CN111215648A - Electric spindle reliability rapid experiment loading method and loading system - Google Patents
Electric spindle reliability rapid experiment loading method and loading system Download PDFInfo
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- CN111215648A CN111215648A CN202010054600.1A CN202010054600A CN111215648A CN 111215648 A CN111215648 A CN 111215648A CN 202010054600 A CN202010054600 A CN 202010054600A CN 111215648 A CN111215648 A CN 111215648A
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Abstract
The invention discloses a quick test loading method and a quick test loading system for reliability of an electric spindle, wherein the method comprises the following steps: according to the conventional spindle load spectrum and the acceleration factors of the electric spindle fatigue and wear acceleration model, the magnitude and frequency of the loading force and the spindle rotating speed in the conventional spindle load spectrum are improved to obtain an acceleration load spectrum; controlling the electric spindle according to an acceleration load spectrum, calculating pose information of a mechanism according to position information of a motion module in a loading system and parameter information of a five-degree-of-freedom parallel pneumatic loading mechanism, and calculating loading force and frequency on each loading shaft according to the pose information and the acceleration load spectrum; performing an acceleration experiment on the motorized spindle according to the calculated loading force and frequency on each loading shaft; and detecting a plurality of parameters of the electric spindle in an acceleration experiment, and evaluating the performance of the electric spindle according to the parameters. The method can be used for rapidly loading the electric spindle, detecting a plurality of items of spindle state information and the running state of the electric spindle and comprehensively evaluating the reliability of the electric spindle.
Description
Technical Field
The invention relates to the technical field of reliability testing of an electric spindle of a numerical control machine tool, in particular to a loading method and a loading system for a quick experiment of reliability of the electric spindle.
Background
The electric spindle is a complex system integrating machine, electricity and liquid, and is one of the core links of the reliability of a processing center. Under the working conditions of high speed, high power and high load, the main shaft parts are easy to generate various failures such as fatigue wear, cracks and the like, and the occurrence of the failures often leads to chain reaction, aggravates the breakage of the rest parts of the main shaft and further deteriorates the performance state of the main shaft.
In order to improve the reliability of the electric spindle, a reliability loading test needs to be carried out on the electric spindle, so that the electric spindle can eliminate or greatly reduce early faults within a limited period and acceptable cost. However, the conventional method directly carries out reliability loading on a machine tool, has the defects of long test period, slow effect, large required sample amount, high cost and the like, needs to occupy a plurality of machine tools for testing, brings uncertain influence factors into other parts in the machine tool, and is not beneficial to the special research on the reliability of the main shaft. Therefore, in order to improve the reliability of the spindle and perform a loading test and data acquisition in a controllable environment, an electric spindle reliability loading test and detection system needs to be established in a laboratory.
According to research and development, domestic main shaft manufacturers mainly use idle running, main shaft dynamometer double drag or constant force loading tests in reliability tests before main shafts leave factories, and although the main shafts reach the factory requirements when leaving factories, the precision and the reliability of the main shafts are greatly reduced after the main shafts are used for a period of time, so that the problems of the reliability and the precision retentivity of the main shafts restrict the development of domestic numerical control machine tool electric main shaft manufacturers for a long time. On the other hand, the time consumption of simple constant force loading test on a plurality of main shafts is huge, the test cost is very high, the real load of the main shafts is difficult to simulate, and the timeliness of the products on the market is influenced.
Disclosure of Invention
The present invention is directed to solving, at least to some extent, one of the technical problems in the related art.
Therefore, the invention provides a quick test loading method and a loading system for the reliability of an electric spindle, which aim to solve the technical problems of long test period, high cost and inaccurate test in the process of testing the electric spindle, and can be used for quickly loading the electric spindle, detecting a plurality of items of spindle state information and the running state of the electric spindle and comprehensively evaluating the reliability of the electric spindle.
An embodiment of the invention provides a method for loading an electric spindle reliability rapid experiment, which comprises the following steps:
s1, establishing a fatigue and wear acceleration model of the electric spindle;
s2, increasing the loading force and frequency in the conventional spindle load spectrum and the spindle rotating speed according to the conventional spindle load spectrum and the acceleration factor in the fatigue and wear acceleration model of the electric spindle to obtain an acceleration load spectrum;
s3, controlling the electric spindle in a loading system according to an accelerated load spectrum, acquiring position information of a motion module in the loading system and parameter information of a five-degree-of-freedom parallel pneumatic loading mechanism, calculating pose information of the five-degree-of-freedom parallel pneumatic loading mechanism according to the position information and the parameter information, and calculating loading force and frequency on each loading shaft of the five-degree-of-freedom parallel pneumatic loading mechanism according to the pose information and the accelerated load spectrum;
and S4, performing an acceleration experiment on the motorized spindle according to the calculated loading force and frequency on each loading shaft, detecting a plurality of parameters of the motorized spindle in the acceleration experiment, and evaluating the performance of the motorized spindle according to the parameters.
In another aspect, an embodiment of the present invention provides a system for loading an electric spindle for a rapid reliability experiment, including:
the device comprises a main shaft (1), a main shaft base frame (2), a horizontal iron (3), a plane motion module, a precision detection module (6), a five-degree-of-freedom parallel pneumatic loading mechanism (7), a motion control module and a data acquisition and analysis module (9);
the front bearing and the rear bearing of the ground flat iron (3) and the main shaft (1) are respectively provided with a temperature sensor and a vibration sensor for collecting temperature data and vibration data;
the main shaft base frame (2) is connected with the main shaft (1) and used for fixing the main shaft (1);
the plane motion module comprises an X-direction motion module (4) and a Y-direction motion module (5), the plane motion module is used for driving the precision detection module (6) and the five-degree-of-freedom parallel pneumatic loading mechanism (7) to move, the X-direction motion module (4) is fixed on the ground flat iron (3), and the Y-direction motion module (5) is installed on the X-direction motion module (4);
the five-degree-of-freedom parallel pneumatic loading mechanism (7) comprises a plurality of loading shafts, each loading shaft is provided with a tension sensor and is used for applying loading force to the main shaft and collecting loading force data, the five-degree-of-freedom parallel pneumatic loading mechanism is fixed on the Y-direction movement module (5) through a plurality of positioning plates, and the upper end of the five-degree-of-freedom parallel pneumatic loading mechanism is connected with the main shaft (1);
the precision detection module is fixed on a positioning plate of the five-degree-of-freedom parallel pneumatic loading mechanism and used for detecting the rotation precision and the deformation of the main shaft;
the motion control module includes host computer (10) and motion control cabinet (8), the mutual inductance of current sensor and the voltmeter of installing on the motion control cabinet (8), motion control cabinet (8) include: the motion control system comprises a main shaft motion control module and an XY motion module motor motion control module, wherein a motion control cabinet (8) can be communicated with a control program of an upper computer (10) through USB serial port communication to perform instruction control on a main shaft, the XY motion module motor motion control module controls the motion of an XY motion module motor and reads position information of the XY motion module motor through an NI controller, the pose state of the five-freedom-degree parallel pneumatic loading mechanism is obtained according to the position information and parameter information of the five-freedom-degree parallel pneumatic loading mechanism, the magnitude of force required to be applied by each loading shaft is calculated by combining the magnitude and direction of each force loaded by a load spectrum, and a loading experiment is performed on the loading system;
and the data acquisition and analysis module (9) acquires the state information of each sensor in the experiment loading system and evaluates the performance of the motorized spindle according to the state information.
The technical scheme of the invention at least realizes the following beneficial technical effects:
the loading system capable of simulating the actual loading condition of the main shaft can load the main shaft, the reliability acceleration test is realized through a certain acceleration factor based on an acceleration model, the actual loading condition of the main shaft can be simulated at a low cost, the test speed can be accelerated, the performance state of the main shaft is monitored through various sensors arranged, the precision and the reliability of the main shaft are evaluated, and the main shaft loading system has a wide application prospect.
Additional aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
Drawings
The foregoing and/or additional aspects and advantages of the present invention will become apparent and readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
FIG. 1 is a flowchart of a method for fast experimental loading of reliability of an electric spindle according to an embodiment of the present invention;
FIG. 2 is a block diagram of a method for loading an experiment on the reliability of an electric spindle according to an embodiment of the present invention;
FIG. 3 is a flow diagram of acceleration model building according to one embodiment of the invention;
FIG. 4 is a schematic view of a spindle configuration according to one embodiment of the present invention;
FIG. 5 is a schematic three-dimensional structure diagram of an embodiment of a loading system according to the invention;
FIG. 6 is a schematic diagram of a five degree-of-freedom parallel pneumatic loading mechanism according to one embodiment of the present invention;
FIG. 7 is a schematic diagram of an accuracy detection module according to one embodiment of the invention;
FIG. 8 is a schematic view of a spindle mounting arrangement according to one embodiment of the present invention;
FIG. 9 is a schematic view of an XY motion module, according to one embodiment of the invention;
FIG. 10 is a schematic diagram of a Y-direction motion module according to one embodiment of the invention.
Reference numerals: 1-machining a central electric spindle; 2-a main shaft pedestal; 3-ground flat iron; a 4-X direction moving module; 5-Y direction moving module; 6-a precision detection module; 7-five-degree-of-freedom parallel pneumatic loading mechanism; 8-a motion control cabinet; 9-a data acquisition and analysis module; 10-an upper computer; 21-a main shaft positioning plate; 22-upper part of main shaft base frame; 23-a spindle pedestal base; a 51-Y direction module motion platform; 52-a first baffle; 53-a first lead screw nut; 54-motion block; 55-motion block flange; 56-a slide block; 57-a guide rail; 58-Y direction module bottom plate; 59-lead screw; 510-a second lead screw nut; 511-coupling; 512-Y direction module motor; 513-a motor mounting plate; 514-motor module connection; 515-a second baffle; 61-a first magnetic base; 62-a second magnetic seat; 63-a sensor mount; 64-first bit sensor; 65-a second position sensor; 66-a third position sensor; 67-rotational speed sensor; 681-adjusting mount base; 682-first set screw; 683-a second set screw; 684-adjusting screw; 685-adjusting nut; 686 — adjusting the mount platform; 71-a second positioning plate; 72-a second loading shaft; 73-a third loading shaft; 74-a detection rod; 75-moving the platform; 76-spindle shank interface; 77-fourth loading shaft; 78-fifth loading shaft; 79 — first loading shaft; 710-a third positioning plate; 711-middle positioning plate; 712-first positioning plate.
Detailed Description
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the drawings are illustrative and intended to be illustrative of the invention and are not to be construed as limiting the invention.
The following describes a loading method and a loading device for an electric spindle reliability rapid experiment according to an embodiment of the present invention with reference to the accompanying drawings.
First, a method for loading an electric spindle reliability rapid experiment according to an embodiment of the present invention will be described with reference to the accompanying drawings.
Fig. 1 is a flowchart of a method for loading an electric spindle reliability rapid experiment according to an embodiment of the present invention.
As shown in fig. 1, the method for loading an electric spindle reliability rapid experiment comprises the following steps:
in step S101, a fatigue and wear acceleration model of the electric spindle is established.
In the embodiment of the invention, based on the principle of 'proportional expansion of accumulated wear amount and accumulated fatigue damage and the like', a fatigue model based on the criterion of Manson-Hall bilinear fatigue damage and the like and a main shaft bearing wear model based on Archard and Hertz contact theory and the like are used for carrying out a reliability acceleration test on a main shaft based on the magnitude and frequency of a loading force, the rotating speed of the main shaft and the like, the reliability acceleration test is carried out by improving the magnitude and frequency of the loading force, the rotating speed of the main shaft and other factors in a standard load spectrum, and the performance of the main shaft is evaluated by detecting rotation precision decline, temperature rise change, vibration signals, harmonic current signals and the like.
And step S2, increasing the loading force and frequency in the conventional spindle load spectrum and the spindle rotating speed according to the conventional spindle load spectrum and the acceleration factor in the fatigue and abrasion acceleration model of the electric spindle to obtain an acceleration load spectrum.
And step S3, controlling the electric spindle in the loading system according to the acceleration load spectrum, acquiring the position information of the motion module in the loading system and the parameter information of the five-degree-of-freedom parallel pneumatic loading mechanism, calculating the pose information of the five-degree-of-freedom parallel pneumatic loading mechanism according to the position information and the parameter information, and calculating the loading force and frequency on each loading shaft of the five-degree-of-freedom parallel pneumatic loading mechanism according to the pose information and the acceleration load spectrum.
And step S4, performing an acceleration experiment on the motorized spindle according to the calculated loading force and frequency on each loading shaft, detecting a plurality of parameters of the motorized spindle in the acceleration experiment, and evaluating the performance of the motorized spindle according to the plurality of parameters.
As shown in fig. 2, firstly, based on the principle of "proportional expansion of cumulative wear amount and cumulative fatigue damage", a fatigue model based on the criterion of bilinear fatigue damage and the like and a bearing wear model based on the Archard and Hertz contact theory and the like are used to obtain an acceleration model of fatigue and wear of the main shaft; the magnitude and frequency of loading force, the rotating speed of the main shaft and the like are improved by combining a conventional main shaft load spectrum and an acceleration factor in an acceleration model to obtain an acceleration load spectrum; an upper computer in a data acquisition and analysis module 9 realizes system control based on an acceleration load spectrum, an X-direction movement module 4 and a Y-direction movement module 5 simulate the plane movement of a machine tool, the position information of the movement modules is obtained through a motor of the movement modules, the position information of the mechanism is obtained by combining the size parameters of a five-degree-of-freedom parallel pneumatic loading mechanism, the force and the frequency which are required to be loaded by each loading shaft are obtained by combining the acceleration load spectrum, and the force and the frequency are output to air cylinders on the corresponding loading shafts, so that the purpose of a rapid loading test is achieved; the main shaft rotation precision is detected through the rotation precision module 6, the temperature rise condition of the system is detected through a temperature sensor, the abnormal information of a main shaft bearing is detected through a vibration sensor, and whether abnormal harmonic current is generated or not is detected through a current sensor.
As shown in fig. 3, a process of establishing an acceleration model is shown, a main shaft reliability acceleration test method is based on a principle of proportional expansion of accumulated wear loss and accumulated fatigue damage, a fatigue model based on Manson-hall bilinear fatigue damage and other criteria and a bearing wear model based on arcard and Hertz contact theory and the like are used, a reliability acceleration test is performed by improving factors such as loading force magnitude and frequency in a standard load spectrum, main shaft rotating speed and the like, and main shaft performance is evaluated by detecting rotation precision decline, temperature rise change, vibration signals, harmonic current signals and the like.
As shown in fig. 4, a schematic diagram of a spindle structure is shown, a simple stress model of the spindle is established according to fig. 3, and a relationship between an external load and an internal force is found out:
wherein: l is1、L2Is a main shaft size parameter; f is loading force; g1Is the weight of the motor; g2Is the weight of the spindle;
secondly, calculating the corresponding fatigue life under a single loading level, and using a fatigue model based on the criteria of Manson-Hall bilinear fatigue damage and the like, wherein the fatigue life is as follows:
wherein: k1＝8.627×1056；
d is the diameter of the axis of the main shaft;
establishing a main shaft front bearing abrasion model based on Archard and Hertz contact theory and the like:
wherein: wvi、WvoAccumulating the abrasion loss for the inner and outer rings of the bearing; k is the wear coefficient; k' is the lubrication coefficient; n isiIs the inner ring rotation speed, DiIs the inner diameter; n isoIs the outer ring rotation speed, DoThe diameter of the outer ring; h is the hardness of the softer material; dbThe diameter of the center of the ellipse; k is a radical ofpIs the pressure coefficient; theta is a rotation angle; t is t1、t2The starting time and the stopping time of rotation;
and precision loss amount of abrasion:
wherein: Σ ρ is the sum of the principal curvatures; m isa、mbThe coefficients of a long half shaft and a short half shaft;
let F0The loading force for the routine test, F1To accelerate the loading force of the test, f0Frequency of the original loading force, f1The frequency of the loading force for acceleration test, f is the frequency of the spindle rotation under the conventional test, knMain shaft rotation speed ratio, k, for accelerated experiments and routine experimentswTo accelerate the wear ratio of the experiment and the routine experiment, kDTo speed up the ratio of cumulative fatigue damage from the experiment and from the routine experiment:
let m be f0M is determined according to the working state of the acceleration test required by the actual requirement, such as milling, and the m is determined by the number of cutter teeth on the milling cutter; and (5) turning, wherein m is 1. M can be considered a known quantity.
Setting a loading frequency multiple:
loading force multiple:
thus:
according to the principle of proportional amplification of accumulated wear loss and accumulated fatigue damage, the acceleration factor is K, and the method comprises the following steps:
substituting to obtain:
wherein, a, b, ai,biAll the parameters are determined by the geometric parameters and the dead weight of the main shaft, and can be regarded as known quantities; f0The loading force, which is a routine test, can be measured directly at the machine tool site by sensors, which can be considered as a known quantity. Therefore, there are three unknowns (k)F,kn,kf) Two equations, solution set, have one degree of freedom.
Get knAs parameters, solve for:
in one embodiment of the invention, the force required to be applied by each loading shaft of the five-degree-of-freedom parallel pneumatic loading mechanism is calculated by the following process:
firstly, carrying out stress analysis on a movable platform of a five-degree-of-freedom parallel pneumatic loading mechanism:
wherein: m isMMass of the moving platform, g is gravitational acceleration, feAnd neTo simplify the loading to the origin o of the moving platform coordinate system M,BIM＝BRM MIM BRM Tis the representation of the inertia matrix of the movable platform relative to the mass center in a coordinate system { B } of the static platform;
secondly, the loading shaft is subjected to stress analysis:
no movement part i on ith loading axis1And a moving part i2The vector sum of the acting force and the inertia force about the respective mass centers can be expressed in a loading axis coordinate system { i }, and the specific form is as follows:
in the formula, mi1And mi2Are respectively a member i1And i2The mass of (a) of (b),iIi1andiIi2are respectively a member i1And i2The moment of inertia of the centroid is represented in the branched chain coordinate system i.
And finally, performing dynamic modeling on the five-degree-of-freedom parallel pneumatic loading mechanism by adopting a virtual work principle method:
the virtual displacement δ q of the driving joint and the virtual displacement δ X input by the movable platform terminal can be connected through a Jacobian matrix J:
δq＝JδX
no movement part i on ith loading axis1And a moving part i2Virtual shift delta ofixi1And deltaixi2And δ X may also be passed through the Jacobian matrixiJi1AndiJi2in connection with this:
δixi1＝iJi1δX
δixi2＝iJi2δX
the virtual displacement delta X and delta X of the movable platform can pass through a Jacobian matrix JvIn connection with this:
δx＝JvδX
establishing an imaginary work equation:
obtaining the following components in a simultaneous manner:
since the above holds true at any position, velocity and acceleration, it is possible to obtain:
obtaining the driving force of the mechanism:
the NI controller outputs a corresponding loading shaft cylinder analog quantity control value according to the obtained driving force, and the target of applying the specified load is achieved.
In step S4, detecting a plurality of parameters of the electric spindle in the acceleration experiment includes, but is not limited to, detecting degradation of revolution accuracy, temperature rise change, vibration signal and harmonic current signal.
According to the rapid experiment loading method for the reliability of the electric spindle, provided by the embodiment of the invention, a spindle reliability acceleration test model is established based on a fatigue model of a criterion such as Manson-Hall bilinear fatigue damage and a bearing wear model based on Archard and Hertz contact theories, and a reliability acceleration test based on the magnitude and frequency of a loading force, the rotating speed of the spindle and the like is performed on the spindle. The five-degree-of-freedom parallel pneumatic loading mechanism in the electric spindle reliability loading system can apply axial force, radial force, tangential force and moments in two directions to the electric spindle to simulate the actual stress state of the spindle. When a load based on a load spectrum is applied to the electric spindle, the performance and the health state of a series of electric spindles such as the rotation precision of the electric spindle, the temperature rise of the spindle, the vibration state of a key bearing, the harmonic current of the spindle and the like can be monitored, the performance state of the electric spindle is reflected in real time, and the reliability and the precision retentivity level of the electric spindle are finally evaluated. Therefore, the electric spindle can be rapidly loaded, a plurality of items of spindle state information and the running state of the electric spindle can be detected, and the reliability of the electric spindle can be comprehensively evaluated.
Next, a system for loading an electric spindle with a rapid reliability experiment according to an embodiment of the present invention will be described with reference to the drawings.
Fig. 5 is a schematic three-dimensional structure diagram of an embodiment of a loading system according to an embodiment of the present invention.
As shown in fig. 5, the loading system includes: the method comprises the following steps: the device comprises a main shaft 1, a main shaft base frame 2, a horizontal iron 3, a plane motion module, a precision detection module 6, a five-degree-of-freedom parallel pneumatic loading mechanism 7, a motion control module and a data acquisition and analysis module 9.
The ground flat iron 3 and the front bearing and the rear bearing of the main shaft are respectively provided with a temperature sensor and a vibration sensor for acquiring temperature data and vibration data.
The main shaft base frame 2 is connected with the main shaft 1 and used for fixing the main shaft 1;
the plane motion module comprises an X-direction motion module 4 and a Y-direction motion module 5, the plane motion module is used for driving the precision detection module 6 and the five-freedom-degree parallel pneumatic loading mechanism 7 to move, the X-direction motion module 4 is fixed on the ground flat iron 3, and the Y-direction motion module 5 is installed on the X-direction motion module 4.
The five-degree-of-freedom parallel pneumatic loading mechanism 7 comprises a plurality of loading shafts, each loading shaft is provided with a tension sensor and is used for applying loading force to the main shaft and collecting loading force data, the five-degree-of-freedom parallel pneumatic loading mechanism is fixed on the Y-direction movement module 5 through a plurality of positioning plates, and the upper end of the five-degree-of-freedom parallel pneumatic loading mechanism is connected with the main shaft 1.
The five-degree-of-freedom parallel pneumatic loading mechanism can simulate the stress state of a main shaft during cutting of a machining center and apply force and moment with different frequencies, directions and magnitudes to the machining center.
The precision detection module is fixed on a positioning plate of the five-degree-of-freedom parallel pneumatic loading mechanism and used for detecting the rotation precision and the deformation of the electric spindle;
the motion control module includes host computer 10 and motion control cabinet 8, and the mutual inductance of current sensor and the voltmeter that install on the motion control cabinet 8, motion control cabinet 8 includes: the motion control cabinet 8 can be communicated with a control program of an upper computer 10 through USB serial port communication to perform instruction control on a main shaft, the XY motion module motor motion control module controls the motion of an XY motion module motor and reads position information of the XY motion module motor through an NI controller, the pose state of the five-freedom-degree parallel pneumatic loading mechanism is obtained according to the position information and parameter information of the five-freedom-degree parallel pneumatic loading mechanism, the magnitude of force required to be applied by each loading shaft is calculated by combining the magnitude and direction of each force loaded by a load spectrum, a loading experiment is performed on a loading system, and the NI controller outputs a corresponding loading shaft cylinder analog quantity control value according to the obtained driving force to achieve the target of applying a specified load.
The data acquisition and analysis module 9 acquires the state information of each sensor in the experiment loading system, and evaluates the performance of the motorized spindle according to the state information.
The data acquisition and analysis module can acquire the position information, the actual loading force and the performance state of the main shaft of the system in real time, and can evaluate and monitor the health state of the electric main shaft of the machining center according to the acquired signals mainly through signals such as a temperature sensor, a vibration sensor and a current sensor which are arranged on the electric main shaft and signals such as a tension and pressure sensor which is arranged on a five-degree-of-freedom dynamic force loading mechanism.
The data acquisition and analysis module 9 comprises a current mutual inductance sensor and a voltmeter which are arranged on a motion control cabinet 8, 5 pull pressure sensors which are arranged on a five-degree-of-freedom parallel pneumatic loading mechanism 7, temperature sensors, vibration sensors, an NI synchronous data acquisition and control device and a software system thereof, wherein the temperature sensors and the vibration sensors are respectively arranged on a front bearing, a rear bearing and a ground iron 3 of the main shaft.
As shown in fig. 5, the motion control cabinet 8 of the motion control module integrates a motion control system of the main shaft 1, a motor control system of the X-direction motion module 4, a motor control system of the Y-direction motion module 5, and a pneumatic control system of the five-degree-of-freedom parallel pneumatic loading mechanism 7, so that the upper computer 10 can control the motion of the rest of the mechanical devices through the motion control cabinet 8.
The data acquisition and analysis module 9 is connected with each sensor through an acquisition board card and acquires rotation precision, vibration signals, temperature signals, current signals and the like. A three-phase current mutual inductance sensor and a voltmeter for detecting the current and voltage information of the main shaft are installed in a motion control cabinet 8 of the motion control module, a tension and pressure sensor is respectively installed on a loading shaft of the five-freedom-degree parallel pneumatic loading mechanism 7, and a temperature sensor and a vibration sensor are respectively installed on a front bearing, a rear bearing and a ground flat iron of the main shaft. The motion control cabinet 8 can communicate with a control program of the upper computer 10 through USB serial port communication, and the upper computer 10 can send HEX instruction control through CRC check to the positive and negative rotation, start and stop, rotating speed and the like of the main shaft.
Fig. 6 is a schematic diagram of a five-degree-of-freedom parallel pneumatic loading mechanism. The five-degree-of-freedom parallel pneumatic loading mechanism 7 is mounted on the workbench 51 of the Y-direction movement module 5 through four positioning plates, a main shaft tool shank interface 76 at the upper part is connected with the main shaft 1, and the interface can be provided with a BT40 tool shank or an HSK tool shank.
The detection rod on the five-degree-of-freedom parallel pneumatic loading mechanism is a cylindrical rod and is used for detecting radial rotation precision, axial rotation precision and comprehensive rotation precision, and the rotating speed of the spindle is detected through the infrared feedback paster on the cylindrical rod.
The precision detection module 6 is adsorbed on the middle positioning plate 711, the axis of the first displacement sensor 64 is overlapped with the axis of the detection rod 74, the distance between the first displacement sensor and the detection rod 74 keeps 5-10 mu m required, the second displacement sensor 65 and the third displacement sensor 66 are perpendicular to the detection rod 74, the distance between the second displacement sensor and the third displacement sensor keeps 5-10 mu m required, the rotating speed sensor 67 is perpendicular to the detection rod 74, and the distance between the rotating speed sensor 67 and the detection rod 74 can be kept 1 mm; the lower end of a first loading shaft 79 is arranged on a first positioning plate 712, the lower ends of a second loading shaft 72 and a third loading shaft 73 are arranged on a second positioning plate 71, the lower ends of a fourth loading shaft 77 and a fifth loading shaft 78 are arranged on a third positioning plate 710, the upper end of each loading shaft is arranged on a movable platform 75, a main shaft handle interface 76 is arranged on the movable platform 75, is connected with the main shaft 1 and rotates along with the main shaft, and the lower end of the main shaft handle interface 76 clamps a detection rod 74 through a tool fixture for detecting the radial rotation precision, the axial rotation precision and the comprehensive rotation precision of the main shaft; the first loading shaft 79, the third loading shaft 73 and the fourth loading shaft 74 of the five-degree-of-freedom parallel pneumatic loading mechanism 7 are in a UPS configuration, the second loading shaft 72 and the fifth loading shaft 78 are in a UPU configuration, and an anti-rotation design is adopted, so that the irreversible damage of the mechanism caused by the over-rotation of the mechanism can be avoided.
Fig. 7 is a schematic diagram of the precision detection module. The height of the adjusting mounting seat 68 is adjusted by a simple lifting device, the height is adjusted by adjusting the degree of screwing the adjusting screw 684 into the adjusting mounting seat base 681, the adjusting screw is fixed by screwing the adjusting nut 685, and the first positioning screw 682 and the second positioning screw 683 are correspondingly screwed, so that the precision detection module has proper height and can be accurately mounted at a specified position; adjust mount pad 68 and pass through the screw rigid coupling on first magnet holder 61, the second magnet holder adsorbs the regulation mount pad platform 686 on adjusting mount pad 68, sensor mount pad 63 passes through the screw rigid coupling on second magnet holder 62, first displacement sensor 64, second displacement sensor 65, third displacement sensor 66 installs at sensor mount pad 63, and its axis is through the same point, revolution speed sensor 67 is installed in third displacement sensor 66 top, a signal for detecting the reflection of the red outer feedback sticker on detecting stick 74 monitors the main shaft rotational speed.
Fig. 8 is a schematic view of the spindle mounting apparatus. Wherein, main shaft 1 installs main shaft bed frame upper portion 22 on main shaft bed frame 2 through main shaft locating plate 21, and main shaft bed frame divide into two parts from top to bottom: spindle bed frame upper portion 22 and spindle bed frame base 23 are cast iron and welding component, and spindle bed frame upper portion 22 passes through screw nut rigid coupling with spindle bed frame base 23, and spindle bed frame base 23 installs on ground flat iron 3, and spindle bed frame 2 has a plurality of round holes for sensor, trachea, electric wire cable walk the line.
Fig. 9 is a schematic diagram of the XY motion module. FIG. 10 is a schematic view of the Y-direction motion module. The X-direction movement module and the Y-direction movement module are in modular design and driven by a lead screw-guide rail scheme, and the X-direction movement module 4 is similar to the Y-direction movement module 5 in structure.
The Y-direction movement module 5 is in a double-guide-rail 57 and four-slider 56 configuration, the stroke meets the working space requirement of the five-degree-of-freedom parallel pneumatic loading mechanism 7, the guide rails 57 are arranged on a Y-direction module bottom plate 58 in parallel, the sliders 56 are arranged on the guide rails 57 according to requirements, a Y-direction module workbench 51 is arranged on the guide rails 57, and threaded holes are drilled in the Y-direction module workbench 51 and used for installing 4 positioning plates. The first baffle plate 52 and the second baffle plate 515 are arranged on two sides of the Y-direction module bottom plate 58, the middle part of the Y-direction module bottom plate penetrates through a lead screw 59, two ends of the lead screw 59 are fixed by a first lead screw nut 53 and a second lead screw nut 510, the moving block flange 55 moves along with the lead screw 59 through the lead screw 59 and is connected with the moving block 54, the upper plane of the moving block 54 is fixedly connected with the Y-direction module workbench 51, and therefore the moving block 54 and the Y-direction module workbench 51 are driven by the movement of the lead screw 59 to move along the direction of the guide rail. The motor module comprises a coupler 511, a motor 512, a motor mounting plate 513 and a motor module connecting piece 514, wherein the motor 512 is mounted on the motor mounting plate 513, the motor mounting plate 513 is fixedly connected to the second baffle 515 through the motor module connecting piece 514, and the motor 512 is connected with the lead screw 59 through the coupler 511, so that the lead screw 59 is driven to rotate.
The motor rotation amounts of the X-direction movement module 4 and the Y-direction movement module 5 are controlled by the data acquisition and analysis module 9 through the movement control module 8, the position information of the X-direction movement module and the Y-direction movement module is read, the pose state of the mechanism is solved by combining the parameters of the five-degree-of-freedom parallel pneumatic loading mechanism 7, the force required to be applied by each loading shaft can be solved according to the force and the direction loaded by the load spectrum, and the specific solving process is analyzed above.
It should be noted that the foregoing explanation of the method embodiment is also applicable to the system of this embodiment, and is not repeated here.
According to the loading system for the electric spindle reliability rapid experiment provided by the embodiment of the invention, the loading system capable of simulating the actual loading condition of the spindle realizes the loading of the spindle, the reliability acceleration experiment is realized through a certain acceleration factor based on an acceleration model, the actual loading condition of the spindle can be simulated at lower cost, the test speed can be accelerated, and meanwhile, the spindle performance state is monitored through a plurality of sensors arranged, the precision and the reliability of the spindle are evaluated, so that the loading system has a wide application prospect.
Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, "a plurality" means at least two, e.g., two, three, etc., unless specifically limited otherwise.
In the description herein, references to the description of the term "one embodiment," "some embodiments," "an example," "a specific example," or "some examples," etc., mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above are not necessarily intended to refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, various embodiments or examples and features of different embodiments or examples described in this specification can be combined and combined by one skilled in the art without contradiction.
Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention, and that variations, modifications, substitutions and alterations can be made to the above embodiments by those of ordinary skill in the art within the scope of the present invention.
Claims (10)
1. A quick test loading method for reliability of an electric spindle is characterized by comprising the following steps:
s1, establishing a fatigue and wear acceleration model of the electric spindle;
s2, increasing the loading force and frequency in the conventional spindle load spectrum and the spindle rotating speed according to the conventional spindle load spectrum and the acceleration factor in the fatigue and wear acceleration model of the electric spindle to obtain an acceleration load spectrum;
s3, controlling the electric spindle in a loading system according to an accelerated load spectrum, acquiring position information of a motion module in the loading system and parameter information of a five-degree-of-freedom parallel pneumatic loading mechanism, calculating pose information of the five-degree-of-freedom parallel pneumatic loading mechanism according to the position information and the parameter information, and calculating loading force and frequency on each loading shaft of the five-degree-of-freedom parallel pneumatic loading mechanism according to the pose information and the accelerated load spectrum;
and S4, performing an acceleration experiment on the motorized spindle according to the calculated loading force and frequency on each loading shaft, detecting a plurality of parameters of the motorized spindle in the acceleration experiment, and evaluating the performance of the motorized spindle according to the parameters.
2. The rapid experiment loading method for reliability of electric spindle according to claim 1,
and establishing a fatigue and wear acceleration model of the electric spindle according to a fatigue model based on a Manson-Hall bilinear fatigue damage rule and a bearing wear model based on Archard and Hertz contact theories.
3. The method for loading an electric spindle through a reliability rapid experiment according to claim 1, wherein calculating the loading force on each loading shaft of the five-degree-of-freedom parallel pneumatic loading mechanism comprises:
carrying out stress analysis on a movable platform of the five-degree-of-freedom parallel pneumatic loading mechanism:
wherein f isMVector of force to which the moving platform is subjected, nMThe moment vector which is applied to the movable platform,
is the acceleration vector of the movable platform,
is the angular acceleration vector of the moving platform, omega is the angular velocity vector of the moving platform, mMMass of the moving platform, g is gravitational acceleration, feAnd neTo simplify the loading to the origin o of the moving platform coordinate system M,BIM＝BRM MIM BRM Tis the representation of the inertia matrix of the moving platform with respect to the center of mass in the stationary platform coordinate system B,BRMis a rotation matrix of the movable platform relative to a base coordinate system of the static platform,MIMis an inertia matrix of the movable platform to the mass center thereof,BRM Tthe transposition of a rotating matrix of the movable platform relative to a base coordinate system of the static platform;
and (3) carrying out stress analysis on a plurality of loading shafts:
no movement part i on ith loading axis1And a moving part i2The vector sum of the acting force and the inertia force about the respective mass centers can be represented in the loading axis coordinate system{ i } below, in a specific form:
wherein m isi1And mi2Are respectively a member i1And i2The mass of (a) of (b),iIi1andiIi2are respectively a member i1And i2The representation of the moment of inertia of the centroid in the branched chain coordinate system i,ifi1andifi2is a component i1And i2With respect to the force vector in the loading axis coordinate system i,ini1andini2is a component i1And i2With respect to the inertial force vector in the loading axis coordinate system i,iRBto load the rotation matrix of the axis coordinate system i relative to the base coordinate system of the stationary platform,
and
is a component i1And i2The acceleration vector of (a) is,iωithe angular acceleration vector of the ith loading axis relative to the centroid thereof;
performing dynamic modeling on the five-degree-of-freedom parallel pneumatic loading mechanism according to a virtual work principle method:
the virtual displacement delta q of the driving joint is connected with the virtual displacement delta X input by the movable platform terminal through a Jacobian matrix J:
δq＝JδX
component i in the ith loading shaft1And i2Virtual shift delta ofixi1And deltaixi2And δ X may also be passed through the Jacobian matrixiJi1AndiJi2contact theTo:
δixi1＝iJi1δX
δixi2＝iJi2δX
the imaginary displacements δ X and δ X are passed through the jacobian matrix JvIn connection with this:
δx＝JvδX
establishing an imaginary work equation:
obtaining the following components in a simultaneous manner:
obtaining:
obtaining the driving force of the five-degree-of-freedom parallel pneumatic loading mechanism:
4. the method for loading an electric spindle reliability rapid experiment according to claim 1, wherein the S2 further comprises:
establishing a simple stress model of the main shaft, and acquiring the relation between the external load and the internal force:
wherein L is1、L2Is the main shaft size parameter, F is the loading force, G1Is the weight of the motor, G2Is the weight of the spindle;
calculating the corresponding fatigue life under a single loading level, and using a fatigue model based on a Manson-Hall bilinear fatigue damage criterion, wherein the fatigue life is as follows:
wherein, K1＝8.627×1056，
d is the diameter of the axis of the main shaft;
establishing a main shaft front bearing abrasion model based on Archard and Hertz contact theory:
wherein, Wvi、WvoThe accumulated wear of the inner and outer rings of the bearing, K is the wear coefficient, K' is the lubrication coefficient, niIs the inner ring rotation speed, DiIs the diameter of the inner ring, noIs the outer ring rotation speed, DoOuter ring diameter, H is the hardness of the softer material, DbDiameter of center of ellipse, kpIs the pressure coefficient, theta is the rotation angle, t1、t2The starting time and the stopping time of rotation;
establishing the precision loss amount of abrasion:
where Σ ρ is the sum of the principal curvatures, ma、mbThe coefficients of a long half shaft and a short half shaft;
let F0The loading force for the routine test, F1To accelerate the loading force of the test, f0Frequency of the original loading force, f1Loading for accelerated testingFrequency of force, f is the frequency of spindle rotation under routine experimentation, knFor the main shaft rotation speed ratio of the acceleration experiment to the conventional experiment, fFIs the frequency, k, of the spindle load under routine experimentswTo accelerate the wear ratio of the experiment and the routine experiment, kDTo speed up the ratio of cumulative fatigue damage from the experiment and from the routine experiment:
let m be f0Setting a loading frequency multiple:
loading force multiple:
thus, there are:
according to the principle of proportional amplification of accumulated wear loss and accumulated fatigue damage, the acceleration factor is K, and the method comprises the following steps:
substituting to obtain:
wherein, a, b, ai,biKnown quantities, both determined by the geometrical parameters of the main shaft itself and by the dead weight;
get knAs parameters, solve for:
5. the loading method for the rapid experiment of the reliability of the electric spindle according to claim 1, wherein the detecting of the plurality of parameters of the electric spindle in the acceleration experiment includes, but is not limited to, detecting of revolution accuracy degradation, temperature rise change, vibration signal and harmonic current signal.
6. The utility model provides a quick experiment loading system of electricity main shaft reliability which characterized in that includes: the device comprises a main shaft (1), a main shaft base frame (2), a horizontal iron (3), a plane motion module, a precision detection module (6), a five-degree-of-freedom parallel pneumatic loading mechanism (7), a motion control module and a data acquisition and analysis module (9);
the front bearing and the rear bearing of the ground flat iron (3) and the main shaft (1) are respectively provided with a temperature sensor and a vibration sensor for collecting temperature data and vibration data;
the main shaft base frame (2) is connected with the main shaft (1) and used for fixing the main shaft (1);
the plane motion module comprises an X-direction motion module (4) and a Y-direction motion module (5), the plane motion module is used for driving the precision detection module (6) and the five-degree-of-freedom parallel pneumatic loading mechanism (7) to move, the X-direction motion module (4) is fixed on the ground flat iron (3), and the Y-direction motion module (5) is installed on the X-direction motion module (4);
the five-degree-of-freedom parallel pneumatic loading mechanism (7) comprises a plurality of loading shafts, each loading shaft is provided with a tension sensor and is used for applying loading force to the main shaft and collecting loading force data, the five-degree-of-freedom parallel pneumatic loading mechanism is fixed on the Y-direction movement module (5) through a plurality of positioning plates, and the upper end of the five-degree-of-freedom parallel pneumatic loading mechanism is connected with the main shaft (1);
the precision detection module is fixed on a positioning plate of the five-degree-of-freedom parallel pneumatic loading mechanism and used for detecting the rotation precision and the deformation of the main shaft;
the motion control module includes host computer (10) and motion control cabinet (8), the mutual inductance of current sensor and the voltmeter of installing on the motion control cabinet (8), motion control cabinet (8) include: the motion control system comprises a main shaft motion control module and an XY motion module motor motion control module, wherein a motion control cabinet (8) can be communicated with a control program of an upper computer (10) through USB serial port communication to perform instruction control on a main shaft, the XY motion module motor motion control module controls the motion of an XY motion module motor and reads position information of the XY motion module motor through an NI controller, the pose state of the five-freedom-degree parallel pneumatic loading mechanism is obtained according to the position information and parameter information of the five-freedom-degree parallel pneumatic loading mechanism, the magnitude of force required to be applied by each loading shaft is calculated by combining the magnitude and direction of each force loaded by a load spectrum, and a loading experiment is performed on the loading system;
the data acquisition and analysis module (9) is used for acquiring the state information of each sensor in the experiment loading system and evaluating the performance of the electric spindle according to the state information.
7. The electric spindle reliability rapid experiment loading system according to claim 6, wherein the spindle base frame (2) comprises: a main shaft positioning plate (21), a main shaft pedestal upper part (22) and a main shaft pedestal base (23);
main shaft (1) is installed main shaft bed frame upper portion (22) on main shaft bed frame (2) through main shaft locating plate (21), and main shaft bed frame (2) divide into two parts from top to bottom: main shaft bed frame upper portion (22) and main shaft bed frame base (23), for cast iron and welding component, main shaft bed frame upper portion (22) and main shaft bed frame base (23) pass through screw nut rigid coupling, and install on ground flat iron (3) main shaft bed frame base (23), and main shaft bed frame (2) have a plurality of round holes for sensor, trachea or electric wire cable walk the line.
8. The electric spindle reliability rapid experiment loading system according to claim 6, wherein the plane motion module comprises:
the Y-direction movement module (5) adopts a double-guide-rail (57) and four-slide-block (56) structure, the guide rail (57) is parallelly installed on a Y-direction movement module bottom plate (58), the slide block (56) is installed on the guide rail (57), a Y-direction module workbench (51) is installed on the guide rail (57), and threaded holes are drilled in the Y-direction module workbench (51) and used for installing a plurality of positioning plates;
the first baffle (52) and the second baffle (515) are arranged on two sides of a Y-direction module bottom plate (58), a lead screw (59) penetrates through the middle of the Y-direction module bottom plate, two ends of the lead screw (59) are fixed by a first lead screw nut (53) and a second lead screw nut (510), a moving block flange plate (55) moves along with the lead screw (59) and is connected with a moving block (54), the upper plane of the moving block (54) is fixedly connected with a Y-direction module workbench (51), and therefore the moving block (54) and the Y-direction module workbench (51) are driven to move along the direction of a guide rail (57) by the movement of the lead screw (59);
the motor module of plane motion module contains shaft coupling (511), motor (512), motor mounting panel (513) and motor module connecting piece (514), and motor (512) are installed on motor mounting panel (513), and motor mounting panel (513) pass through motor module connecting piece (514) rigid coupling on second baffle (515), and motor (512) pass through shaft coupling (511) and are connected with lead screw (59) to drive lead screw (59) and rotate.
9. The rapid experiment loading system for reliability of electric spindle according to claim 6, characterized in that the precision detection module (6) comprises:
the height of the adjusting mounting seat (68) is adjusted by adopting a lifting device, the height is adjusted by adjusting the screwing degree of the adjusting screw (684) into the adjusting mounting seat base (681), and the adjusting mounting seat base (68) is fixed by screwing the adjusting nut (685), the first positioning screw (682) and the second positioning screw (683);
adjust mount pad (68) and pass through the screw rigid coupling on first magnetic base (61), second magnetic base (62) adsorb regulation mount pad platform (686) on adjusting mount pad (68), sensor mount pad (63) pass through the screw rigid coupling on second magnetic base (62), first displacement sensor (64), second displacement sensor (65), install in sensor mount pad (63) third displacement sensor (66), its axis is through the same point, tachometric sensor (67) are installed in third displacement sensor (66) top, a signal for detecting the reflection of the red feedback sticker on detection stick (74) monitors the main shaft rotational speed.
10. The electric spindle reliability rapid experiment loading system according to claim 9, wherein the five-degree-of-freedom parallel pneumatic loading mechanism (7) comprises:
the five-degree-of-freedom parallel pneumatic loading mechanism (7) is arranged on a workbench (51) of the Y-direction movement module (5) through a plurality of positioning plates, and a main shaft knife handle interface (76) at the upper part is connected with the main shaft (1);
the precision detection module (6) is adsorbed on the middle positioning plate (711), the axis of the first displacement sensor (64) is overlapped with the axis of the detection rod (74), the second displacement sensor (65) and the third displacement sensor (66) are perpendicular to the detection rod (74), and the rotating speed sensor (67) is perpendicular to the detection rod (74);
the lower end of each loading shaft is arranged on the positioning plate, the upper end of each loading shaft is arranged on the movable platform (75), a main shaft handle interface (76) is arranged on the movable platform (75), is connected with the main shaft (1) and rotates along with the main shaft (1), and the lower end of the main shaft handle interface (76) clamps a detection rod (74) through a tool fixture and is used for detecting the radial rotation precision, the axial rotation precision and the comprehensive rotation precision of the main shaft;
the first loading shaft (79), the third loading shaft (73) and the fourth loading shaft (74) of the five-degree-of-freedom parallel pneumatic loading mechanism (7) are in a UPS (uninterrupted power supply) configuration, the second loading shaft (72) and the fifth loading shaft (78) are in a UPU (unified power unit) configuration, and an anti-rotation design is adopted, so that excessive rotation of the mechanism is avoided.
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