CN109909804A - Tool breakage and abrasion on-line monitoring method based on main shaft drives electric current and work step - Google Patents
Tool breakage and abrasion on-line monitoring method based on main shaft drives electric current and work step Download PDFInfo
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Abstract
The invention discloses the tool breakage and abrasion on-line monitoring methods based on main shaft drives electric current and work step, tooling step information is obtained by realizing to communicate with digital control system, main shaft drives electric current and load are monitored simultaneously, based on normal cutter and wear damaged Tool in Cutting torque difference analysis and statistical quality control principle, the control figure of required average current/load is processed by drawing each work step, rational control figure control line, determine that each work step using cutting-tool wear state, formulates tool changing or tool sharpening rule.Deviate transient current/load variations rule situation in normal process with process according to spindle motor current instantaneous in the processing of each work step or instantaneous load and determine tool failure, issues alarm signal notice digital control system emergency shutdown to avoid the serious consequence of damage workpiece and lathe.On the one hand this method can reduce part scrap rate and machine failure rate, on the other hand can also improve to the maximum extent cutter life, reduce factory's cutter use cost.
Description
Technical field
The present invention relates to the method and apparatus more particularly to one that a kind of on-line monitoring cutting tool for CNC machine wears damaged state
Tool breakage and abrasion on-line monitoring method of the kind based on main shaft of numerical control machine tool driving current and work pieces process work step information, belongs to number
Control conditions of machine tool monitoring technical field.
Background technique
As continuous development manufacture system the degree of automation of intelligent Manufacturing Technology is higher and higher, production process is intended to nothing
People's state on duty, especially the cutter frequently constantly abrasion in cutting process using long-time in the actual production process.Knife
The abrasion breakage of tool is the most common phenomenon in machining manufacturing process, and less serious case causes workpiece to be scrapped, and severe one leads to knife, main shaft
The serious consequences such as damage.Conventional tool wear monitoring has the direct method of measurement and the indirect method of measurement.The direct method of measurement is using measurement
Blade appearance, geometric dimension, but need to shut down detection and occupy public working hour, according to industrial statistics statistics indicate that when shutdown resulting from
Between account for 20%~30% or so of lathe total down-time；The indirect method of measurement mostly uses installation sensor monitoring feature signal, but
Sensor installs and uses the structure that will affect normal process or even need to change lathe, is applied to proof theory mostly and studies.
Domestic and foreign scholars study in terms of tool wear on-line monitoring field and achieve significant achievement, but still deposit in actual production link
In subproblem, in the actual production process departing from actual processing operating condition, for production technology, workpieces processing, lathe property
Equal Variable Factors applicability is poor.
Summary of the invention
It is an object of the invention to overcome the deficiencies of the prior art and provide one kind to be based on numerically-controlled machine tool driving current and workpiece
The tool breakage and abrasion on-line monitoring method of tooling step information.
To achieve the goals above, the technical scheme adopted by the invention is that the cutter based on main shaft drives electric current and work step
Wear damaged on-line monitoring method, it is characterised in that: for mass processing equipment part, while monitor tooling step information and
Spindle motor current/information on load, by the average current/load statistic processes control for drawing each work step of batch machining workpiece automatically
Drawing determines tool wear degenerate state, formulates tool changing and sharpening rule；By drawing each work step of batch machining workpiece automatically
Transient current/load variations tendency chart, in normal process transient current/load trend chart comparison when determine cutter
Damaged state, and issue stopping alarm signal.
Tool breakage and abrasion database is for storing control figure sample data, work step data, historical data.
Data acquisition is mainly communicated with machine tool numerical control system foundation by data-interface and obtains respective major axes electric current/load number
According to, work step information.
Systematic learning process obtains given amount of data by human-computer interaction, automatically creates work step information, control figure information.
Multiple groups normal process (to wear cutter) work step electric current/load data in the process is obtained, is eliminated at random by average
The reference waveform changed by transient current/load during the corresponding work step normal process of fitting creation with process time after error
Figure.
Fixed batch normal process (to wear cutter) work step average current/load data in the process is obtained, using process
Control theory calculates the very poor control line of mean value, control figure.
Using statistical process control, corresponding work step average major-axis electric current/load control system figure is analyzed, judgement pair
Answer work step cutter for same wear degradation situation.
Monitor instantaneous spindle motor current/load variations situation in each work step process on-line, it is automatic to draw instantaneous electricity
Stream/load variations waveform diagram.
By transient current when corresponding to work step normal process in comparative analysis electric current/load waveform diagram and database/negative
Lotus changes the difference sex determination tool failure of waveform diagram, when continuous several times detect that instantaneous parameters and sample parameter ratio are more than N
Determine that cutting tool state is breakage when (warning multiplying power), issues alarm signal to digital control system and trigger numerically-controlled machine tool emergency shutdown.
Average major-axis electric current/load control system figure is analyzed, when unusual fluctuations occurs in control figure, is fluctuated according to control figure
Principle determines tool wear degenerate state, when determining that corresponding work step institute reached capacity state using tool wear, issues alarm
Signal notifies operator to replace cutter or carries out tool sharpening.
Significant benefit of the invention is to combine work pieces process work step using cutter with institute, can be monitored simultaneously online more
Knife position is fixed a cutting tool state, realizes that tool failure alarm and cutting-tool wear state dynamic formulate knife in numerical-controlled machine tool machining process
The tool changing or sharpening rule of tool.Batch machining workshop tool life management can be made to realize the advanced prediction based on state
On the one hand management can reduce workpiece rejection rate and machine failure rate, on the one hand can also improve to the maximum extent cutter life,
Reduce factory's cutter use cost.
Detailed description of the invention
Fig. 1 is the structural schematic diagram of present system；
Normal average load mean chart during Fig. 2 normal process (to wear cutter)；
Fig. 3 forecasts stage work step exception average load mean chart；
Fig. 4 forecast stage instantaneous load curve that is above standard corresponds to time point；
Specific embodiment
Monitoring system provided by the invention obtains main shaft drives electric current/load, processing work by digital control system data-interface
Information is walked, transient current/load is with process time during fitting work step normal process after average elimination random error
The reference waveform curve of variation.Transient current/load is monitored in that proces of numerically controlled machine tool and is compared with standard curve,
Alarm signal triggering lathe emergency shutdown protection is issued when determining tool failure.Furthermore average electricity is created after work pieces process
Stream/load mean chart simultaneously analyzes cutting-tool wear state, and dynamic adjusts process tool tool changing or sharpening rule.
Tool breakage and abrasion on-line monitoring method based on main shaft drives electric current and work step, for mass processing equipment zero
Part, while tooling step information and spindle motor current/information on load are monitored, by drawing each work step of batch machining part automatically
Average current/load statistical process control determines tool wear degenerate state, formulates tool changing and sharpening rule；By certainly
Dynamic transient current/load variations the tendency chart for drawing each work step of batch machining part, with transient current/load in normal process
Trend chart comparison determine tool failure state, and issue stopping alarm signal.
Each work step processing is monitored by obtaining the work step information of nc program for batch machining machine components
Spindle motor current in the process/load variations situation, by the average major-axis electricity in each work step process of batch machining part
Stream/load data is analyzed using the mean range chart in statistical process control, when mean range chart goes out
Existing unusual fluctuations determine that corresponding work step institute is reached capacity state using tool wear, issue alarm signal and notify operator
It replaces cutter or carries out tool sharpening.
Each work step processing is monitored by obtaining the work step information of nc program for batch machining machine components
Instantaneous spindle motor current/load variations situation in the process draws each work step transient current/load variations waveform diagram automatically.So
Pass through transient current/load variations waveform diagram otherness in analysis electric current/load waveform diagram and each work step normal process afterwards
Determine tool failure, issues alarm signal notice digital control system emergency shutdown to avoid the serious consequence of damage workpiece and lathe.
Mean value electric current/load control system figure control line of each work step of batch machining part need to be by acquiring normal process
Average current/load of each work step when not wearing cutter acquires data, and according to mean range chart control line meter
Calculation method carries out calculating analysis acquisition.When online judgement cutting-tool wear state, every electric current for acquiring a fixed part volume/negative
After lotus data, division of labor step draws average current/load mean range chart of each work step, is controlled and is determined according to statistical quality
The principle of control figure unusual fluctuations determines the wear degradation situation of the used cutter of each work step online.
Each work step when the transient current of each work step of batch machining part/load waveform diagram acquired normal process of need
Transient current/load data, and at least acquire multi-group data after obtained after average elimination random error by curve matching
The reference waveform curve that transient current/load changes with process time during to each work step normal process.Sentence in real time online
When determining tool failure, as soon as it often monitors in time transient current/load data, with reference waveform curve under Identical Processing
Transient current/load compares, and corresponds to if transient current/load of continuous several times monitoring obviously exceeds positive reference waveform curve
N times of the transient current/load at moment determines tool failure, and issues alarm signal to digital control system.Wherein, N is warning times
Rate rule of thumb sets and corrects.
Small computing devices (such as built-in industrial control machine) is installed in numerically-controlled machine tool power control cabinet, and passes through data-interface and lathe
Digital control system establishes communication, and the status informations such as the current processing program of acquisition digital control system and machine spindle speed, canonical loading are main
Axis revolving speed or information on load can also directly monitor spindle drive motor electric current by current sensor, be calculated according to current waveform figure
The speed of mainshaft and canonical loading.
For the reliable accurate on-line identification for carrying out tool breakage and abrasion state, system work process be divided into the study stage and
Two stages of forecast stage.The study stage need to be met the stated number of system-computed requirement by operator by human-computer interaction acquisition
The work step information and status information of the complete machining process of part are measured, system automatic identification divides work step and cutter model, and draws
Make the average current/load mean range chart and transient current/load criterion wavy curve of each work step.In forecast rank
Section determines cutting-tool wear state according to the control figure of current average current/load, judges knife according to current transient current/load
Has damaged state.
As shown in Figure 1, monitoring system provided by the invention include data acquisition module, study module, breakage alarm module,
Wear prediction module, tool breakage and abrasion database.Digital control system data-interface is reported with breakage respectively by data acquisition module
Alert module, tool breakage and abrasion database are connected with study module.Breakage alarm module is connect with wear prediction module, breakage report
Alert module, wear prediction module and study module are connect with tool breakage and abrasion database.
After data acquisition module is connect with machine tool numerical control system data-interface, currently processed for real-time monitoring numerically-controlled machine tool
State starts to acquire data when the judgement positive work in-process triggering collection module of numerically-controlled machine tool.
Acquisition module mainly acquires current processing program information, canonical loading, rotary speed parameter, and submits under corresponding state
Study module or breakage alarm module carry out data processing.
Data acquisition module creates data storage file when determining in numerical control machine tooling, when judgement data reach a fixed number
Amount or work step terminate, after the completion of work pieces process by the cutting parameter saved in memory not coverage mode write it is right in database
The data file answered.
Study level-learning module receives a lot number of user's input by human-computer interaction interface, and replaces using not
It wears cutter and carries out operation.
After given batch size completes the process fitting creation transient current/load change over time reference waveform curve,
Average current/load control system figure (as shown in Figure 2), tooling step parameter are simultaneously saved in database.
Forecast stage breakage alarm module matches work step reference waveform curve to data base querying according to current work step information.
Transient current/load data and reference waveform curve otherness are compared, when continuous several times determine that transient data is more than
When reference waveform curve corresponds to N times of transient current/load of moment, as shown in figure 4, determining tool failure.
It is protected after determining tool failure to digital control system transmission alarm signal triggering lathe emergency shutdown.
Forecast stage wear prediction module after a work pieces process is completed inquires the work pieces process mistake from database
Generated in journey to close data, average current/load mean range chart of corresponding work step is respectively created.
Control figure is analyzed, determines that tool wear is moved back when abnormal foundation control figure unusual fluctuations principle occurs in control figure
Change situation, dynamic adjusts tool changing or sharpening rule,
When control figure unusual fluctuations, as shown in figure 3, determine to issue when tool wear reaches the limit warning note operator into
Cutter changing.
Claims (8)
1. the tool breakage and abrasion on-line monitoring method based on main shaft drives electric current and work step, it is characterised in that: for mass
Processing equipment part, while tooling step information and spindle motor current/information on load are monitored, by drawing batch machining part automatically
Average current/load statistical process control of each work step determines tool wear degenerate state, formulates tool changing and sharpening rule
Then；It is and instantaneous in normal process by drawing transient current/load variations tendency chart of each work step of batch machining part automatically
The comparison of electric current/load trend chart determines tool failure state, and issues stopping alarm signal.
2. the tool breakage and abrasion on-line monitoring method according to claim 1 based on main shaft drives electric current and work step,
It is characterized in that: monitoring each work step processing by obtaining the work step information of nc program for batch machining machine components
Spindle motor current in the process/load variations situation, by the average major-axis electricity in each work step process of batch machining part
Stream/load data is analyzed using the mean range chart in statistical process control, when mean range chart goes out
Existing unusual fluctuations determine that corresponding work step institute is reached capacity state using tool wear, issue alarm signal and notify operator
It replaces cutter or carries out tool sharpening.
3. the tool breakage and abrasion on-line monitoring method according to claim 1 based on main shaft drives electric current and work step,
It is characterized in that: monitoring each work step processing by obtaining the work step information of nc program for batch machining machine components
Instantaneous spindle motor current/load variations situation in the process draws each work step transient current/load variations waveform diagram automatically；So
Pass through transient current/load variations waveform diagram otherness in analysis electric current/load waveform diagram and each work step normal process afterwards
Determine tool failure, issues alarm signal notice digital control system emergency shutdown to avoid the serious consequence of damage workpiece and lathe.
4. the tool breakage and abrasion on-line monitoring method according to claim 1 based on main shaft drives electric current and work step,
Be characterized in that: mean value electric current/load control system figure control line of each work step of batch machining part need to be by acquiring normal add
Average current/load of each work step when work does not wear cutter acquires data, and according to mean range chart control line
Calculation method carries out calculating analysis acquisition；When online judgement cutting-tool wear state, every electric current for acquiring a fixed part volume/
After load data, division of labor step draws average current/load mean range chart of each work step, is sentenced according to statistical quality control
The principle of control figure unusual fluctuations is determined to determine the wear degradation situation of the used cutter of each work step online.
5. the tool breakage and abrasion on-line monitoring method according to claim 1 based on main shaft drives electric current and work step,
It is characterized in that: each work when the transient current of each work step of batch machining part/load waveform diagram acquired normal process of need
Transient current/load data of step, and pass through curve matching after average elimination random error after at least acquiring multi-group data
Obtain the reference waveform curve that transient current/load during each work step normal process changes with process time；It is online real-time
When determining tool failure, as soon as it often monitors in time transient current/load data, with reference waveform curve under Identical Processing
Transient current/load compare, if continuous several times monitoring transient current/load obviously exceed positive reference waveform curve pair
N times of the transient current/load at moment is answered, determines tool failure, and issue alarm signal to digital control system；Wherein, N is warning
Multiplying power rule of thumb sets and corrects.
6. the tool breakage and abrasion on-line monitoring method according to claim 1 based on main shaft drives electric current and work step,
It is characterized in that: Small computing devices being installed in numerically-controlled machine tool power control cabinet, and is established and is led to by data-interface and machine tool numerical control system
News, the status informations such as the current processing program of acquisition digital control system and machine spindle speed, canonical loading, the speed of mainshaft or load letter
Breath can also directly monitor spindle drive motor electric current by current sensor, calculate the speed of mainshaft and main shaft according to current waveform figure
Load.
7. the tool breakage and abrasion on-line monitoring method according to claim 1 based on main shaft drives electric current and work step,
Be characterized in that: for the reliable accurate on-line identification for carrying out tool breakage and abrasion state, system work process be divided into the study stage and
Two stages of forecast stage；The study stage need to be met the stated number of system-computed requirement by operator by human-computer interaction acquisition
The work step information and status information of the complete machining process of part are measured, system automatic identification divides work step and cutter model, and draws
Make the average current/load mean range chart and transient current/load criterion wavy curve of each work step；In forecast rank
Section determines cutting-tool wear state according to the control figure of current average current/load, judges knife according to current transient current/load
Has damaged state.
8. realizing the monitoring system of monitoring method according to claim 1, it is characterised in that: comprising data acquisition module, learn
Practise module, breakage alarm module, wear prediction module, tool breakage and abrasion database；Digital control system data-interface passes through data
Acquisition module is connect with breakage alarm module, tool breakage and abrasion database and study module respectively；Breakage alarm module and mill
Forecast module connection is damaged, breakage alarm module, wear prediction module and study module are connect with tool breakage and abrasion database；
After data acquisition module is connect with machine tool numerical control system data-interface, it to be used for the current machining state of real-time monitoring numerically-controlled machine tool
When the judgement positive work in-process triggering collection module of numerically-controlled machine tool starts to acquire data；
Acquisition module acquires current processing program information, canonical loading, rotary speed parameter, and submits to the study mould under corresponding state
Block or breakage alarm module carry out data processing；
Data acquisition module determine numerical control machine tooling in when create data storage file, when determine data reach certain amount or
Person's work step terminates, after the completion of work pieces process by the cutting parameter saved in memory not coverage mode write it is corresponding in database
Data file；
Study level-learning module receives a lot number of user's input by human-computer interaction interface, and replaces to use and not wear
Cutter carries out operation.
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