CN109781244B - System and method for detecting vibration signal of numerical control machine tool cutter - Google Patents
System and method for detecting vibration signal of numerical control machine tool cutter Download PDFInfo
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Abstract
The invention discloses a system and a method for detecting vibration signals of a numerical control machine tool cutter, wherein the system comprises a vibration signal acquisition device, a data processing module and an analysis and judgment module; the vibration signal acquisition device is fixed on a tool post of the numerical control machine tool and used for detecting tool vibration information and outputting corresponding detection signals to the data processing module; the data processing module is used for carrying out differential amplification processing on the detection signal and then outputting data to be analyzed to the analysis and judgment module; the analysis and judgment module is used for judging and classifying the currently acquired data to be analyzed according to the pre-stored data category and outputting an early warning signal when judging that the data is the abnormal vibration data category. The rigid vibration signal acquisition device fixed on the machine tool in a packaging mode acquires the running state information of the machine tool cutter in a non-contact mode, fault detection and early warning of the cutter vibration signal are achieved based on the data type of pre-training identification, and the rigid vibration signal acquisition device has the advantages of being high in sensitivity, non-contact detection, high in measurement identification accuracy and the like.
Description
Technical Field
The invention relates to the technical field of vibration detection, in particular to a system and a method for detecting vibration signals of a numerical control machine tool cutter.
Background
The function of the numerical control machine tool is indispensable in modern manufacturing industries such as aerospace, mechanical manufacturing, petrochemical industry and the like, the level of independent innovation and development of the numerical control machine tool and the requirements of national economy and national construction have very important strategic significance on the development of future science and technology in China. The vibration detection and analysis of the numerical control machine tool has important significance, wherein the cutter is a part which is damaged most frequently on the machine tool, the machining precision of the machine tool can be influenced by the abrasion of the cutter, and serious economic loss is caused, so that the abnormal vibration of the numerical control machine tool is mainly detected aiming at the abnormal vibration of the machine tool cutter.
At present, most of the conventional sensors, such as a speed sensor and an acceleration sensor, are used for detecting vibration signals of the tool of the numerical control machine tool, and then the change of the sensor parameters is recorded and analyzed. However, the conventional sensor generally has a small variation range of the resistance value under the condition of vibration of the tool of the numerical control machine tool, and most sensors are in contact detection, which does not reflect the abnormal vibration of the tool of the machine tool accurately enough, and the acquired data has a large error, which affects the accuracy of the analysis result.
Thus, the prior art has yet to be improved and enhanced.
Disclosure of Invention
In view of the defects of the prior art, the invention aims to provide a system and a method for detecting vibration signals of a numerical control machine tool cutter.
In order to achieve the purpose, the invention adopts the following technical scheme:
a vibration signal detection system for a numerical control machine tool cutter comprises a vibration signal acquisition device, a data processing module and an analysis and judgment module; the vibration signal acquisition device is fixed on a tool post of the numerical control machine tool and is electrically connected with the data processing module, and the vibration signal acquisition device is used for detecting vibration information of the tool and outputting a corresponding detection signal to the data processing module; the data processing module is also electrically connected with the analysis and judgment module and is used for carrying out differential amplification processing on the received detection signal and outputting data to be analyzed to the analysis and judgment module; the analysis and judgment module is used for judging and classifying the currently acquired data to be analyzed according to the pre-stored data category and outputting an early warning signal when judging that the data is the abnormal vibration data category.
The utility model discloses a digit control machine tool cutter vibration signal detection system, including being fixed in the protective housing on the digit control machine tool platform, vibration signal acquisition device and paste the inside surface of protective housing has the flexible foil gage of crackle array, the surface of flexible foil gage still coats and has conductive coating, the both ends of flexible foil gage be provided with the electrode lead that the data processing module electricity is connected, the resistance that the flexible foil gage changes in real time according to cutter vibration information output is to data processing module.
In the system for detecting the vibration signal of the cutter of the numerical control machine tool, the protective shell comprises a base and a protective outer cover, the base comprises a substrate, a support frame is arranged on the substrate, two ends of the flexible strain gauge are correspondingly adhered to two ends of the support frame, a first groove is formed in the middle of the support frame, and a frame matched with the protective outer cover is further arranged around the support frame; the bottom of the protection housing is provided with a second groove, the protection housing and the base are assembled into a whole through the frame and the second groove, and the side face of the protection housing is also provided with a through wire hole.
Digit control machine tool cutter vibration signal detecting system in, be provided with first screw hole on the base plate, on the protection dustcoat with the position that first screw hole corresponds is provided with the second screw hole, runs through the connecting piece will behind first screw hole and the second screw hole vibration signal collection system is fixed in on the digit control machine tool sword platform to realize non-contact's lathe cutter vibration information acquisition.
In the system for detecting the vibration signal of the numerical control machine tool cutter, sealant is arranged between the frame and the second groove and in the through hole.
In the system for detecting the vibration signal of the numerical control machine tool cutter, the data processing module comprises a conversion unit, a differential amplification unit and a data acquisition unit; the conversion unit is electrically connected with the flexible strain gauge and the differential amplification unit and is used for converting the real-time change resistance value of the flexible strain gauge into a corresponding voltage signal and outputting the voltage signal to the differential amplification unit; the differential amplification unit is connected with the data acquisition unit and is used for performing differential calculation on the voltage signal, amplifying the voltage signal and outputting a discrete signal to the data acquisition unit; the data acquisition unit is also connected with the analysis and judgment module and is used for acquiring the discrete signals output by the differential amplification unit and then outputting the data to be analyzed to the analysis and judgment module.
In the system for detecting the vibration signal of the cutter of the numerical control machine tool, the conversion unit is a Wheatstone bridge, the flexible strain gauge is connected with an empty bridge arm of the Wheatstone bridge through electrode leads at two ends, and the output end of the Wheatstone bridge is connected with the differential amplification unit.
In the system for detecting the vibration signal of the cutter of the numerical control machine tool, the analysis and judgment module comprises a training and recognition unit, a classification unit and a fault early warning unit; the training identification unit is used for generating corresponding data categories according to pre-collected training samples and a preset training model; the classification unit is used for judging and classifying the currently acquired data to be analyzed according to the data category; the fault early warning unit is used for outputting an early warning signal when the current data to be analyzed is judged to be the abnormal vibration data type.
A method for detecting vibration signals of a cutter of a numerical control machine tool comprises the following steps:
detecting tool vibration information by a vibration signal acquisition device fixed on a tool post of the numerical control machine tool and outputting a corresponding detection signal;
carrying out differential amplification processing on the received detection signals and outputting data to be analyzed;
judging and classifying the currently acquired data to be analyzed according to the pre-stored data category, and outputting an early warning signal when judging that the data is the abnormal vibration data category.
In the method for detecting the vibration signal of the cutter of the numerical control machine tool, the steps of judging and classifying the currently collected data to be analyzed according to the pre-stored data category and outputting the early warning signal when judging the data category to be analyzed is abnormal vibration data category comprise:
generating corresponding data categories according to pre-collected training samples and a preset training model;
judging and classifying the currently acquired data to be analyzed according to the data category;
and outputting an early warning signal when the current data to be analyzed is judged to be the abnormal vibration data type.
Compared with the prior art, in the system and the method for detecting the vibration signal of the numerical control machine tool cutter, the system for detecting the vibration signal of the numerical control machine tool cutter comprises a vibration signal acquisition device, a data processing module and an analysis and judgment module; the vibration signal acquisition device is fixed on a tool post of the numerical control machine tool and is electrically connected with the data processing module, and the vibration signal acquisition device is used for detecting vibration information of the tool and outputting a corresponding detection signal to the data processing module; the data processing module is also electrically connected with the analysis and judgment module and is used for carrying out differential amplification processing on the received detection signal and outputting data to be analyzed to the analysis and judgment module; the analysis and judgment module is used for judging and classifying the currently acquired data to be analyzed according to the pre-stored data category and outputting an early warning signal when judging that the data is the abnormal vibration data category. The rigid vibration signal acquisition device fixed on the machine tool in a packaging mode acquires the running state information of the machine tool cutter in a non-contact mode, fault detection and early warning of the cutter vibration signal are achieved based on the data type of pre-training identification, and the rigid vibration signal acquisition device has the advantages of being high in sensitivity, non-contact detection, high in measurement identification accuracy and the like.
Drawings
Fig. 1 is a block diagram of a vibration signal detection system of a tool of a numerical control machine tool provided by the invention.
Fig. 2 is a schematic side view of a flexible strain gauge and a base in the vibration signal acquisition device provided by the invention.
Fig. 3 is a perspective view of a flexible strain gauge and a base in the vibration signal acquisition device provided by the invention.
Fig. 4 is a perspective view of an angle of a protective cover in the vibration signal acquisition apparatus provided by the present invention.
Fig. 5 is a perspective view of another angle of the protective cover of the vibration signal acquisition device provided by the present invention.
Fig. 6 is a schematic diagram of a flexible strain gauge in a vibration signal acquisition device provided by the invention in a pressed state.
Fig. 7 is a schematic diagram of a flexible strain gauge in a vibration signal acquisition device provided by the invention in a stretching state.
FIG. 8 is a circuit diagram of a Wheatstone bridge in the system for detecting vibration signals of the tool of the numerical control machine tool provided by the present invention.
Fig. 9 is a circuit diagram of a differential amplification unit in the system for detecting vibration signals of the tool of the numerical control machine tool provided by the invention.
Fig. 10 to 19 are circuit diagrams of a data acquisition unit in the system for detecting vibration signals of a tool of a numerical control machine tool according to the present invention.
Fig. 20 is a flowchart of a method for detecting vibration signals of a tool of a numerical control machine tool according to the present invention.
Detailed Description
The invention provides a system and a method for detecting vibration signals of a numerical control machine tool cutter.
In order to make the objects, technical solutions and effects of the present invention clearer and clearer, the present invention is further described in detail below with reference to the accompanying drawings and examples. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Referring to fig. 1, the system for detecting vibration signals of a cutting tool of a numerical control machine tool according to the present invention comprises a vibration signal collecting device 1, a data processing module 2 and an analyzing and judging module 3, the vibration signal acquisition device 1 is fixed on a tool post of the numerical control machine tool and is electrically connected with the data processing module 2, the data processing module 2 is also electrically connected with the analysis and judgment module 3, wherein, the vibration signal acquisition device 1 is used for detecting the vibration information of the cutter and outputting a corresponding detection signal to the data processing module 2, the data processing module 2 is used for performing differential amplification processing on the received detection signal and outputting data to be analyzed to the analysis and judgment module 3, the analysis and judgment module 3 is used for judging and classifying the currently acquired data to be analyzed according to the pre-stored data category, and outputting an early warning signal when judging that the data is the abnormal vibration data category. In the vibration signal detection system for the cutter of the numerical control machine tool, the vibration signal acquisition device 1 arranged on the numerical control machine tool is used for acquiring the running state information of the cutter of the machine tool in a non-contact mode, feeding back data to be analyzed after data processing is carried out on detection signals, judging and classifying the currently acquired data to be analyzed based on the data types which are trained, identified and stored in advance, and outputting early warning signals in time when the data types are judged to be abnormal vibration data types, so that the fault detection and early warning of the vibration signals of the cutter are realized, and the vibration signal detection system has the advantages of high sensitivity, non-contact detection, high measurement and identification precision and the like.
Specifically, please refer to fig. 2 to 7, which are schematic structural diagrams of a vibration signal acquisition device 1 in the system for detecting vibration signals of a tool of a numerical control machine tool provided by the present invention, wherein the vibration signal acquisition device 1 includes a protective shell fixed on a tool post of the numerical control machine tool, and a flexible strain gauge 10 having a crack array on a surface thereof and adhered to an inner portion of the protective shell, a conductive coating is further coated on a surface of the flexible strain gauge 10, electrode leads 101 electrically connected to the data processing module 2 are disposed at two ends of the flexible strain gauge 10, and the flexible strain gauge 10 outputs a real-time changing resistance value to the data processing module 2 according to tool vibration information. The vibration signal acquisition device 1 provided by the invention is characterized in that the flexible strain gauge 10 with the crack array and the rigid protective shell are assembled into a whole and then fixed on a cutter table of a numerical control machine tool, the numerical control machine tool can vibrate during operation, the flexible strain gauge 10 vibrates along with the flexible strain gauge, the micro-crack structure on the surface of the flexible strain gauge 10 changes when the flexible strain gauge 10 vibrates, so that the resistance of the flexible strain gauge 10 changes, the real-time changed resistance value is used as a detection signal of cutter vibration and is converted into an electric signal to be output through the data processing module 2 subsequently, the flexible strain gauge 10 is adopted to sense the vibration of the cutter of the numerical control machine tool, the vibration information of the cutter is detected and analyzed in a non-contact manner, the response is sensitive, the measurement precision is high, and the accuracy of.
Preferably, the surface of the flexible strain gauge 10 has a microcrack array with a regularly controllable arrangement, and specifically, a crack pattern can be designed according to actual requirements, the crack array in this embodiment is preferably a scorpion crack-like structure, and belongs to a biomimetic sensor, that is, a method of using the easy-to-crack property of Polystyrene (PS) to induce expansion by a solvent and transfer by a double template is used to prepare a plurality of parallel crack structures on the surface of Polydimethylsiloxane (PDMS), and a conductive coating is coated on the surface of the flexible strain gauge 10, that is, conductive particles are uniformly distributed on two walls of a crack distributed on the surface of a flexible material, when a numerical control machine vibrates, the flexible strain gauge 10 vibrates and deforms, as shown in fig. 6 and 7, when the flexible strain gauge 10 is extruded or stretched along with the generation of the vibration, the crack width of the crack changes, for example, the crack width a in the extruded state is obviously smaller than the crack width b in the stretched state, this will cause the contact state of the conductive particles between the cracks to change, and the number of the electronic channels changes, which is directly expressed as the resistance changes, and finally converted into an electric signal to be output, thereby realizing the detection of the vibration of the cutter.
During specific implementation, the protective housing includes base 11 and protection dustcoat 12, wherein base 11 base plate 111, be provided with support frame 112 on the base plate 111, the both ends correspondence of flexible foil gage 10 paste in the both ends of support frame 112, the middle part of support frame 112 has first recess 113, support frame 112 still be provided with all around with protection dustcoat 12 complex frame 114, the bottom of protection dustcoat 12 is provided with second recess 121, protection dustcoat 12 and base 11 pass through frame 114 and second recess 121 assemble as an organic whole, the side of protection dustcoat 12 still is provided with through-wire hole 122.
Be provided with first screw hole 115 on the base plate 111, on the protection dustcoat 12 with the position that first screw hole 115 corresponds is provided with second screw hole 123, runs through the connecting piece will behind first screw hole 115 and the second screw hole 123 vibration signal collection system 1 is fixed in on the digit control machine tool sword platform to realize non-contact's lathe cutter vibration information acquisition.
In this embodiment, the support frame 112 supports the both ends of flexible foil gage 10, specifically the bottom of flexible foil gage 10 is elastic insulation material for it is insulating between flexible foil gage 10 and the base 11, the mid portion of support frame 112 is first recess 113, and the mid portion of flexible foil gage 10 is unsettled promptly, just in time makes the crack structure on the flexible foil gage 10 be in unsettled state like this, has effectively increased the vibration scope of flexible foil gage 10, is favorable to flexible foil gage 10 to make more sensitive response to the vibration, ensures the best collection effect that has to vibration information. Protection dustcoat 12 and base 11 are when the assembly, realize the block and then assemble as an organic wholely through the protruding frame 114 and the second recess 121 that mutually support, still be provided with logical line hole 122 in the side of protection dustcoat 12 simultaneously, be convenient for draw the electrode lead wire 101 at flexible foil gage 10 both ends, after base 11 and protection dustcoat 12 have been assembled, through first screw hole 115 on the base 11 and the second screw hole 123 on the protection dustcoat 12, fix whole vibration signal collection system 1 to the saddle of digit control machine tool with connecting piece such as screw bolt and nut, the saddle is hugged closely to the bottom surface of base 11, realize non-contact and highly sensitive vibration response.
Preferably, a sealant is disposed between the frame 114 and the second groove 121, and inside the through hole 122. Namely, after the flexible strain gauge 10 is fixed and the electrode lead 101 is led out, the through hole 122 on the protective shell and between the frame 114 and the second groove 121 are sealed by hot melt adhesive, so that the coolant of the numerical control machine tool is prevented from entering, the vibration signal acquisition device 1 is enabled to break down, and the stability and the reliability of vibration detection are improved.
Further, the base 11 and the protective outer cover 12 are preferably made of aluminum, and due to the light weight and the good strength and hardness of aluminum, the flexible strain gauge 10 arranged inside can be effectively protected, and the safety of the operation of the whole vibration signal acquisition device 1 is ensured.
In the system for detecting the vibration signal of the numerical control machine tool cutter, the data processing module 2 comprises a conversion unit, a differential amplification unit and a data acquisition unit, the conversion unit is connected with electrode leads 101 at two ends of the flexible strain gauge 10, the conversion unit, the differential amplification unit and the data acquisition unit are sequentially connected, the data acquisition unit is also connected with the analysis and judgment module 3, wherein the conversion unit is used for converting the real-time change resistance value of the flexible strain gauge 10 into a corresponding voltage signal and outputting the voltage signal to the differential amplification unit, the differential amplification unit is used for carrying out differential calculation on the voltage signal, amplifying the voltage signal and outputting a discrete signal to the data acquisition unit, the data acquisition unit is used for acquiring the discrete signals output by the differential amplification unit and then outputting data to be analyzed to the analysis and judgment module 3. In this embodiment, when the flexible strain gauge 10 deforms along with the vibration of the tool to change the resistance, the real-time changing resistance of the flexible strain gauge 10 is converted into a corresponding voltage signal by the conversion unit and then two signals are output to the differential amplification unit, the differential amplification unit subtracts the two input signals and amplifies the input differential signal, then the amplified signal is output to the data acquisition unit, the data to be analyzed is output to the analysis and judgment module 3 after the data acquisition unit acquires the discrete signal, so that the analysis and judgment module 3 can judge and recognize the working state of the current tool, and the non-contact vibration information detection with accurate measurement and high sensitivity is realized.
In a specific implementation, the conversion unit is a wheatstone bridge, the flexible strain gauge 10 is connected to the empty bridge arm of the wheatstone bridge through the electrode leads 101 at the two ends, and the output end of the wheatstone bridge is connected to the differential amplification unit. Please refer to fig. 8, which is a circuit diagram of a wheatstone bridge, and the wheatstone bridge includes a first resistor R1, a second resistor R2, a third resistor R3, and a fourth resistor R4, wherein one end of the first resistor R1 and one end of the second resistor R2 are both connected to a VCC power supply terminal, the other end of the first resistor R1 is connected to one end of the fourth resistor R4 and the differential amplification unit, the other end of the second resistor R2 is connected to one end of the third resistor R3 and the differential amplification unit, and the other end of the fourth resistor R4 and the other end of the third resistor R3 are both grounded. The first resistor R1, the second resistor R2 and the fourth resistor R4 are fixed value resistors, the resistance values are all 100 ohms, the bridge arm of the third resistor R3 is a hollow bridge arm, namely, the bridge arm is connected with the electrode leads 101 at the two ends of the flexible strain gauge 10, the resistance value of the third resistor R3 is the real-time resistance value of the flexible strain gauge 10, when the numerical control machine tool vibrates, the vibration signal acquisition device 1 vibrates along with the bridge arm, the resistance value of the flexible strain gauge 10 changes obviously, and the real-time voltage at the two ends is equal to
Wherein
In order to obtain a constant value of resistance,
for a given voltage across the bridge,
is the real-time resistance of the flexible strain gauge 10 imitating the structure of a scorpion seam. The flexible strain gauge 10 imitating the scorpion seam structure has a large resistance change range, the resistance value is 120 ohms in a static state, and the resistance value change range can reach 100-2000 ohms, so that the slight vibration can change the upper seam structure of the flexible strain gauge, further the resistance value is changed, and the vibration detection with wide range and high sensitivity is realized.
Further, the differential amplification unit comprises an operational amplifier U1, a fifth resistor R5, a sixth resistor R6, a seventh resistor R7, an eighth resistor R8, a ninth resistor R9, a tenth resistor R10, a first capacitor C1, a second capacitor C2, a third capacitor C3, a fourth capacitor C4 and a fifth capacitor C5; a pin 2 of the operational amplifier U1 is connected to one end of a fifth resistor R5 and one end of a sixth resistor R6, the other end of the fifth resistor R5 is connected to a pin 6 of the operational amplifier U1, the other end of the sixth resistor R6 is connected to one end of a first capacitor C1 through a seventh resistor R7, and the other end of the first capacitor C1 is connected to the other end of the second resistor R2 through a second interface P2; the pin 3 of the operational amplifier U1 is connected to the ground through an eighth resistor R8, and is further connected to one end of a second capacitor C2 through a ninth resistor R9, and the other end of the second capacitor C2 is connected to the other end of the first resistor R1 through a third interface P3; the 4 th pin of the operational amplifier U1 is grounded through a fifth capacitor C5; the 6 th pin of the operational amplifier U1 is connected with one end of a fourth capacitor C4, the other end of the fourth capacitor C4 is connected with a data acquisition unit through a first interface P1, the 7 th pin of the operational amplifier U1 is connected with a VDD power supply end and one end of a third capacitor C3, the other end of the third capacitor C3 is grounded, the 2 nd pin and the 6 th pin of the operational amplifier U1 are also connected through a tenth resistor R10, wherein the tenth resistor R10 is a variable resistor and used for adjusting amplification factors, specifically, the 2 nd pin and the 3 rd pin of the operational amplifier U1 are connected with OUT-and OUT + pins of a Wheatstone bridge to receive voltage signals, and the voltage signals are output to the data acquisition unit through the 6 th pin after differential calculation and amplification, so that the change of the flexible strain gauge 10 is converted into accurate electric signals to be output, and the measurement precision of vibration detection is improved.
Further, please refer to fig. 10 to 19 together, which are circuit diagrams of a data acquisition unit in the system for detecting vibration signals of a tool bit of a numerical control machine tool provided by the present invention, wherein the data acquisition unit includes a controller U2, a flash memory U3, a data acquisition unit U4, a connector U5, a USB interface P4, a switching chip U6 and a voltage stabilizer U7, so as to realize the acquisition of discrete signals and output data to be analyzed to the analysis and judgment module 3.
As shown in fig. 11, the flash memory U3 is used for temporarily storing data to realize a data temporary storage function, wherein the 1 st pin of the flash memory U3 is connected to the PD7 pin of the controller U2 and is also connected to the 3.3V power supply terminal through the twelfth resistor R12, the 6 th pin, the 5 th pin and the 2 nd pin of the flash memory U3 are respectively connected to the PB13 pin, the PB14 pin and the PB15 pin of the controller U2, the 3 rd pin and the 7 th pin of the flash memory U3 are connected to the 3.3V power supply terminal through the eleventh resistor R11, the 8 th pin of the flash memory U3 is grounded through the sixth capacitor C6, in an embodiment, the flash memory U3 may adopt a flash memory U3 of the model W25Q80B, the controller U2 may adopt a controller U2 of the model STM32F103ZE, and in other embodiments, the flash memory U3 and the controller U2 having the same function may be adopted without limitation of the present invention.
As shown in fig. 12 and 13, the data collector U4 is configured to collect an output signal of the differential amplification unit and transmit the output signal to the controller U2, and the connector U5 is configured to provide an external signal input for the data collector U4, where the 7 th pin and the 8 th pin of the data collector U4 are connected to and connected to the PB pin of the controller U2, the 3 rd pin of the data collector U4 is connected to the PC13 pin of the controller U2, the 17 th pin, the 18 th pin, the 10 th pin, the 14 th pin, the 28 th pin, the 29 th pin, and the 30 th pin of the data collector U4 correspond to the PD0 pin, the PD 638 pin, the PD4 pin, the PD6 pin, the PD8 pin, the PD9 th pin, and the PD 84 pin of the controller U2, and the 6 th pin, the 5 th pin, the 4 th pin, the 19 th pin, the 20 th pin, the 21 th pin, the 22 th pin, the 23 th pin, the 25 th pin, the 3727 th pin, the PE 2 th pin and the PE 2 th pin of the data collector U4 correspond to the, The data collector U4 comprises a PE5 pin, a PE6 pin, a PE7 pin, a PE8 pin, a PE9 pin, a PE10 pin, a PE11 pin, a PE12 pin, a PE13 pin, a PE14 pin and a PE15 pin, wherein the 9 th pin of the data collector U4 is connected with a PF5 pin of the controller U2, and the 12 th pin and the 11 th pin of the five data collector U4 are respectively and correspondingly connected with a PG6 pin and a PG9 pin of the controller U2. In a specific implementation, the data collector U4 may be a data collector U4 with a model AD7606, and the connector U5 may be an AMP connector U5 with a model AMP — 20ch, although in other embodiments, other data collectors U4 and U5 with the same function may also be used, and the present invention is not limited thereto.
Further, as shown in fig. 14, the USB interface P4 is configured to transmit data to be analyzed, which is collected and output by the controller U2, to the analysis and judgment module 3, wherein the 2 nd pin and the 3 rd pin of the USB interface P4 are configured to be connected to the analysis and judgment module 3, and the left floating pin of the USB interface P4 is configured to be connected to a receiving and transmitting pin, i.e., an RX/TX pin, of the controller U2.
Preferably, as shown in fig. 15, the USB conversion circuit is a USB conversion circuit, which can convert USB signals into serial signals and is suitable for more data transmission scenarios, wherein the pin 3 of the transit chip U6 is connected to the pin PA9 of the controller U2, the pins 4 and 16 of the transit chip U6 are connected to the 3.3V power supply, the pin 4 is further connected to ground through an eighth capacitor C8, and the pin 16 is further connected to the pin 1 and ground through a seventh capacitor C7; the 5 th pin and the 6 th pin of the switching chip U6 are respectively connected to the 3 rd pin and the 2 nd pin of the USB interface P4, the 7 th pin of the switching chip U6 is connected to one end of the ninth capacitor C9 and one end of the first crystal oscillator Y1, the 8 th pin of the switching chip U6 is connected to one end of the tenth capacitor C10 and the other end of the first crystal oscillator Y1, the other end of the ninth capacitor C9 and the other end of the tenth capacitor C10 are both grounded, the first crystal oscillator Y1 is configured to provide a clock signal to the switching chip U6, in a specific implementation, the switching chip U6 may be the switching chip U6 of the type CH340G, and in other embodiments, other switching chips U6 having the same function may also be used, which is not limited in this invention.
Further, as shown in fig. 16, the power conversion circuit is used for stably supplying power to other chips and the controller U2 after a 5V power source is converted into a 3.3V power source, wherein a3 rd pin of the voltage regulator U7 is connected to a 5V power supply end, and is further connected to an anode of an eleventh capacitor C11 and one end of a twelfth capacitor C12, a cathode of the eleventh capacitor C11 and the other end of the twelfth capacitor C12 are both grounded, a2 nd pin and a 4 th pin of the voltage regulator U7 are connected to a 3.3V power supply end and further output a 3.3V voltage to supply power to other parts, the 2 nd pin and the 4 th pin of the voltage regulator U7 are both connected to an anode of a thirteenth capacitor C13 and one end of a fourteenth capacitor C14, a cathode of the thirteenth capacitor C13 and the other end of a fourteenth capacitor C14 are grounded, and both an input end and an output end are both denoised by capacitors, so as to improve stability of the power supply voltage.
Further, as shown in fig. 17, 18 and 19, the data acquisition unit further includes a second crystal oscillator Y2 and a third crystal oscillator Y3 for providing a clock signal to the controller U2, and a reset circuit for resetting the controller U2, wherein one end of the second crystal oscillator Y2 is connected to the 10 th pin of the controller U2 and is also grounded through a fifteenth capacitor C15, and the other end of the second crystal oscillator Y2 is connected to the 11 th pin of the controller U2 and is also grounded through a sixteenth capacitor C16; one end of the third oscillator Y3 is connected to the 23 rd pin of the controller U2 and further connected to ground through a seventeenth capacitor C17, and the other end of the third oscillator Y3 is connected to the 24 th pin of the controller U2 and further connected to ground through an eighteenth capacitor C18, so that a high-precision clock signal is provided to the controller U2 through the second oscillator Y2 and the third oscillator Y3. In the reset circuit, one end of a thirteenth resistor R13 is connected with a 3.3V power supply end, the other end of a thirteenth resistor R13 is connected with one end of a reset switch RST and a 25 th pin of a controller U2, the other end of the thirteenth resistor R13 is grounded through a nineteenth capacitor C19, and the reset circuit is connected with a reset pin of the controller U2, so that the reset operation of the controller U2 can be realized when the reset switch RST is pressed down, data recovery operation can be conveniently carried out under the conditions of changing detection environments and the like, and the latest and most accurate vibration detection data can be obtained.
Further, in the system for detecting the vibration signal of the numerical control machine tool cutter provided by the invention, the analysis and judgment module 3 can adopt an upper computer which comprises a training identification unit, a classification unit and a fault early warning unit, wherein the training identification unit, the classification unit and the fault early warning unit are sequentially connected, the training identification unit is also connected with the data acquisition unit, and the training identification unit is used for generating corresponding data types according to pre-acquired training samples and a preset training model; the classification unit is used for judging and classifying the currently acquired data to be analyzed according to the data category; the fault early warning unit is used for outputting an early warning signal when the current data to be analyzed is judged to be the abnormal vibration data type. In the embodiment, the continuous working data of the machine tool in a period of time is collected in advance as a training sample, the vibration working conditions of time change and failure time are recorded, the collected training sample is trained and classified through a preset training model, particularly, an SVM algorithm is adopted for classification, in the embodiment, the training sample is divided into two types and corresponding data types are generated, the data in normal working is one type and is defined as a normal vibration data type, the data in abnormal change of vibration before failure is one type and is defined as an abnormal vibration data type, subsequently, the new data to be analyzed collected at present is judged and classified according to the two types of data types through the preset training model, the newly collected data is further distinguished as the normal vibration data type or the abnormal vibration data type, and an early warning signal is output when the new data is judged to be the abnormal vibration data type, the fault early warning is carried out before the fault occurs, the fault early warning function is realized, the damage to equipment caused by long-time abnormal work of a machine tool cutter is avoided, and the intelligent degree of vibration detection is improved.
Based on the system for detecting the vibration signal of the numerical control machine tool cutter, the invention also correspondingly provides a method for detecting the vibration signal of the numerical control machine tool cutter, and as shown in fig. 20, the method for detecting the vibration signal of the numerical control machine tool cutter comprises the following steps:
s10, detecting the vibration information of the cutter by a vibration signal acquisition device fixed on a tool post of the numerical control machine tool and outputting a corresponding detection signal;
s20, carrying out differential amplification processing on the received detection signals and outputting data to be analyzed;
and S30, judging and classifying the currently collected data to be analyzed according to the pre-stored data type, and outputting an early warning signal when judging that the data is the abnormal vibration data type.
The step S30 includes the steps of:
s301, generating corresponding data types according to pre-collected training samples and a preset training model;
s302, judging and classifying the currently acquired data to be analyzed according to the data category;
and S303, outputting an early warning signal when the current data to be analyzed is judged to be the abnormal vibration data type.
Since the vibration signal detection system of the tool bit of the numerical control machine tool has been described in detail above, it will not be described in detail here.
In summary, in the system and the method for detecting vibration signals of a numerical control machine tool cutter provided by the invention, the system for detecting vibration signals of a numerical control machine tool cutter comprises a vibration signal acquisition device, a data processing module and an analysis and judgment module; the vibration signal acquisition device is fixed on a tool post of the numerical control machine tool and is electrically connected with the data processing module, and the vibration signal acquisition device is used for detecting vibration information of the tool and outputting a corresponding detection signal to the data processing module; the data processing module is also electrically connected with the analysis and judgment module and is used for carrying out differential amplification processing on the received detection signal and outputting data to be analyzed to the analysis and judgment module; the analysis and judgment module is used for judging and classifying the currently acquired data to be analyzed according to the pre-stored data category and outputting an early warning signal when judging that the data is the abnormal vibration data category. The rigid vibration signal acquisition device fixed on the machine tool in a packaging mode acquires the running state information of the machine tool cutter in a non-contact mode, fault detection and early warning of the cutter vibration signal are achieved based on the data type of pre-training identification, and the rigid vibration signal acquisition device has the advantages of being high in sensitivity, non-contact detection, high in measurement identification accuracy and the like.
It should be understood that equivalents and modifications of the technical solution and inventive concept thereof may occur to those skilled in the art, and all such modifications and alterations should fall within the scope of the appended claims.
Claims (6)
1. A vibration signal detection system for a numerical control machine tool cutter is characterized by comprising a vibration signal acquisition device, a data processing module and an analysis and judgment module; the vibration signal acquisition device is fixed on a tool post of the numerical control machine tool and is electrically connected with the data processing module, and the vibration signal acquisition device is used for detecting vibration information of the tool and outputting a corresponding detection signal to the data processing module; the data processing module is also electrically connected with the analysis and judgment module and is used for carrying out differential amplification processing on the received detection signal and outputting data to be analyzed to the analysis and judgment module; the analysis and judgment module is used for judging and classifying the currently acquired data to be analyzed according to the pre-stored data category and outputting an early warning signal when judging that the data is the abnormal vibration data category;
the vibration signal acquisition device comprises a protective shell fixed on a tool post of the numerical control machine tool and a flexible strain gauge which is stuck in the protective shell and has a crack array on the surface, the surface of the flexible strain gauge is coated with a conductive coating, electrode leads electrically connected with the data processing module are arranged at two ends of the flexible strain gauge, and the flexible strain gauge outputs real-time changed resistance values to the data processing module according to tool vibration information;
the protective shell comprises a base and a protective outer cover, the base comprises a substrate, a support frame is arranged on the substrate, two ends of the flexible strain gauge are correspondingly adhered to two ends of the support frame, a first groove is formed in the middle of the support frame, and a frame matched with the protective outer cover is arranged around the support frame; the bottom of the protective outer cover is provided with a second groove, the protective outer cover and the base are assembled into a whole through the frame and the second groove, and the side surface of the protective outer cover is also provided with a through wire hole;
the base plate is provided with a first screw hole, a second screw hole is arranged at a position, corresponding to the first screw hole, on the protective outer cover, and the vibration signal acquisition device is fixed on a tool post of the numerical control machine tool after penetrating through the first screw hole and the second screw hole through a connecting piece so as to realize non-contact type vibration information acquisition of the tool of the machine tool; and sealant is arranged between the frame and the second groove and in the through hole.
2. The system for detecting vibration signals of a numerical control machine tool cutter according to claim 1, wherein the data processing module comprises a conversion unit, a differential amplification unit and a data acquisition unit; the conversion unit is electrically connected with the flexible strain gauge and the differential amplification unit and is used for converting the real-time change resistance value of the flexible strain gauge into a corresponding voltage signal and outputting the voltage signal to the differential amplification unit; the differential amplification unit is connected with the data acquisition unit and is used for performing differential calculation on the voltage signal, amplifying the voltage signal and outputting a discrete signal to the data acquisition unit; the data acquisition unit is also connected with the analysis and judgment module and is used for acquiring the discrete signals output by the differential amplification unit and then outputting the data to be analyzed to the analysis and judgment module.
3. The system for detecting vibration signals of a numerical control machine tool cutter according to claim 1, wherein the converting unit is a wheatstone bridge, the flexible strain gauge is connected with the empty bridge arm of the wheatstone bridge through electrode leads at two ends, and the output end of the wheatstone bridge is connected with the differential amplifying unit.
4. The system for detecting vibration signals of a numerical control machine tool cutter according to claim 1, wherein the analysis and judgment module comprises a training recognition unit, a classification unit and a fault early warning unit; the training identification unit is used for generating corresponding data categories according to pre-collected training samples and a preset training model; the classification unit is used for judging and classifying the currently acquired data to be analyzed according to the data category; the fault early warning unit is used for outputting an early warning signal when the current data to be analyzed is judged to be the abnormal vibration data type.
5. A method for detecting vibration signals of a numerical control machine tool cutter is characterized by comprising the following steps:
detecting tool vibration information by a vibration signal acquisition device fixed on a tool post of the numerical control machine tool and outputting a corresponding detection signal;
carrying out differential amplification processing on the received detection signals and outputting data to be analyzed;
judging and classifying the currently acquired data to be analyzed according to the pre-stored data category, and outputting an early warning signal when judging that the data is the abnormal vibration data category;
the vibration signal acquisition device comprises a protective shell fixed on a tool post of the numerical control machine tool and a flexible strain gauge which is stuck inside the protective shell and has a crack array on the surface, the surface of the flexible strain gauge is coated with a conductive coating, electrode leads electrically connected with the data processing module are arranged at two ends of the flexible strain gauge, and the flexible strain gauge outputs real-time changed resistance to the data processing module according to the vibration information of the tool;
the protective shell comprises a base and a protective outer cover, the base comprises a substrate, a support frame is arranged on the substrate, two ends of the flexible strain gauge are correspondingly adhered to two ends of the support frame, a first groove is formed in the middle of the support frame, and a frame matched with the protective outer cover is arranged around the support frame; the bottom of the protective outer cover is provided with a second groove, the protective outer cover and the base are assembled into a whole through the frame and the second groove, and the side surface of the protective outer cover is also provided with a through wire hole;
the base plate is provided with a first screw hole, a second screw hole is arranged at a position, corresponding to the first screw hole, on the protective outer cover, and the vibration signal acquisition device is fixed on a tool post of the numerical control machine tool after penetrating through the first screw hole and the second screw hole through a connecting piece so as to realize non-contact type vibration information acquisition of the tool of the machine tool; and sealant is arranged between the frame and the second groove and in the through hole.
6. The method for detecting vibration signals of a numerical control machine tool cutter according to claim 5, wherein the step of judging and classifying the currently collected data to be analyzed according to the pre-stored data category and outputting the early warning signal when judging the data to be analyzed as the abnormal vibration data category comprises the steps of:
generating corresponding data categories according to pre-collected training samples and a preset training model;
judging and classifying the currently acquired data to be analyzed according to the data category;
and outputting an early warning signal when the current data to be analyzed is judged to be the abnormal vibration data type.
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| CN117686037B (en) * | 2024-02-02 | 2024-04-02 | 中国科学院工程热物理研究所 | Device and method for detecting performance of hole making cutter |
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