CN111113151B - Online fault diagnosis method and system in sawing process of bimetal saw band - Google Patents
Online fault diagnosis method and system in sawing process of bimetal saw band Download PDFInfo
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- 238000005520 cutting process Methods 0.000 description 15
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/09—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
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- B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
- B23D59/00—Accessories specially designed for sawing machines or sawing devices
Abstract
The invention discloses an online fault diagnosis method and system in a sawing process of a bimetal saw band, wherein the online fault diagnosis method comprises the following steps: collecting acoustic emission signals emitted in the sawing process of the bimetal saw band; the acoustic emission signal is filtered and amplified and then converted into a digital voltage signal; calculating a mean value X, a peak value F and a variance D of the digital voltage signal; judging whether the conditions 1 to 5 are satisfied: when the condition 1 is met, outputting a diagnosis result as normal; when the condition 2 is met, outputting a diagnosis result as a cut-off slope; when the condition 3 is met, outputting a diagnosis result as severe abrasion; when the condition 4 is met, outputting a diagnosis result as broken teeth; when the condition 5 is satisfied, the diagnosis result is output as failure. The invention can efficiently and accurately judge whether the sawing process of the bimetal saw band is in an abnormal working condition in real time, realizes diagnosis and early warning of common defects in the sawing process, improves the efficiency, reduces the cost and ensures the precision of parts obtained by sawing.
Description
Technical Field
The invention belongs to the technical field of fault diagnosis, and particularly relates to an online fault diagnosis method and system in a sawing process of a bimetal saw band.
Background
Sawing is an important process for cutting and blanking common metal raw materials, and in modern manufacturing industry, sawing is used as a starting point of processing some metal materials and is one of important links in the processing and manufacturing process. The sawing can improve the productivity, save raw materials and reduce the secondary processing amount, and various types of sawing machines, especially automatic sawing machines, are widely applied to many fields such as machinery, steel, automobiles, petroleum, shipbuilding, mines, aerospace and the like.
However, during the sawing process, as the saw band is worn away, the usual disadvantages of the process occur: tooth breakage, skew cutting, severe wear and failure. And the processing defects are occasionally uncontrollable, which can cause material waste, increase the processing cost and worsen the economic benefit. In the prior art, a method for detecting faults in the sawing process of the bimetal saw band does not exist.
Based on this, the abnormal sawing working condition of the saw belt is accurately identified and early warned, so that adjustment (replacement of the saw belt) is performed according to the diagnosis result, and the method has important practical significance for improving the sawing efficiency and reducing the rejection rate in actual production so as to reduce the production cost.
Disclosure of Invention
The invention aims to provide an online fault diagnosis method and system in the sawing process of a bimetal saw band, aiming at the defects of the prior art, which can efficiently and accurately judge whether the sawing process of the bimetal saw band is in an abnormal sawing working condition in real time, can accurately judge the processing state of the bimetal saw band, can realize the diagnosis and early warning of common defects in the sawing processing process, improve the sawing processing efficiency, reduce the sawing processing cost and ensure the precision of parts obtained by sawing.
In order to solve the technical problems, the technical scheme adopted by the invention is as follows:
an online fault diagnosis method in the sawing process of a bimetal saw band is characterized by comprising the following steps:
In a preferred embodiment, in step 1, an acoustic emission sensor is used to collect an acoustic emission signal.
Preferably, before diagnosis, the acoustic emission sensor is coated with a coupling agent, and is arranged on the surface of the sawed workpiece in a magnetic attraction manner by using a clamp.
Based on the same conception, the invention also provides an online fault diagnosis system in the sawing process of the bimetal saw band, which is characterized by comprising an acoustic emission sensor, a preamplifier, a data acquisition card and an industrial personal computer which are connected in sequence, wherein:
an acoustic emission sensor: the acoustic emission signal is used for collecting an acoustic emission signal emitted in the sawing process of the bimetal saw band;
a preamplifier: the acoustic emission sensor is used for filtering and amplifying acoustic emission signals output by the acoustic emission sensor;
a data acquisition card: the signal output by the preamplifier is converted into a digital voltage signal;
the industrial personal computer is used for receiving and processing the digital voltage signal output by the data acquisition card;
the industrial personal computer comprises a computing unit, a judging unit and an output unit; the calculating unit is used for calculating the mean value X, the peak value F and the variance D of the digital voltage signal; the judging unit is used for judging whether conditions 1-5 are met, wherein the condition 1 is as follows: x is less than X1, F is less than F1; the condition 2 is: x is more than X1 and less than X2, F is more than F1 and less than F2; the condition 3 is: x is more than X3 and less than X4, F is more than F3 and less than F4; condition 4 is: x is less than X1, F3 is less than F4; the condition 5 is: x5 is less than X, F5 is less than F, and D is more than D1; wherein X1, X2, X3, X4, X5, F1, F2, F3, F4, F5 and D1 are all set values, X1 < X2 < X3 < X4 < X5, F1 < F2 < F3 < F4 < F5; the output unit is used for outputting the diagnosis result to be normal when the condition 1 is met; when the condition 2 is met, outputting a diagnosis result as a cut-off slope; when the condition 3 is met, outputting a diagnosis result as severe abrasion; when the condition 4 is met, outputting a diagnosis result as broken teeth; when the condition 5 is satisfied, the diagnosis result is output as failure.
Compared with the prior art, the method can effectively and accurately judge whether the sawing process of the bimetal saw band is in the abnormal sawing working condition in real time, can accurately judge the processing state of the bimetal saw band, can realize diagnosis and early warning of common defects (such as cut skew, serious abrasion, tooth breakage and failure) in the sawing processing process, improves the sawing processing efficiency, reduces the sawing processing cost, and ensures the precision of parts obtained by sawing processing.
Drawings
Fig. 1 is a block diagram of an online fault diagnosis system according to the present invention.
Wherein, 1 is an acoustic emission sensor, 2 is a preamplifier, 3 is a data acquisition card, 4 is an industrial personal computer, and 5 is a processing workpiece.
Detailed Description
As shown in fig. 1, the technical principle of the present invention is:
arranging the acoustic emission sensor 1 on a workpiece 5 to be sawn, starting sawing, collecting acoustic emission signals by the acoustic emission sensor 1, amplifying and filtering the obtained acoustic emission signals by the preamplifier 2, converting the acoustic emission signals into digital voltage signals by the data acquisition card 3, finally entering a software system of the industrial personal computer 4, collecting, analyzing and processing the signals, and judging the sawing condition at the moment.
The online fault diagnosis system in the sawing process of the bimetal saw band comprises an acoustic emission sensor 1, a preamplifier 2, a data acquisition card 3 and an industrial personal computer 4 which are connected in sequence, wherein:
acoustic emission sensor 1: the acoustic emission signal is used for collecting an acoustic emission signal emitted in the sawing process of the bimetal saw band;
the preamplifier 2: the acoustic emission sensor is used for filtering and amplifying the acoustic emission signal output by the acoustic emission sensor 1;
a data acquisition card 3: for converting the signal output by the preamplifier 2 into a digital voltage signal;
the industrial personal computer 4 is used for receiving and processing the digital voltage signals output by the data acquisition card 3;
the industrial personal computer 4 comprises a computing unit, a judging unit and an output unit; the calculating unit is used for calculating the mean value X, the peak value F and the variance D of the digital voltage signal; the judging unit is used for judging whether conditions 1-5 are met, wherein the condition 1 is as follows: x is less than X1, F is less than F1; the condition 2 is: x is more than X1 and less than X2, F is more than F1 and less than F2; the condition 3 is: x is more than X3 and less than X4, F is more than F3 and less than F4; condition 4 is: x is less than X1, F3 is less than F4; the condition 5 is: x5 is less than X, F5 is less than F, and D is more than D1; wherein X1, X2, X3, X4, X5, F1, F2, F3, F4, F5 and D1 are all set values, X1 < X2 < X3 < X4 < X5, F1 < F2 < F3 < F4 < F5; the output unit is used for outputting the diagnosis result to be normal when the condition 1 is met; when the condition 2 is met, outputting a diagnosis result as a cut-off slope; when the condition 3 is met, outputting a diagnosis result as severe abrasion; when the condition 4 is met, outputting a diagnosis result as broken teeth; when the condition 5 is satisfied, the diagnosis result is output as failure.
Specifically, the online fault diagnosis system in the sawing process of the bimetal saw band comprises the following specific parts:
1. hardware system
A general purpose acoustic emission monitoring system generally includes: the price of the sensor, the amplifier and the acquisition card is over 10 ten thousand yuan, the price is high, and the sensor, the amplifier and the acquisition card do not have the capability of being matched with the actual specific production condition. Therefore, the model selection acoustic emission sensor 1, the preamplifier 2, the general data acquisition card 3 and the development integrated software system are used as a research system platform. The developed fault diagnosis system platform aims at the specific production working state of saw cutting processing, and is high in matching degree and low in cost. The specific selection scheme is as follows:
acoustic emission sensor 1: and a universal sensor with a wide frequency range is selected to collect acoustic emission signals obtained in the sawing process.
The preamplifier 2: the preamplifier 2 refers to a circuit or an electronic device disposed between a source and an amplifier stage, and is designed to receive a weak voltage signal from the source. Since the output signal of the acoustic emission sensor 1 is a very weak voltage signal, a preamplifier 2 is required to amplify a useful acoustic voltage signal (and also to amplify a noise signal). In order to obtain the appropriate amplification, the adjustable gain preamplifier 2 is selected so that by adjusting the amplification, the appropriate acoustic emission signal values are extracted.
A data acquisition card 3: the data acquisition card 3 can automatically acquire non-electric quantity or electric quantity signals in analog and digital tested units such as sensors and other devices to be tested, and send the signals to an upper computer for analysis and processing, and is a computer expansion card for realizing a Data Acquisition (DAQ) function. The acoustic emission signal has wide frequency range and large data volume, and a data processing method of multi-channel sensor fusion may be adopted in the later stage of research, so that a data acquisition card 3 with high transmission speed, multiple channels and capability of accepting multiple communication interfaces needs to be selected. In this embodiment, an NI USB6351 acquisition card is used.
2. Software system
After the fault diagnosis system device is selected, installed and connected, a data acquisition system of sounding signals needs to be started, Lab VIEW is graphical programming software developed by US NI (national instruments) company, the programming mode is convenient and fast, and the hardware compatibility with various measuring instruments and data acquisition cards 3 is good, so that the fault diagnosis system device is widely applied to various measurement monitoring systems. The NI general purpose data acquisition card 3 contains a driver function with Lab VIEW software. Using these drive functions, an acoustic emission signal acquisition storage program based on Lab VIEW can be written. After the program is opened, the hardware parameters of the acoustic emission data acquisition card 3 need to be set first when the program runs for the first time. After the hardware parameters are set, the sampling time length and the storage path of the data file are set, and then the acquisition can be started. After the signal data is collected for the desired length of time, the data is saved in a file of a particular format. The TDMS format file for storing data in the program is a binary record file mainly pushed by the American NI company, and has the advantages of high speed, easy access, convenience and the like. The post-processing can be directly opened by Lab VIEW programming, and the software system mainly comprises the following parts:
acoustic emission signal acquisition software: the acoustic emission device is used for collecting acoustic emission signals in the sawing process and storing the acoustic emission signals as binary TDMS files.
Acoustic emission signal analysis software: and the acoustic emission analysis module is used for analyzing and processing the acquired acoustic emission signals and analyzing the acoustic emission signals under different working conditions. Because the acoustic emission signals obtained under different working conditions are different, the signals are analyzed and processed by analysis software to obtain the characteristic values of the acoustic emission signals under each working condition: in the normal sawing stage, the average peak value of the acoustic emission signals is small; in the oblique cutting and severe abrasion stages, the average peak value is large; in the tooth breaking stage, the mean value is small but the peak value is large; in the failure stage, the peak value average value exceeds a certain value and the fluctuation is serious.
Working condition real-time monitoring and early warning software: and establishing discrimination thresholds of different working conditions according to the characteristic values of the acoustic emission signals under different working conditions obtained by collection and analysis, and monitoring and discriminating different working conditions of the sawing engineering in real time.
Based on the acoustic emission technology, the invention extracts the characteristic signals of initial stage of saw cutting, stable processing of saw cutting, late stage of saw cutting abrasion, beveling, tooth breaking and fracture according to the collected original acoustic emission signals, establishes the mapping relation between the acoustic signal characteristics and the life cycle of the saw band based on different saw cutting stages of acoustic signal characterization, realizes the real-time monitoring of the working condition of the saw band, and provides the acoustic emission characteristic threshold value of the service life termination of the saw band and the request of the saw cutting processing termination.
The online fault diagnosis method in the sawing process of the bimetal saw band comprises the following steps:
The acoustic emission sensor 1 collects acoustic emission signals emitted in the sawing process of the bimetal saw band and transmits the acoustic emission signals to the preamplifier 2.
And 2, after the acoustic emission signals are filtered and amplified by the preamplifier 2, the filtered and amplified signals are transmitted to a data acquisition card 3 with the model of NI-USB6351, and the data acquisition card 3 converts the acquired, filtered and amplified acoustic emission signals into digital voltage signals.
And 3, transmitting the signals processed by the data acquisition card 3 into a real-time monitoring and early warning program based on LABVIEW software through a USB port of the industrial personal computer 4, and further processing the program to obtain characteristic values of the signals: the peak value, the mean value and the variance are different, the early warning threshold values of different defects are different, and when the signal characteristic value reaches the alarm threshold value set by the defect, the corresponding alarm lamp of the program is turned on.
The specific diagnostic logic is as follows:
calculating the mean value X, the peak value F and the variance D of the digital voltage signals in the step 2; judging whether the conditions 1 to 5 are satisfied: when the condition 1 is met, outputting a diagnosis result as normal; when the condition 2 is met, outputting a diagnosis result as a cut-off slope; when the condition 3 is met, outputting a diagnosis result as severe abrasion; when the condition 4 is met, outputting a diagnosis result as broken teeth; when the condition 5 is met, outputting a diagnosis result as failure; wherein, condition 1 is: x is less than X1, F is less than F1; the condition 2 is: x is more than X1 and less than X2, F is more than F1 and less than F2; the condition 3 is: x is more than X3 and less than X4, F is more than F3 and less than F4; condition 4 is: x is less than X1, F3 is less than F4; the condition 5 is: x5 is less than X, F5 is less than F, and D is more than D1; wherein X1, X2, X3, X4, X5, F1, F2, F3, F4, F5 and D1 are all set values, X1 < X2 < X3 < X4 < X5, F1 < F2 < F3 < F4 < F5.
The effective feasibility of the invention was verified by the following examples:
1. the acoustic emission sensor 1 is arranged on the surface of the workpiece 5 to be sawn in a magnetic attraction manner by using a special clamp.
2. All components of the system are connected, installed and adjusted according to steps.
3. The GCR15 bearing steel is sawed on a sawing machine by using a saw belt with the model number of 2734, and the obtained signals are collected and analyzed by using the fault diagnosis system.
4. When the saw cutting is carried out to the 52 knives, the inclination cutting alarm is generated, after the saw cutting of the knives is finished, the obtained parts are detected, and the parts are slightly inclined.
5. When the saw cutting is carried out to 80 knives, serious abrasion and inclination cutting alarm occur, after the saw cutting is finished, the obtained parts are detected, and the parts are seriously inclined and the saw belt is seriously abraded.
6. And (3) replacing the saw belt to continue the sawing experiment, when the saw reaches 34 knives, the teeth breaking alarm is generated, the saw belt is detected after the knives saw, and the teeth breaking defect occurs in the saw belt.
Therefore, the method and the device can realize diagnosis and early warning of common defects in the sawing process, thereby improving the sawing efficiency, reducing the sawing cost and ensuring the precision of parts obtained by sawing.
While the present invention has been described with reference to the embodiments shown in the drawings, the present invention is not limited to the embodiments, which are illustrative and not restrictive, and it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the invention as defined in the appended claims.
Claims (4)
1. An online fault diagnosis method in the sawing process of a bimetal saw band is characterized by comprising the following steps:
step 1, collecting acoustic emission signals emitted in the sawing process of the bimetal saw band;
step 2, filtering and amplifying the acoustic emission signal, and converting the acoustic emission signal into a digital voltage signal;
step 3, calculating the mean value X, the peak value F and the variance D of the digital voltage signals in the step 2; judging whether the conditions 1 to 5 are satisfied: when the condition 1 is met, outputting a diagnosis result as normal; when the condition 2 is met, outputting a diagnosis result as a cut-off slope; when the condition 3 is met, outputting a diagnosis result as severe abrasion; when the condition 4 is met, outputting a diagnosis result as broken teeth; when the condition 5 is met, outputting a diagnosis result as failure; wherein, condition 1 is: x is less than X1, F is less than F1; the condition 2 is: x is more than X1 and less than X2, F is more than F1 and less than F2; the condition 3 is: x is more than X3 and less than X4, F is more than F3 and less than F4; condition 4 is: x is less than X1, F3 is less than F4; the condition 5 is: x5 is less than X, F5 is less than F, and D is more than D1; wherein X1, X2, X3, X4, X5, F1, F2, F3, F4, F5 and D1 are all set values, X1 < X2 < X3 < X4 < X5, F1 < F2 < F3 < F4 < F5.
2. The method for diagnosing faults during sawing of a bimetal saw band as claimed in claim 1, wherein in step 1, acoustic emission signals are acquired by using an acoustic emission sensor (1).
3. The method for diagnosing the fault in the sawing process of the bimetal saw band as claimed in claim 2, wherein before the diagnosis, a couplant is smeared on the acoustic emission sensor (1), and the acoustic emission sensor (1) is arranged on the surface of the processed workpiece (5) to be sawn in a magnetic attraction manner by using a clamp.
4. The utility model provides an online fault diagnosis system among bimetal saw band sawing process, its characterized in that, includes consecutive acoustic emission sensor (1), preamplifier (2), data acquisition card (3) and industrial computer (4), wherein:
acoustic emission sensor (1): the acoustic emission signal is used for collecting an acoustic emission signal emitted in the sawing process of the bimetal saw band;
preamplifier (2): the acoustic emission sensor is used for filtering and amplifying acoustic emission signals output by the acoustic emission sensor (1);
data acquisition card (3): the signal output by the preamplifier (2) is converted into a digital voltage signal;
the industrial personal computer (4) is used for receiving and processing the digital voltage signals output by the data acquisition card (3);
the industrial personal computer (4) comprises a computing unit, a judging unit and an output unit; the calculating unit is used for calculating the mean value X, the peak value F and the variance D of the digital voltage signal; the judging unit is used for judging whether conditions 1-5 are met, wherein the condition 1 is as follows: x is less than X1, F is less than F1; the condition 2 is: x is more than X1 and less than X2, F is more than F1 and less than F2; the condition 3 is: x is more than X3 and less than X4, F is more than F3 and less than F4; condition 4 is: x is less than X1, F3 is less than F4; the condition 5 is: x5 is less than X, F5 is less than F, and D is more than D1; wherein X1, X2, X3, X4, X5, F1, F2, F3, F4, F5 and D1 are all set values, X1 < X2 < X3 < X4 < X5, F1 < F2 < F3 < F4 < F5; the output unit is used for outputting the diagnosis result to be normal when the condition 1 is met; when the condition 2 is met, outputting a diagnosis result as a cut-off slope; when the condition 3 is met, outputting a diagnosis result as severe abrasion; when the condition 4 is met, outputting a diagnosis result as broken teeth; when the condition 5 is satisfied, the diagnosis result is output as failure.
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