CN109807690B - Metal cutting system - Google Patents
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- CN109807690B CN109807690B CN201910250180.1A CN201910250180A CN109807690B CN 109807690 B CN109807690 B CN 109807690B CN 201910250180 A CN201910250180 A CN 201910250180A CN 109807690 B CN109807690 B CN 109807690B
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Abstract
The invention relates to a metal cutting processing system, which comprises a workbench, a driving control device, a flutter detection device and a circulating device, wherein the workbench comprises an oil supply device, a spindle box, a rotating workpiece, a drill rod support, a feeding seat, a bearing table, a lathe bed, a center frame and a sliding seat; the flutter detection equipment comprises an industrial personal computer, a vibration sensor and an audio sensor, wherein the vibration sensor and the audio sensor are installed on a feeding seat of the workbench to measure mechanical vibration signals and noise signals of cutter cutting and transmit the mechanical vibration signals and the noise signals to the industrial personal computer, and the industrial personal computer judges whether the cutting is normal or not through the mechanical vibration signals and the noise signals.
Description
Technical Field
The present application relates to a machining system, and more particularly to a metal cutting machining system.
Background
The need for deep-hole drilling technology has gone up to the advent of the european slide cavity gun (the 14 th century), but deep-hole drilling technology has not come out until the first half of the 20 th century. In the later 18 th century, people invented a flat drill to process a more precise gun barrel, the flat drill is the oldest solid drilling tool, once applied to processing short and shallow small holes of wood, ironware, bronze ware and the like for a long time, and then continuously improved to be still used for processing a single small batch of deep hole parts till now, but in the deep hole processing process, due to the existence of a cross edge and the limitation of the condition that the cutting edge is not sharp, the processing efficiency is extremely low, continuous processing cannot be performed, and a drill bit is easy to deviate.
In the metal cutting process, friction and abrasion always exist, and the friction and the abrasion have close relation with the consumption of cutting power, the service life of a cutter and the processing quality of a workpiece. In cutting machining, it is therefore necessary to reduce this friction and wear and at the same time to reduce the heat of cutting in order to increase the cutting efficiency and to achieve optimum economic machining, this being achieved, on the one hand, by improving the tool material and geometry and, on the other hand, by the rational use of cutting fluids as the material for the machining process. At present, the method for improving the metal cutting process by utilizing the cutting fluid to wash the cutting edge part is generally applied, and deep hole machining needs to use a large amount of circulating special cutting fluid to continuously cool and lubricate the cutting edge part so as to achieve an ideal cutting effect.
The existing processing equipment has insufficient processing precision, unstable cutter operation and insufficient cooling performance, and is lack of accurate feedback control of a servo motor to realize accurate positioning of cutter feeding, effective cooling and early warning of chatter.
Disclosure of Invention
In order to solve the problems of the prior art, the invention provides a metal cutting machining system.
The technical scheme of the invention is as follows: a metal cutting system comprises a workbench, a driving control device, a flutter detection device and a circulating device,
the workbench comprises an oil supply device, a spindle box, a rotating workpiece, a drill rod support, a feeding seat, a bearing table, a lathe bed, a center frame and a sliding seat, wherein the left end of the rotating workpiece is arranged in a three-jaw chuck of the spindle box, the right end of the rotating workpiece is close to the oil supply device, the rotating workpiece is supported by the center frame and used for increasing rigidity and ensuring the coaxiality of parts, the handle part of the drill rod is clamped in a positioning hole of the feeding seat, and the drill rod support is arranged in the middle of the drill rod and;
the drive control equipment comprises a motion controller, an encoder, a Hall current sensor, a decoding circuit, an optical coupling isolation circuit, a servo motor and an intelligent power control module, wherein the Hall current sensor acquires U-phase and V-phase currents of the servo motor and feeds the U-phase and V-phase currents back to the motion controller;
the chatter detection equipment comprises an industrial personal computer, a vibration sensor and an audio sensor, wherein the vibration sensor and the audio sensor are arranged on a feeding seat of the workbench to measure a mechanical vibration signal and a noise signal of cutting of the cutter and transmit the mechanical vibration signal and the noise signal to the industrial personal computer, and the industrial personal computer judges whether the cutting is normal or not according to the mechanical vibration signal and the noise signal;
the circulating equipment comprises an oil pump, a filter screen, a liquid discharge pipe, a magnetic filter and a cooler, wherein cutting fluid sucked out by the oil pump is conveyed to an oil supplier and reaches the cutting edge part of the drill bit through an annular gap of the drill rod, the cutting fluid washes out chips while cooling and lubricating the cutting edge part, the chips flow through the inside of the drill rod along with high-temperature cutting fluid and are discharged by the liquid discharge pipe, the chips with larger volume fall into a chip storage box, the chips with smaller volume flow through an oil groove along with the cutting fluid through meshes at the bottom of the chip storage box, the cutting fluid with partial chips enters the magnetic filter after being filtered by the filter screen in the oil groove and then flows into an oil tank, and the chips are sucked out by the oil pump.
The invention has the beneficial effects that:
the workbench realizes stable transverse feeding by using a feeding seat with a ball screw, and realizes high positioning precision and high repetition precision by using a bearing platform with balls matched with a linear guide rail;
the drive control equipment has optical coupling isolation, so that the reliability of hardware is improved, the drive control equipment obtains better dynamic following performance and anti-interference performance by using a three-closed-loop cascade control structure, the precise control of a servo motor can be automatically and effectively realized through fuzzy control, and the waste on efficiency and the inaccuracy on precision caused by repeated modification of manual setting are reduced;
when the tool vibrates during cutting a workpiece, the vibration detection equipment gives an alarm in time to prevent the damage of the workpiece and the tool from causing setting accidents;
the circulation equipment uses the magnetic filter to realize the adsorption of cutting scraps, and the cooler is provided with the bidirectional spiral elliptical tube to realize effective refrigeration.
Drawings
FIG. 1 is a diagram of the table of the present invention;
FIG. 2 is a view of the feed block of the present invention;
FIG. 3 is a schematic diagram of the motion control of the present invention;
FIG. 4 is a schematic diagram of fuzzy control according to the present invention;
FIG. 5 is a block diagram of a magnetic filter according to the present invention;
fig. 6 is a structural view of a cooler of the present invention.
Detailed Description
The invention is further described with reference to the following figures and examples.
Embodiments of the invention are illustrated with reference to fig. 1-6.
A metal cutting system comprises a workbench, a driving control device, a flutter detection device and a circulating device,
the workbench comprises a main spindle box, a rotating workpiece, an oil supplier, a drill rod support, a feeding seat, a bearing table, a lathe bed, a center frame and a sliding seat, wherein the left end of the rotating workpiece is installed in a three-jaw chuck of the main spindle box, the right end of the rotating workpiece is close to the oil supplier, the rotating workpiece is supported by the center frame and used for increasing rigidity and ensuring the coaxiality of parts, a handle part of the drill rod is clamped in a positioning hole of the feeding seat, the drill rod support is installed in the middle of the drill rod and used for supporting, the oil supplier sends high-pressure cutting fluid into a cutting area, the contact part of the rotating workpiece and a cutting edge of the drill rod is cooled and lubricated, chips escape backwards along with the high-pressure cutting fluid through the interior of the drill rod and are splashed into a.
The feeding seat comprises a dustproof cover plate, a pre-tightening nut, a switching flange, a coupler, a ball screw, a supporting bearing, a profile component and a supporting bearing, one end of the ball screw is connected with the servo motor, the other end of the ball screw is connected with a drill rod through the coupler, the middle of the ball screw is connected with the supporting bearing, the supporting bearing is connected with a dustproof cover cap through the switching flange, so that relative rotation of the feeding seat and the dustproof cover plate and support for the ball screw are achieved, and the profile component forms a combined position of the ball screw and the servo motor.
The maximum stroke of the ball screw platform is 100mm, and the precision grade is 3 grade;
the feeding seat realizes the transverse drill rod feeding.
The bearing platform comprises a lubricating nozzle, an end cover sealing gasket, an end cover, a moving frame, an upper end retainer, a lower end retainer, balls, a lower sealing gasket and a guide rail, wherein a feeding seat is arranged at the top of the moving frame, moving frame tunnels for mounting the balls are arranged at two sides of the moving frame in the length direction, the balls are filled in the moving frame tunnels and freely roll in the moving frame tunnels, a contact part between the moving frame and the guide rail support forms a combined tunnel with the same diameter as the moving frame tunnels, the balls are filled in the combined tunnel and freely roll in the combined tunnel, the moving frame tunnels and the combined tunnels form a closed-loop tunnel, the balls circularly roll in the closed, and then relative motion between motion frame and the guide rail is made, the upper end keeps ware, the lower extreme keeps ware centre gripping combination tunnel and makes the ball can not spill, and the end cover seals motion frame both ends through the end cover sealed pad, and the lubricated nozzle sets up in the end cover inboard, sprays lubricating oil to the ball and lubricates.
The bearing table realizes longitudinal drill rod feeding.
The oil supply device is arranged on a sliding seat which is connected with a guide rail of the bearing table in a sliding way and used for spraying cooling liquid at the cutting position of the cutter.
The bearing table uses a linear guide rail, and has four-direction stress design of high positioning precision, high repeatability precision, low resistance, long-range high precision and high rigidity.
Drive controlgear includes motion control ware, the encoder, hall current sensor, the decoding circuit, optical coupling buffer circuit, servo motor and intelligent power control module, hall current sensor gathers servo motor's U looks and V phase current, feed back to motion control ware, the encoder feeds back servo motor actual position to motion control ware through the decoding circuit in real time, motion control ware receives target position information through serial bus, the target position, single-axis logic control is done to actual position and actual current in motion control ware, time schedule through vector control exports pulse width modulation signal, provide intelligent power control module and convert power control signal into through optical coupling buffer circuit.
The optical coupling isolation circuit realizes the complete isolation of the control part circuit and the power part circuit, and greatly improves the reliability of hardware.
The servo motor adopts a permanent magnet synchronous form, the stator consists of three-phase windings and an iron core, the armature windings are in star connection, the permanent magnets form a rotor, and the main magnetic flux and the torque of the servo motor are controlled by the power electronic converter through magnetizing current in the same direction as an air gap magnetic field and effective current perpendicular to the air gap magnetic field.
Because exciting current is not needed, the power factor can be obviously improved, the stator current and the stator resistance loss are reduced, rotor resistance loss does not exist in stable operation, the servo motor is coaxially connected with the screw rod, and the ball screw rod also rotates for one circle when the servo motor rotates for one circle.
The motion controller outputs a control signal to the motor control module, the motor control module outputs a driving current to the servo motor according to a signal of the industrial personal computer and controls the rotation direction, and an encoder at the tail of the servo motor outputs a pulse signal to be fed back to the processor.
The drive control equipment is in full closed-loop control and comprises a position, speed and current three-closed-loop cascade control structure, wherein a current loop and a speed loop are inner loops, a position loop is an outer loop, and the three-closed-loop cascade control structure enables the drive control equipment to obtain better dynamic following performance and anti-interference performance.
The current loop transforms a transfer function of an inner loop control object, so that the rapidity of the system is improved, and the interference in the current loop is suppressed in time; the maximum current is limited, so that the system has enough acceleration torque, the safe operation of the system is guaranteed, and the speed ring has the functions of enhancing the load disturbance resistance of the system and inhibiting the speed fluctuation. The position ring has the function of ensuring the static precision and the dynamic tracking performance of the system, so that the whole servo system can operate stably and with high performance.
The current loop control is realized in the drive control equipment, and is provided with a current regulator, an inverter and current feedback, a control algorithm is preset by the drive control equipment, the current loop adopts a PI regulator, the proportional integral coefficient of the PI regulator is the maximum value under the condition that the drive control equipment does not generate oscillation, so that the amplitude, the phase and the frequency of the three-phase alternating current of the controlled servo motor can rapidly change along with a given value, the current loop directly controls the output torque of the servo motor, and the response speed of the current loop is higher than that of a speed loop;
the regulator of the speed loop adopts a PI compensation method, signals output by an encoder at the tail part of the servo motor are fed back to a driving control device, the driving control device forms a frequency converter, the rotating speed of the servo motor is changed by changing the output frequency, the response time of the speed loop is related to the mechanical time constant of a mechanical system and is lower than the response of a current loop, the response period of the speed loop is larger than lms, the transfer function of a control object comprises an integral link and an inertia link, and the integral link is behind the action point of load disturbance.
The main disturbance of the speed ring is load disturbance, no static error of the rotating speed is realized, an integral link is arranged before a disturbance action point, namely, a rotating speed regulator is designed according to a typical II type system, and excellent dynamic anti-interference performance is realized.
The position ring adopts a constant coefficient proportional regulator, so that the system is increased to the amplitude limiting speed at the maximum acceleration, is quickly close to the target position at the amplitude limiting speed, and is braked by the servo motor at the maximum reverse current when reaching a deceleration point. When the system decelerates to the near terminal point with the maximum deceleration, the system enters a low-speed approach positioning point stage, the cut-off frequency of a position ring at the outermost ring is 50Hz and is lower than the cut-off frequencies of a speed ring and a current ring at the inner side, and the position ring control parameters comprise: PID parameter value, automatic tuning gain, automatic advance gain, position regulator gain, feedforward filter time constant, zero deviation amplitude and positioning end judgment time.
The motion controller is connected with an industrial personal computer and a servo motor, the motion controller is a semi-packaged microcomputer system, integrates a two-character instruction set and an analysis function thereof, and can carry out system setting, the motion controller consists of a processor, a watchdog, a communication interface and a motor control module, the processor is a system on chip and comprises an interface layer, an algorithm control layer and a fault-tolerant control layer, wherein the interface layer is of an FPGA structure and is responsible for information interaction with the motor control module and controlling a servo device, the algorithm control layer is of an ARM and DSP dual-core structure, an ARM core is responsible for various peripheral drives, a DSP end is responsible for a large number of matrix floating point type calculations such as kinematics modeling, trajectory planning and the like, the fault-tolerant control layer uses 32-bit controllers and carries out real-time monitoring on the interface layer and the algorithm control layer, fault-tolerant planning is carried out according, the fault-tolerant control layer uses a servo calibration method, and simultaneously expands a visual feedback interface, so that secondary correction of later visual feedback is realized;
the interface layer is provided with a peripheral interface circuit, so that data interaction including instruction sending and feedback data receiving with the servo device is realized, and the port driving force is enhanced by adopting the bus transceiver; setting an EMIF interface and an algorithm control layer to complete information interaction; setting a UART interface to establish communication with a fault-tolerant control layer to complete monitoring interaction; an FPGA clock is set, an active 40Mhz crystal oscillator is selected by an external clock, and JTAG and AS modes are introduced simultaneously for debugging and loading programs of the FPGA.
The algorithm control layer and the fault-tolerant control layer complete information interaction to ensure the reliable work of the system, and the target position of the alternating current servo motor and the actual position from the encoder, which are sent by the receiving interface layer, are received to carry out fuzzy control on the servo motor.
Wherein, the algorithm control layer comprises a differentiator, a fuzzification interface, an output quantity conversion module, an inference machine and a knowledge base, an encoder provides the measured position information of a servo motor to the differentiator through a band-pass filter, the differentiator subtracts the set position information input by an operator from the measured position information to obtain an error value E, the error value E obtains an error change rate dE/dt through the differentiator, the error value E and the error change rate dE/dt are provided to the fuzzification interface, the error value E and the error change rate dE/dt are subjected to fuzzification assignment to respectively obtain a fuzzification error value ME and a fuzzification error change value MEC, the fuzzification error value ME and the fuzzification error change value MEC are provided to the inference machine, the knowledge base inquires cutting parameter values according to workpiece materials, processing modes, size precision, surface quality requirements, tool coding and cutting fluid types and generates input and output membership, the inference machine carries out fuzzy inference on the fuzzification error value ME and the fuzzification error change value MEC according to the input and output membership degree vector value and the logic inference rule to obtain a fuzzy control quantity MU, the output quantity conversion module converts the fuzzy control quantity MU into an actual control quantity U, and the power supply is controlled to provide voltage for the servo motor according to the actual control quantity U.
The knowledge base stores the inferred knowledge information and comprises a cutter base, a cutting fluid base, a machine tool base, a workpiece base and a cutting parameter base,
the tool library provides query and reference of tool parameters, wherein tool codes determine the uniqueness of the tools, and the tool library carries out coding according to a processing mode, a tool name and a structure class. The tool magazine includes: solid deep and bore drills for drilling solid materials for rough machining, reamers and reamers for regrinding corrected reamers and reamers on already bored workpieces for semi-finishing, and finishing honing and rolling tools for boring.
The cutting fluid library provides query and reference of cutting fluid types, the cutting fluid types are divided according to the performance of the cutting fluid and are set with priorities, and the division is as follows:
A. lubricating property: mineral oil, emulsion, semisynthetic cutting fluid and fully synthetic cutting fluid;
B. cooling performance: the total synthetic cutting fluid, the semisynthetic cutting fluid, the emulsion and the cutting oil are mixed;
C. antirust performance: the cutting oil is water-based cutting fluid, semi-synthetic cutting fluid or fully-synthetic cutting fluid;
D. cleaning performance: the water-based cutting fluid is semisynthetic cutting fluid, and the total synthetic cutting fluid is cutting oil.
The machine tool library comprises machine tool models and relevant technical parameters thereof.
The workpiece library comprises the material type, the machining precision and the surface quality index of the workpiece.
The cutting parameter library comprises cutting amount and feed speed.
The fuzzy control method specifically comprises the following steps: selecting parameters PL, PB, PM, PS, ZO, NS, NM, NB and BL according to language variables of an operator, wherein the parameters respectively represent positive oversize, positive centering, positive small, zero, negative small, negative centering, negative large and negative oversize, and a corresponding fuzzy set is { -n, -n +1,. once.. 0,. once.. n-1, n }, n is 4, and n is a primary fuzzy set variable;
determination of the quantization factor, keN/e, wherein keIs the error value quantization factor, e is the measured maximum error value, kec＝n/ec，kecIs the error rate quantization factor, ec is the measured maximum error rate,
if m is less than or equal to keE is less than or equal to m +1, m is less than n, the fuzzification error value ME is k roundedeE, m is a secondary fuzzy set variable;
if k iseWhen E is less than-n, the fuzzification error value ME is-n;
if k iseE is larger than n, the fuzzification error value ME is n;
if m is less than or equal to kecE is less than or equal to m +1, m is less than n, then the variation value MEC of the fuzzification error is k after roundingecE；
If k isecWhen E is less than-n, the fuzzification error variation value MEC is-n;
if k isecAnd E is more than n, the variation value MEC of the fuzzification error is n.
Further, the knowledge base comprises a database and a rule base,
the fuzzy membership vector values of the input variables and the output variables are stored in the database, the vector values are a set of corresponding values of the input variables and the output variables after discretization through corresponding domains and the like, if the corresponding domains are continuous, the corresponding domains can be used as membership functions, for the input fuzzy variables, the membership functions are stored in the database, and data are provided for an inference engine in a fuzzy inference relationship.
The rule base stores fuzzy rules, which are formed on the basis of long-term accumulated experience of operators and expert knowledge and are expressed by related vocabularies of logical relations, such as if-then, else, end, and, or the like.
The precise control of the servo motor can be automatically and effectively realized through fuzzy control, and the waste on efficiency and the inaccuracy of precision caused by repeated modification of manual setting are reduced.
The tool inevitably generates vibration in the process of cutting a workpiece, and the vibration can cause damage setting accidents of the workpiece and the tool, so the vibration needs to be avoided as much as possible.
Wherein, the detection equipment that shimmys includes industrial computer, vibration sensor and audio sensor install on the seat that feeds of workstation in order to measure the mechanical vibration signal and the noise signal of cutter cutting to transmit for the industrial computer, the industrial computer judges through mechanical vibration signal and noise signal whether normally cut, and concrete step is as follows:
step 1, filtering the mechanical vibration signal and the noise signal, removing useless signals, and obtaining a mechanical vibration frequency function fzSum noise frequency function fc；
And step 2, calculating the sound level,
wherein L is the sound level intensity, t is time, e is the base of the natural logarithmic function, lg is the logarithmic function, j is the argument of the complex exponential, F () is the impulse function, He() As a structural response function of the stage, a is a sound level weighting coefficient, σradAcoustic radiation coefficient of the structure of the working table, etasIs the internal damping coefficient of the worktable, d is the average thickness of the workpiece, and Re represents the real part of the complex number;
step 3, drawing a curve of the sound level intensity L, extracting an envelope signal, forming an envelope curve, performing down-sampling processing on the envelope signal, and performing data compression;
step 4, performing low-frequency reconstruction on the compressed data to obtain a low-frequency reconstruction signal;
and 5, comparing the low-frequency reconstruction signal with a pre-measured critical low-frequency reconstruction signal which just generates the flutter through the trained three-layer BP neural network, and judging whether the flutter occurs.
The circulating equipment comprises an oil supply device, an oil pump, a filter screen, a liquid discharge pipe, a magnetic filter and a cooler, wherein cutting fluid sucked out by the oil pump is conveyed to the oil supply device and reaches the cutting edge part of the drill bit through an annular gap of the drill rod, the cutting fluid washes out chips while cooling and lubricating the cutting edge part of the drill bit, the chips flow through the interior of the drill rod along with high-temperature cutting fluid and are discharged by the liquid discharge pipe, the chips with larger volume fall into a chip storage box, the chips with smaller volume flow through an oil groove along with the cutting fluid through meshes at the bottom of the chip storage box, the cutting fluid with partial chips enters the magnetic filter after being filtered by the filter screen in the oil groove, then flows into the oil tank, is sucked out.
Magnetic filter's end cover passes through screw and casing fixed connection, and the end cover bottom is connected with a plurality of magnetic cores, and the casing bottom then the design has the magnetic core cover that corresponds quantity, and the magnetic core cover is the metal-back, and inside is hollow, and its space just can hold the magnetic core to make it reciprocate, and detachable stopper is installed to blowoff hole department. In the deep hole machining process, the cutting fluid filtered by the filter screen enters the inner cavity of the filter from the inlet of the magnetic filter, and the residual debris in the cutting fluid is adsorbed to the magnetic core cover under the magnetic action of the magnetic core, so that the cutting fluid is finely filtered.
When needs clear up magnetic filter, open the end cover, then the magnetic core is removed in the lump, and the piece that adsorbs on the magnetic core cover no longer receives magnetic force, washs magnetic core cover surface with clear water, finishes the back, pulls out the stopper of drainage department, can sewage discharge.
The cooler comprises a bidirectional spiral elliptical tube, a turbulence device and a tube side clapboard,
the bidirectional spiral elliptical tube is made of a circular tube through periodic bidirectional spiral distortion, the cross sections of the other parts except the cross section of the circular tube, which is placed at the end parts of the two sides, are ellipses with the same size and different directions, and a transition section is arranged in the process of changing the rotation direction, and the transition section has no spiral structure.
The bidirectional spiral elliptical tube has the following functions: cooling water is made to flow through the pipe to cool the high temperature cutting fluid outside the pipe.
The shell side of the bidirectional spiral elliptical tube cooler eliminates most of flow paths with poor heat transfer effect, only flow paths are left, so that shell side fluid fully participates in heat transfer, although the flow path of the fluid is not as long as that of the shell-and-tube cooler, the effective heat transfer flow path is greatly increased, and the utilization rate of the heat transfer area is greatly increased, so that the shell side structure of the bidirectional spiral elliptical tube cooler has good heat transfer enhancement effect, in the bidirectional spiral elliptical tube cooler, the sectional area of a spiral channel between shell side heat exchange tubes is basically unchanged, the flow rate of the shell side fluid is continuously and uniformly changed, and in addition, the transition section of the heat exchange tube structure relieves disturbance when the speed direction of the fluid is changed, thereby reducing resistance, reducing the energy loss of the shell side fluid, effectively saving energy, the shell side fluid of the bidirectional spiral elliptical tube cooler mainly flows longitudinally, and does not form transverse scouring on heat exchange tube bundles, the induced vibration is overcome, and the stability of the whole structure is improved by periodic point contact among the heat exchange tubes.
The cooling water flows into the lower tube side from the cooling water inlet at the lower part, enters the cavity through the bidirectional spiral elliptical tube, flows into the upper tube side from the bidirectional spiral elliptical tube at the other side, and finally flows back to the water tank through the cooling water outlet at the upper part, and the high-temperature cutting fluid flows into the gap of the bidirectional spiral elliptical tube in the cavity from the cutting fluid inlet at the upper part and flows back to the oil tank through the cutting fluid outlet at the lower part.
The tube pass partition plate comprises an end enclosure, a partition plate, a tube plate and a sealing block, and the upper tube pass and the lower tube pass are separated by the partition plate;
the turbulence device comprises a spiral sheet and a cutting fluid inlet flange connecting pipe, wherein the spiral sheet is positioned in the cutting fluid inlet flange connecting pipe in a bent spiral manner, so that the cutting fluid is buffered to enter a cooler to vertically scour the bidirectional spiral elliptical tube, the transverse compression load of the tube bundle is reduced, and the vibration generated in the scouring process of the cutting fluid is reduced.
Wherein, the cooling water entry, the cooling water export, the cutting fluid entry, install flow sensor on the cutting fluid export, pressure sensor, temperature sensor and wireless transmission device, flow for gathering cooling water and cutting fluid, temperature and pressure information, and change this information into the signal of telecommunication, transmit the industrial computer by wireless transmission device, the industrial computer receives the cooling water that temperature sensor detected, cutting fluid temperature, compare with preset's temperature value, rotational speed through converter control water pump motor and then adjust the cooling water output, change the total coefficient of heat transfer of cooler, reach the purpose of adjusting cutting fluid temperature.
In order to maintain the optimal cutting fluid temperature, firstly, the optimal temperature value of the cutting fluid is set in an industrial personal computer according to the temperature requirement of the cutting fluid, when the temperature of the cutting fluid is not changed, no instruction is output by the industrial personal computer, and the output flow of a water pump is not changed; when the temperature sensor detects that the temperature of the cutting fluid rises, the industrial personal computer performs A/D conversion on the feedback signal, compares and calculates the converted digital signal with an optimal temperature value, converts the calculation result into an analog signal through the D/A converter, and acts on the frequency converter as an instruction, and the frequency converter changes the frequency value according to the instruction, so that the rotating speed of the water pump motor is increased, the flow of the water pump is increased, and the oil temperature is reduced; when the temperature of the cutting fluid is reduced, the rotating speed of a motor of the water pump is reduced, and the output flow of the water pump is reduced, so that the temperature of the oil is increased. Because the temperature of cutting fluid is not stable unchangeable, temperature sensor can constantly gather, feed back the temperature signal that changes, and the singlechip then can compare, calculate different feedback signals to assign the instruction to the converter, with change water pump motor rotational speed, adjust cutting fluid temperature, until the temperature signal value of feedback is the same with the setting value, thereby guarantee that the cutting fluid works under best operating temperature state.
For the cooler, because the tube side and the shell side fluid are not directly contacted, but heat transfer is realized through the tube wall, if the fluid fails in the flowing process, such as leakage or scaling of the tube, the heat transfer effect of the cooler is affected.
The industrial personal computer judges the working condition of the cooler by monitoring the flow, temperature and pressure changes of the cooling water inlet, the cooling water outlet, the cutting fluid inlet and the cutting fluid outlet, so that corresponding measures are taken according to different conditions, and the normal work of the cooler is ensured.
The above-described embodiment merely represents one embodiment of the present invention, but is not to be construed as limiting the scope of the present invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention.
Claims (3)
1. A metal cutting system comprises a workbench, a driving control device, a flutter detection device and a circulating device,
the workbench comprises an oil supply device, a spindle box, a rotating workpiece, a drill rod support, a feeding seat, a bearing table, a lathe bed, a center frame and a sliding seat, wherein the left end of the rotating workpiece is arranged in a three-jaw chuck of the spindle box, the right end of the rotating workpiece is close to the oil supply device, the rotating workpiece is supported by the center frame and used for increasing rigidity and ensuring the coaxiality of parts, the handle part of the drill rod is clamped in a positioning hole of the feeding seat, and the drill rod support is arranged in the middle of the drill rod and;
the drive control equipment comprises a motion controller, an encoder, a Hall current sensor, a decoding circuit, an optical coupling isolation circuit, a servo motor and an intelligent power control module, wherein the Hall current sensor acquires U-phase and V-phase currents of the servo motor and feeds the U-phase and V-phase currents back to the motion controller;
the motion controller outputs a control signal to the motor control module, the motor control module outputs a driving current to the servo motor according to a signal of the industrial personal computer and controls the rotation direction, and an encoder at the tail of the servo motor outputs a pulse signal to be fed back to the processor;
the driving control equipment is full closed-loop control and comprises a position, speed and current three closed-loop cascade control structure, wherein a current loop and a speed loop are inner loops, and a position loop is an outer loop;
the current loop control is realized in the drive control equipment, and is provided with a current regulator, an inverter and current feedback, a control algorithm is preset by the drive control equipment, the current loop adopts a PI regulator, the proportional integral coefficient of the PI regulator is the maximum value under the condition that the drive control equipment does not generate oscillation, so that the amplitude, the phase and the frequency of the three-phase alternating current of the controlled servo motor can rapidly change along with a given value, the current loop directly controls the output torque of the servo motor, and the response speed of the current loop is higher than that of a speed loop;
the regulator of the speed loop adopts a PI compensation method, signals output by an encoder at the tail part of a servo motor are fed back to a driving control device, the driving control device forms a frequency converter, the rotating speed of the servo motor is changed by changing the output frequency, the response time of the speed loop is related to the mechanical time constant of a mechanical system and is lower than the response of a current loop, the response period of the speed loop is greater than lms, the transfer function of a control object comprises an integral link and an inertia link, and the integral link is behind the action point of load disturbance;
the position ring adopts a constant coefficient proportional regulator, so that the system is increased to the amplitude limiting speed at the maximum acceleration, and quickly approaches to a target position at the amplitude limiting speed, when a deceleration point is reached, the servo motor is braked at the maximum reverse current, when the system is decelerated to a near terminal point at the maximum deceleration, the system enters a low-speed approaching positioning point stage, the position ring is positioned at the outermost ring, the cut-off frequency of the position ring is 50Hz and is lower than the cut-off frequencies of the inner speed ring and the current ring, and the position ring control parameters comprise: PID parameter value, automatic tuning gain, automatic advance gain, position regulator gain, feedforward filter time constant, zero deviation amplitude and positioning end judgment time;
the motion controller is connected with an industrial personal computer and a servo motor, the motion controller is a semi-packaged microcomputer system, integrates a two-character instruction set and an analysis function thereof, and can carry out system setting, the motion controller consists of a processor, a watchdog, a communication interface and a motor control module, the processor is a system on chip and comprises an interface layer, an algorithm control layer and a fault-tolerant control layer, wherein the interface layer is of an FPGA structure and is responsible for information interaction with the motor control module and controlling a servo device, the algorithm control layer is of an ARM and DSP dual-core structure, an ARM core is responsible for various peripheral drives, a DSP end is responsible for a large amount of matrix floating point calculation of kinematics modeling and trajectory planning, the fault-tolerant control layer uses 32-bit controllers and carries out real-time monitoring on the interface layer and the algorithm control layer, fault-tolerant planning is carried out on faults according to feedback, the fault-tolerant control layer uses a servo calibration method, and simultaneously expands a visual feedback interface, so that secondary correction of later visual feedback is realized;
the algorithm control layer comprises a differentiator, a fuzzification interface, an output quantity conversion module, an inference machine and a knowledge base, wherein an encoder provides measurement position information of a servo motor to the differentiator through a band-pass filter, the differentiator subtracts set position information input by an operator from the measurement position information to obtain an error value E, the error value E obtains an error change rate dE/dt through the differentiator, the error value E and the error change rate dE/dt are provided to the fuzzification interface, fuzzification assignment is carried out on the error value E and the error change rate dE/dt to respectively obtain a fuzzification error value ME and a fuzzification error change value MEC, the fuzzification error value ME and the fuzzification error change value MEC are provided to the inference machine, the knowledge base inquires cutting parameter values according to workpiece materials, machining modes, size accuracy, surface quality requirements, tool coding and cutting fluid types and generates input and output membership, the fuzzy control amount MU is obtained by fuzzy reasoning of the fuzzy error value ME and the fuzzy error change value MEC through the reasoning machine according to the input and output membership degree vector value and the logic reasoning rule, the fuzzy control amount MU is converted into an actual control amount U through the output amount conversion module, and the power supply is controlled to provide voltage for the servo motor according to the actual control amount U;
the fuzzy control method specifically comprises the following steps: selecting parameters PL, PB, PM, PS, ZO, NS, NM, NB and BL according to language variables of an operator, wherein the parameters respectively represent positive oversize, positive centering, positive small, zero, negative small, negative centering, negative large and negative oversize, and a corresponding fuzzy set is { -n, -n +1,. once.. 0,. once.. n-1, n }, n is 4, and n is a primary fuzzy set variable;
determination of the quantization factor, keN/e, wherein keIs the error value quantization factor, e is the measured maximum error value, kec＝n/ec，kecIs the error rate quantization factor, ec is the measured maximum error rate,
if m is less than or equal to keE≤m+1,m<n, the blurring error value ME is rounded keE, m is a secondary fuzzy set variable;
if k iseE<-n, the fuzzification error value ME is-n;
if k iseE>n, the fuzzification error value ME is n;
if m is less than or equal to kecE≤m+1,m<n, then the blurring error variation value MEC is k rounded offecE；
If k isecE<-n, the blurring error variation value MEC is-n;
if k isecE>n, the fuzzification error variation value MEC is n;
the fuzzy membership vector values of the input variables and the output variables are stored in the database, the vector values are a set of values corresponding to the input variables and the output variables after discretization of corresponding domains, if the corresponding domains are continuous, the vector values are used as membership functions, for the input fuzzy variables, the membership functions are stored in the database, and data are provided for an inference engine in a fuzzy inference relationship;
the chatter detection equipment comprises an industrial personal computer, a vibration sensor and an audio sensor, wherein the vibration sensor and the audio sensor are arranged on a feeding seat of the workbench to measure a mechanical vibration signal and a noise signal of cutting of the cutter and transmit the mechanical vibration signal and the noise signal to the industrial personal computer, and the industrial personal computer judges whether the cutting is normal or not according to the mechanical vibration signal and the noise signal;
the circulating equipment comprises an oil pump, a filter screen, a liquid discharge pipe, a magnetic filter and a cooler, wherein cutting fluid sucked out by the oil pump is conveyed to an oil supplier, reaches the cutting edge part of the drill bit through an annular gap of the drill rod, washes out cuttings while cooling and lubricating the cutting edge part, the cuttings flow through the interior of the drill rod along with high-temperature cutting fluid and are discharged by the liquid discharge pipe, the cuttings with larger volume fall into a cuttings storage box, the cuttings with smaller volume flow through an oil groove along with the cutting fluid through meshes at the bottom of the cuttings storage box, the cutting fluid with partial cuttings flows into the magnetic filter after being filtered by the filter screen in the oil groove, then flows into the oil tank, is sucked out by the oil pump again after being cooled by;
the flutter detection equipment comprises an industrial personal computer, a vibration sensor and an audio sensor, wherein the vibration sensor and the audio sensor are installed on a feeding seat of the workbench to measure mechanical vibration signals and noise signals of cutter cutting and transmit the mechanical vibration signals and the noise signals to the industrial personal computer, and the industrial personal computer judges whether the cutting is normal or not through the mechanical vibration signals and the noise signals, and the specific steps are as follows:
step 1, filtering the mechanical vibration signal and the noise signal, removing useless signals, and obtaining a mechanical vibration frequency function fzSum noise frequency function fc；
And step 2, calculating the sound level,
wherein L is the sound level intensity, t is time, e is the base of the natural logarithmic function, lg is the logarithmic function, j is the argument of the complex exponential, F () is the impulse function, He() As a structural response function of the stage, a is a sound level weighting coefficient, σradAcoustic radiation coefficient of the structure of the working table, etasIs the internal damping coefficient of the worktable, d is the average thickness of the workpiece, and Re represents the real part of the complex number;
step 3, drawing a curve of the sound level intensity L, extracting an envelope signal, forming an envelope curve, performing down-sampling processing on the envelope signal, and performing data compression;
step 4, performing low-frequency reconstruction on the compressed data to obtain a low-frequency reconstruction signal;
step 5, comparing the low-frequency reconstruction signal with a critical low-frequency reconstruction signal which is measured in advance and just generates flutter through a trained three-layer BP neural network, and judging whether the flutter occurs;
the circulating equipment comprises an oil supplier, an oil pump, a filter screen, a liquid discharge pipe, a magnetic filter and a cooler, wherein cutting fluid sucked out by the oil pump is conveyed to the oil supplier and reaches the cutting edge part of the drill bit through an annular gap of the drill rod, the cutting fluid washes out chips while cooling and lubricating the cutting edge part of the drill bit, the chips flow through the interior of the drill rod along with high-temperature cutting fluid and are discharged by the liquid discharge pipe, the chips with larger volume fall into a chip storage box, the chips with smaller volume flow through an oil groove along with the cutting fluid through meshes at the bottom of the chip storage box, the cutting fluid with partial chips enters the magnetic filter after being filtered by the filter screen in the oil groove, then flows into the oil tank, is sucked out by the;
the end cover of the magnetic filter is fixedly connected with the shell through a screw, the bottom of the end cover is connected with a plurality of magnetic cores, the bottom of the shell is provided with a corresponding number of magnetic core covers, each magnetic core cover is a metal shell, the interior of each magnetic core cover is hollow, the magnetic core can be accommodated in the space of each magnetic core and can move up and down, a detachable plug is arranged at a sewage discharge hole, in the deep hole processing process, cutting fluid filtered by a filter screen enters the inner cavity of the filter from the inlet of the magnetic filter, and residual debris in the cutting fluid is adsorbed onto the magnetic core covers under the magnetic force action of the magnetic cores, so that the cutting fluid is finely;
the cooler comprises a bidirectional spiral elliptical tube, a flow disturbing device and a tube side partition plate, wherein the bidirectional spiral elliptical tube is made of a circular tube through periodic bidirectional spiral distortion, the cross sections of the other parts except the cross section which is a circle and is placed in the end parts at the two sides are ellipses with the same size and different directions, and a transition section is arranged in the process of changing the rotary direction and has no spiral structure;
the turbulence device comprises a spiral sheet and a cutting fluid inlet flange connecting pipe, wherein the spiral sheet is positioned in the cutting fluid inlet flange connecting pipe in a bent spiral shape, so that the cutting fluid is buffered to enter a cooler to vertically scour the bidirectional spiral elliptical pipe, the transverse pressure load of the pipe bundle is reduced, and the vibration generated in the scouring process of the cutting fluid is reduced;
the cooling water inlet, the cooling water outlet, the cutting fluid inlet and the cutting fluid outlet are provided with a flow sensor, a pressure sensor, a temperature sensor and a wireless transmission device, the flow sensor, the pressure sensor, the temperature sensor and the wireless transmission device are used for acquiring flow, temperature and pressure information of the cooling water and the cutting fluid, converting the information into an electric signal and transmitting the electric signal to an industrial personal computer by the wireless transmission device, the industrial personal computer receives the cooling water and the cutting fluid temperature detected by the temperature sensor, compares the temperature with a preset temperature value, controls the rotating speed of a water pump motor by a frequency converter so as to adjust the output quantity of the cooling water, changes the total heat transfer coefficient;
firstly, setting an optimal temperature value of cutting fluid in an industrial personal computer according to the temperature requirement of the cutting fluid, wherein when the temperature of the cutting fluid is not changed, the industrial personal computer outputs no instruction, and the output flow of a water pump is not changed; when the temperature sensor detects that the temperature of the cutting fluid rises, the industrial personal computer performs A/D conversion on the feedback signal, compares and calculates the converted digital signal with an optimal temperature value, converts the calculation result into an analog signal through the D/A converter, and acts on the frequency converter as an instruction, and the frequency converter changes the frequency value according to the instruction, so that the rotating speed of the water pump motor is increased, the flow of the water pump is increased, and the oil temperature is reduced; when cutting fluid temperature reduces, then reduce water pump motor rotational speed, reduce water pump output flow, thereby make the oil temperature rise, because the temperature of cutting fluid is not stable unchangeable, temperature sensor can constantly gather the temperature signal of change, the feedback, and the singlechip then can compare different feedback signal, the operation, and assign the instruction to the converter, with change water pump motor rotational speed, adjust cutting fluid temperature, until the temperature signal value of feedback is the same with the setting value, thereby guarantee that cutting fluid works under best operating temperature state.
2. A metal-cutting machining system according to claim 1, characterized in that: the feeding seat comprises a dustproof cover plate, a pre-tightening nut, a switching flange, a coupler, a ball screw, a supporting bearing, a profile component and a supporting bearing, one end of the ball screw is connected with the servo motor, the other end of the ball screw is connected with a drill rod through the coupler, the middle of the ball screw is connected with the supporting bearing, the supporting bearing is connected with a dustproof cover cap through the switching flange, so that relative rotation of the feeding seat and the dustproof cover plate and support for the ball screw are achieved, and the profile component forms a combined position of the ball screw and the servo motor.
3. A metal-cutting machining system according to claim 1, characterized in that: the bearing platform comprises a lubricating nozzle, an end cover sealing gasket, an end cover, a moving frame, an upper end retainer, a lower end retainer, balls, a lower sealing gasket and a guide rail, wherein a feeding seat is arranged at the top of the moving frame, moving frame tunnels for mounting the balls are arranged at two sides of the moving frame in the length direction, the balls are filled in the moving frame tunnels and freely roll in the moving frame tunnels, a contact part between the moving frame and the guide rail support forms a combined tunnel with the same diameter as the moving frame tunnels, the balls are filled in the combined tunnel and freely roll in the combined tunnel, the moving frame tunnels and the combined tunnels form a closed-loop tunnel, the balls circularly roll in the closed, and then relative motion between motion frame and the guide rail is made, the upper end keeps ware, the lower extreme keeps ware centre gripping combination tunnel and makes the ball can not spill, and the end cover seals motion frame both ends through the end cover sealed pad, and the lubricated nozzle sets up in the end cover inboard, sprays lubricating oil to the ball and lubricates.
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| CN112065359B (en) * | 2020-09-21 | 2023-05-16 | 北京三一智造科技有限公司 | Drilling control method and rotary drilling rig |
| CN112122627B (en) * | 2020-09-29 | 2021-05-11 | 苏州孚莱博精密金属科技有限公司 | Two-way simultaneous cutting equipment |
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