, the data calculation module transmits the H and J to the information monitoring module; the information monitoring module respectively combines the H and the J with rated values H and J when receiving the H and the J, compares the H and the J with preset values k and l respectively, and when receiving the H and the J, the information monitoring module respectively combines the H and the J with the rated values H and the J, compares the H and the J with the preset values k and the l
Is greater than the preset value k and is,
when the signal is less than the preset value l, generating a detection signal and transmitting the detection signal to the controller, and otherwise, generating no signal for transmission; when receiving the detection signal, the controller controls the emergency stop button of the numerical control machine to be opened and the warning lamp to flicker, so that after the processing, the operator can be prompted timely, and the controller, the emergency stop button and the emergency stop buttonThe warning light is electrically connected.
Further, the tool changing duration of the tool disc is defined as the time consumed by the tool disc in the process of replacing other tools for machining, and is recorded by a timer.
Further, the period of time is defined as the interval time between the first day of the previous month to the first day of the present month.
A large-scale numerical control machine tool fault monitoring system based on multiple sensors is characterized in that in the working process, data information and working information are collected by a sensor module and a data acquisition module respectively and are transmitted to a summarizing module together, the data information comprises data collected by a temperature sensor, a rotating speed sensor and a voltage sensor respectively, the working information comprises the working time length of a cutter, the using times of the cutter, the cutter changing time length of a cutter disc and the number of cutters which pass when the cutter disc is changed, the summarizing module generates analysis signals and transmits the analysis signals to a data analysis module after receiving the data information and the working information, the temperature data collected by the temperature sensor during working, the working time length of the cutter in the working information and the using times of the cutter together, the data analysis module starts to perform analysis operation after receiving the analysis signals and acquires Ti and Yi, the information monitoring module compares Ti and Yi with preset values t and y respectively, when Ti is larger than the preset value t and Yi is larger than the preset value y, a maintenance signal is generated by a cutter corresponding to Ti or Yi, when Ti is larger than the preset value t and Yi is smaller than or equal to the preset value y, a replacement signal is generated by the cutter corresponding to Ti or Yi, the maintenance signal and the replacement signal are transmitted to the controller, the controller transmits the maintenance signal and the replacement signal to the data interconnection module when receiving the maintenance signal and the replacement signal, the data interconnection module displays the received maintenance signal and the received replacement signal on a mobile phone of a worker, the worker can know the wear condition of the cutter within a period of time and maintain and replace the cutter with large wear degree so as to improve the processing effect and the service life of the cutter, and the controller is also used for transmitting the maintenance signal to the storage module, after receiving the maintenance signal, the storage module generates a maintenance registration table for storage so as to facilitate later checking and checking;
meanwhile, after receiving the data information and the working information, the summarizing module generates processing signals together with the rotating speed data of the main shaft collected by the rotating speed sensor and the output voltage data of the main shaft collected by the voltage sensor and transmits the processing signals to the data processing module, the data processing module starts processing operation after receiving the processing signals and transmits the processing signals to the information monitoring module after obtaining O, P, A and S, the information monitoring module compares the processing signals with preset values O, P, a and S respectively when receiving O, P, A and S, generates a stop signal when meeting the condition that A is less than the preset value a, S is less than the preset value S, O is greater than the preset value O, and P is less than the preset value P, generates a check signal when meeting the condition that A is less than the preset value a, S is less than the preset value S, O is greater than the preset value O, and P is greater than or equal to the preset value P, meanwhile, a stop signal or an inspection signal is transmitted to the controller, when the controller receives the stop signal, the controller immediately controls an emergency stop button of the numerical control machine to be started and an alarm to give an alarm, when the controller receives the inspection signal, the controller transmits the inspection signal to the data interconnection module, the data interconnection module can display the received inspection signal on a mobile phone of a worker, real-time monitoring and calculation of the rotating speed condition of the spindle are facilitated, and meanwhile, the worker can be timely reminded of maintaining the spindle of the numerical control machine so as to avoid influencing the processing precision of the numerical control machine;
and the summarizing module generates a calculation signal together with the tool changing duration of the tool disc in the working information and the number of tools which the tool disc moves during tool changing after receiving the data information and the working information and transmits the calculation signal to the data calculation module, the data calculation module starts calculation operation after receiving the calculation signal and transmits the calculation signal to the information monitoring module after acquiring H and J, the information monitoring module is firstly combined with rated values H and J respectively and then is compared with preset values k and l respectively when receiving H and J, and when receiving H and J, the information monitoring module is used for comparing the H and J with the rated values H and J respectively
Is greater than the preset value k and is,
when being less than default l, generate the detected signal and transmit to the controller, the controller is when receiving detected signal, and the scram button of control digit control machine tool is opened and the warning light scintillation immediately to real-time understanding the tool changing condition of this digit control machine tool, and timely indicate the staff, with the motion accuracy that improves the cutter dish and the processingquality of part.
The invention has the following beneficial effects:
(1) the data analysis module starts analysis operation after receiving an analysis signal, and transmits Ti and Yi to the information monitoring module after obtaining the Ti and Yi, the information monitoring module compares the Ti and Yi with preset values t and y respectively, when the Ti is larger than the preset value t and the Yi is larger than the preset value y, a maintenance signal is generated by a cutter corresponding to the Ti or Yi, when the Ti is larger than the preset value t and the Yi is smaller than or equal to the preset value y, a replacement signal is generated by the cutter corresponding to the Ti or Yi, the maintenance signal and the replacement signal are transmitted to the controller, when the controller receives the maintenance signal and the replacement signal, the controller transmits the maintenance signal and the replacement signal to the data interconnection module, the data interconnection module displays the received maintenance signal and the received replacement signal on a mobile phone of a worker, so that the worker can know the wear condition of the cutter within a period of time, the controller is also used for transmitting the maintenance signal to the storage module, and the storage module generates a maintenance registration table for storage after receiving the maintenance signal so as to facilitate later checking and checking;
(2) the data processing module starts processing operation after receiving a processing signal and transmits O, P, A and S to the information monitoring module after obtaining the processing signal, the information monitoring module compares O, P, A and S with preset values O, P, a and S respectively, generates a stop signal when A is less than a preset value a, S is less than a preset value S, O is greater than a preset value O and P is less than a preset value P, generates a check signal when A is less than a preset value a, S is less than a preset value S, O is greater than a preset value O and P is greater than or equal to a preset value P, and simultaneously transmits the stop signal or the check signal to the controller, the controller immediately controls an emergency stop button of the numerical control machine to be started and an alarm to give an alarm when receiving the stop signal, and transmits the check signal to the data interconnection module when receiving the check signal, the data interconnection module can display the received inspection signal on a mobile phone of a worker, so that the rotation speed condition of the spindle can be monitored and calculated in real time conveniently, and the worker can be reminded of maintaining the spindle of the numerical control machine tool in time so as to avoid influencing the machining precision of the numerical control machine tool;
(3) the data calculation module starts to perform calculation operation after receiving the calculation signal, transmits H and J to the information monitoring module after acquiring the H and the J, and the information monitoring module is firstly combined with rated values H and J respectively and then compared with preset values k and l respectively when receiving the H and the J, and when receiving the H and the J, the information monitoring module compares the H and the J with preset values k and l respectively
Is greater than the preset value k and is,
when being less than default l, generate the detected signal and transmit to the controller, the controller is when receiving detected signal, and the scram button of control digit control machine tool is opened and the warning light scintillation immediately to real-time understanding the tool changing condition of this digit control machine tool, and timely indicate the staff, with the motion accuracy that improves the cutter dish and the processingquality of part.
The foregoing is merely exemplary and illustrative of the present invention and various modifications, additions and substitutions may be made by those skilled in the art to the specific embodiments described without departing from the scope of the invention as defined in the following claims.
Claims (3)
1. A large-scale numerical control machine tool fault monitoring system based on multiple sensors is characterized by comprising a sensor module, a data acquisition module, a summarizing module, a data analysis module, an information monitoring module, a controller, a data interconnection module, a storage module, a data processing module, an emergency stop button, an alarm, a data calculation module and a warning lamp;
the sensor module is used for collecting data information by a sensor, the sensor comprises a temperature sensor, a rotating speed sensor and a voltage sensor, and the sensor module is used for transmitting the collected data information to the summarizing module; the data acquisition module is used for acquiring the working information of the numerical control machine tool, the working information comprises the working time of a cutter, the using times of the cutter, the cutter changing time of a cutter disc and the number of the cutters which pass by the cutter disc during cutter changing, and the data acquisition module is used for transmitting the acquired working information to the summarizing module; the summarizing module is used for receiving data information transmitted in the sensor module and working information transmitted in the data acquisition module, the summarizing module is used for generating analysis signals together with the working time of the cutter and the using times of the cutter in the working information from the data information and transmitting the analysis signals to the data analysis module, and the data collected by the temperature sensor is the working temperature of the cutter; after receiving the analysis signal, the data analysis module starts to perform analysis operation, and the method specifically comprises the following steps:
the method comprises the following steps: acquiring the highest temperature of each cutter in daily work within a period of time, and calibrating the highest temperature as Qij, i being 1.. n, j being 1.. m;
step two: acquiring the working time of each cutter every day in a period of time, and calibrating the working time as Wij, wherein i is 1.. n, j is 1.. m, and Qij corresponds to Wij one by one;
step three: acquiring the use times of each cutter every day in a period of time, and calibrating the use times as Eij, i is 1.. n, j is 1.. m, and Qij and Wij correspond to Eij one by one;
step four: carrying out weight distribution on the influence ratios of Qij, Wij and Eij in the first step to the third step on the service life of the cutter, sequentially distributing the weight ratios to preset values q, w and e, wherein q is greater than e, and obtaining the wear coefficient of each cutter in each day in a period of time according to a formula Rij Qij q + Wij w + Eij;
step five: firstly according to the formula
To obtain the average wear coefficient of each cutter in each day in a period of time, and then according to the formula
The discrete degree of the abrasion coefficient of each cutter in each day in a period of time is obtained;
the data analysis module transmits the Ti and the Yi to the information monitoring module after acquiring the Ti and the Yi; the information monitoring module compares the received Ti and Yi with preset values t and y respectively, generates maintenance signals for the cutter corresponding to the Ti or Yi when the Ti is larger than the preset value t and the Yi is larger than the preset value y, generates replacement signals for the cutter corresponding to the Ti or Yi when the Ti is larger than the preset value t and the Yi is smaller than or equal to the preset value y, and transmits one of the maintenance signals and the replacement signals to the controller; the controller transmits the maintenance signal or the replacement signal to the data interconnection module when receiving the maintenance signal or the replacement signal; the data interconnection module is used for receiving the overhaul signal and the replacement signal and displaying the overhaul signal and the replacement signal on a mobile phone of a worker, and the data interconnection module is in communication connection with the mobile phone of the worker; the controller is also used for transmitting the maintenance signal to the storage module, and the storage module generates a maintenance registration table for storage after receiving the maintenance signal;
the summarizing module is used for receiving data information transmitted in the sensor module and working information transmitted in the data acquisition module, and is also used for generating processing signals together with data collected by the rotating speed sensor and data collected by the voltage sensor in the data information and transmitting the processing signals to the data processing module, wherein the data collected by the rotating speed sensor is the rotating speed of the main shaft, and the data collected by the voltage sensor is the output voltage of the main shaft; after receiving the processing signal, the data processing module starts to perform processing operation, and the specific steps are as follows:
the method comprises the following steps: acquiring the rotation speed difference between the maximum rotation speed and the minimum rotation speed of a main shaft within each minute except the first minute and the last minute in the machining process of the machine tool in real time, and calibrating the rotation speed difference as Ui, wherein i is 1.. n;
step two: acquiring the voltage difference between the maximum output voltage and the minimum output voltage of the spindle within each minute except the first minute and the last minute in the machining process of the machine tool in real time, and calibrating the voltage difference as Ii, i being 1.. n;
step three: firstly according to the formula
The real-time average rotating speed difference of the main shaft in every minute except the first minute and the last minute in the machining process of the machine tool is obtained according to a formula
The discrete degree of the real-time rotation speed difference of the main shaft in every minute except the first minute and the last minute in the machining process of the machine tool is obtained;
step four: firstly according to the formula
To obtain the real-time average voltage difference of the main shaft in every minute except the first minute and the last minute during the machining process of the machine tool, and then according to the formula
The discrete degree of the real-time voltage difference of the main shaft in every minute except the first minute and the last minute in the machining process of the machine tool is obtained;
the data processing module transmits O, P, A and S to the information monitoring module after acquiring the data; the information monitoring module compares O, P, A and S with preset values O, P, a and S respectively when receiving the signals, generates a stop signal when meeting the conditions that A is smaller than the preset value a, S is smaller than the preset value S, O is larger than the preset value O, and P is smaller than the preset value P, generates a check signal when meeting the conditions that A is smaller than the preset value a, S is smaller than the preset value S, O is larger than the preset value O, and P is larger than or equal to the preset value P, and transmits the stop signal or the check signal to the controller; when the controller receives a stop signal, the controller controls an emergency stop button of the numerical control machine tool to be started and an alarm to give an alarm, and the controller is electrically connected with the emergency stop button and the alarm; the controller transmits the inspection signal to the data interconnection module when receiving the inspection signal; the data interconnection module is also used for receiving the inspection signal and displaying the inspection signal on the mobile phone of the worker, and the data interconnection module is in communication connection with the mobile phone of the worker;
the summarizing module is used for receiving data information transmitted in the sensor module and working information transmitted in the data acquisition module, and the summarizing module is also used for generating a calculation signal together with the tool changing time of the tool disc and the number of tools moved by the tool disc during tool changing in the working information and transmitting the calculation signal to the data calculation module; after receiving the calculation signal, the data calculation module starts to perform calculation operation, and the specific steps are as follows:
the method comprises the following steps: acquiring the tool changing duration of a tool disc every time in the machining process of a machine tool in real time, and calibrating the tool changing duration as Di, wherein i is 1.
Step two: acquiring the number of tools which pass through a tool disc every time the tool disc changes in the machining process of the machine tool in real time, and calibrating the number as Fi, wherein i is 1.
Step three: according to the formula
The time for changing one cutter every time when the cutter disc changes the cutter in the machining process of the machine tool is obtained;
step four: firstly according to the formula
The average value of the time spent by changing a knife every time the cutter disc changes the knife in the machining process of the machine tool is obtained, and the pole difference between the longest time spent by changing a knife and the shortest time spent by changing a knife in the machining process of the machine tool is obtained according to the formula J ═ Gi (Max) -Gi (Min) in the machining process of the machine toolA coefficient;
after acquiring H and J, the data calculation module transmits the H and J to the information monitoring module; the information monitoring module respectively combines the H and the J with rated values H and J when receiving the H and the J, compares the H and the J with preset values k and l respectively, and when receiving the H and the J, the information monitoring module respectively combines the H and the J with the rated values H and the J, compares the H and the J with the preset values k and the l
Is greater than the preset value k and is,
when the signal is less than the preset value l, generating a detection signal and transmitting the detection signal to the controller; when the controller receives the detection signal, the controller controls an emergency stop button of the numerical control machine to be started and a warning lamp to flicker, and the controller is electrically connected with the emergency stop button and the warning lamp.
2. The system for monitoring the faults of the large-scale numerical control machine tool based on the multiple sensors as claimed in claim 1, wherein the tool changing duration of the tool disk is defined as the time consumed by the tool disk in the process of replacing other tools for processing, and is recorded by a timer.
3. The system according to claim 1, wherein the period of time is defined as an interval time from the first day of the previous month to the first day of the present month.
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| CN111948978A (en) * | 2019-05-17 | 2020-11-17 | 湖北欧安电气股份有限公司 | Data acquisition and monitoring system based on numerical control machine tool |
| CN112304362A (en) * | 2020-08-26 | 2021-02-02 | 帝杰曼科技股份有限公司 | Real-time monitoring system based on environmental big data |
| CN112305992A (en) * | 2020-10-24 | 2021-02-02 | 西安航天动力测控技术研究所 | Unattended processing method of numerical control processing equipment |
| CN113759826B (en) * | 2021-09-06 | 2022-10-11 | 江苏中智自动化股份有限公司 | Intelligent monitoring system of five-axis machining center |
| CN114047733B (en) * | 2021-11-15 | 2023-12-29 | 界首市粮食机械有限责任公司 | Safety control system based on flexible production line of bearing roller |
| CN117872962A (en) * | 2024-03-11 | 2024-04-12 | 南通钜盛数控机床有限公司 | Control system of numerical control machine tool |
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