CN111273609B - Method and system for state monitoring and fault judgment of numerical control cutting equipment - Google Patents

Abstract

The invention discloses a method and a system for monitoring the state and judging the fault of numerical control cutting equipment, comprising the following steps: the cutting machine comprises a data acquisition system, a state monitoring system and a fault judgment system, wherein the data acquisition system acquires cutting parameters of the cutting machine, converts the cutting parameters into a preset data format and transmits the preset data format to the state monitoring system and the fault judgment system; the data acquisition system also acquires a split and analyzed G instruction corresponding to the cutting machine in real time according to the type of the cutting machine, and transmits the split and analyzed G instruction to the state monitoring system and the fault judgment system; the state monitoring system obtains the running state of the cutting machine according to the received information; and the fault judging system judges whether the cutting machine has a fault according to the received information. The invention ensures the cutting efficiency of the steel plate.

Description

A method and system for state monitoring and fault judgment of CNC cutting equipment

technical field

The invention belongs to the field of lean production of shipbuilding enterprises, and in particular relates to a method and system for state monitoring and fault judgment of numerical control cutting equipment.

Background technique

Steel plate cutting operation is a key link in the shipbuilding process. The quality of steel plate cutting has an important impact on the hull assembly quality, welding quality, coating quality and appearance quality. The steel plate cutting method is also constantly improving with technological progress, from the earliest manual cutting to semi-automatic cutting. CNC cutting, cutting efficiency and cutting quality are getting higher and higher.

The number of steel plates required for hull construction is huge, and affected by the matching of raw materials, equipment and site resources, and the coordination between processes, there are steel plate cutting information that cannot be collected in real time, cutting status cannot be monitored in real time, and cutting faults cannot be judged in real time during the production process of shipbuilding enterprises. Production scheduling lacks scientific basis and other issues, which affects the execution of steel plate cutting plan and cutting operation efficiency, and increases the cache of cutting parts to a certain extent, resulting in site occupation and fund backlog.

Contents of the invention

Purpose of the invention: In order to solve the problems in the prior art that the cutting information cannot be collected in real time, the cutting status cannot be monitored in real time, and the cutting fault cannot be judged in real time. The present invention provides a method and system for state monitoring and fault judgment of CNC cutting equipment.

Technical solution: The present invention provides a method for state monitoring and fault judgment of CNC cutting equipment, which is applied to the automatic cutting of cutting equipment. The method includes the following steps:

Step 1. Split and analyze the G commands of all different types of cutting machines, and store all the G commands after split and analysis to the computer; the G commands after the split and analysis include positioning commands, movement commands, and control commands , to control the trajectory;

Step 2. A certain cutting machine performs a cutting, and the cutting parameters of the cutting machine are collected in real time during the cutting process, and the collected cutting parameters of the cutting machine are converted into a preset data format and displayed in the computer; The cutting parameters of the cutting machine include: the position coordinates of the cutting machine, the moving speed, and the current action;

Step 3. Read the disassembled and analyzed G command of the cutting machine in real time, and display it in the computer;

Step 4. According to the real-time cutting parameters and the G command after splitting and analyzing, determine which step the cutting machine is currently executing; and obtain the operating status of the cutting equipment according to the cutting parameters. The operating status includes: the actual cutting of a certain steel plate starts Time, moving/marking/cutting time, pause time, cutting completion time;

Step 5. According to the trajectory formed by the coordinate positions of the cutting machine collected during the cutting and the control trajectory of the cutting in the G command, it is judged whether the cutting machine is faulty.

Further, XML configuration is used to convert the parameters of the cutting machine collected in real time into a preset data format.

Further, the step 5 is specifically: the cutting machine performs a cutting, and its trajectory is L1, L1 is composed of n consecutive coordinate positions of the cutting machine, L1={A ₁ , A ₂ ,...A _i ,. ..A _n }, A _i is the i-th coordinate position, i=1, 2, 3,..., n; the cutting trajectory corresponding to L1 in the G command is L2, and L2 consists of Q continuous ideal coordinates Composed of points, L2={B ₁ , B ₂ ,...B _q ,...B _Q }; point B _q is the qth ideal coordinate;

Two adjacent points in L2 form a line segment, then L2 is composed of Q-1 continuous line segments, and the shortest distance between n coordinate positions and each line segment is calculated in turn; if there are I positions in n coordinate positions If the shortest distance between the coordinates and any line segment is not within the range of the preset tolerance Range, it is determined that the cutting machine is faulty.

Further, the range of the tolerance Range is [0, 10], and the unit is mm.

Further, I=10%.

A system for state monitoring and fault judgment of CNC cutting equipment, characterized in that the system includes: a data acquisition system, a state monitoring system and a fault judgment system, the data acquisition system collects the cutting parameters of the cutting machine, and the The parameters are converted into a preset data format and sent to the status monitoring system and fault judgment system; the data acquisition system also collects in real time according to the type of cutting machine the G command after splitting and analyzing corresponding to the cutting machine, and splits the G command The analyzed G command is sent to the state monitoring system and the fault judgment system; the state monitoring system obtains the operating state of the cutting machine according to the received information; the fault judgment system judges whether the cutting machine breaks down according to the received information.

Further, an industrial-grade wireless AP is used for signal transmission between the data acquisition system and the state monitoring system; an industrial-grade wireless AP is also used for signal transmission between the data acquisition system and the fault judgment system.

Beneficial effects: the present invention collects the operation information of the CNC cutting equipment in real time through the interconnection of the CNC cutting equipment in the steel plate workshop, and analyzes the operation status of the CNC cutting equipment and whether it is faulty, so that the utilization rate and working hours of the CNC cutting equipment can be further analyzed, thereby Ensure the cutting efficiency of the steel plate.

Description of drawings

Fig. 1 is a structural representation of the present invention;

Fig. 2 is a flow chart of the present invention;

Fig. 3 is the operation interface of the cutting control machine;

Figure 4 is the G command before splitting and analyzing;

Figure 5 is the G command after splitting and analysis.

Detailed ways

The drawings constituting a part of the present invention are used to provide a further understanding of the present invention, and the schematic embodiments and descriptions of the present invention are used to explain the present invention, and do not constitute an improper limitation of the present invention.

As shown in Figure 1 and Figure 2, this embodiment provides a method and system for state monitoring and fault judgment of CNC cutting equipment. The system includes: a data acquisition system, a state monitoring system, and a fault judgment system. The data acquisition system Collect the cutting parameters of the cutting machine, and convert the parameters into a preset data format and send them to the status monitoring system and fault judgment system; the data collection system also collects the corresponding split analysis of the cutting machine in real time according to the type of the cutting machine The final G command, and the G command after the split analysis is sent to the state monitoring system and the fault judgment system; the state monitoring system obtains the operating state of the cutting machine according to the received information; the fault judgment system receives the The information judges whether the cutting machine breaks down; the data acquisition system includes: the cutting equipment operation parameter acquisition service program and the G command acquisition program.

It is obtained by intercepting the action data of the actual running process and matching the cutting instruction (G instruction) of the cutting equipment. The G command name needs to correspond to the unique code of each steel plate in the steel management system.

By developing the operation parameter collection service program of CNC cutting equipment, the relevant parameters of the cutting control interface can be obtained in real time, including horizontal axis position X, vertical axis position Y, current action (moving, marking, cutting), and moving speed.

The data acquisition system starts the cutting machine control machine and runs in the background. The type of data to be collected includes the G command name, location data, operation type and other information currently executed by the cutting machine. Considering that there are many brands of cutting control machines, a single user may There are many types of control machines, and the acquisition service supports running on various types of mainstream cutting machine control machines; in addition, innovative use of preset configuration methods is used to adapt to different cutting control machines, and different cutting control machines can be The feedback data is unified and standardized into a unified type of data, which is convenient for the overall monitoring of the operating status of the cutting machine in the factory area. The operation interface of the cutting control machine is shown in Figure 3 for details.

The way of innovative use of preset configuration is: use XML configuration to establish a corresponding relationship between the collected data of the cutting control machine and the data that needs to be standardized into a unified type. The configuration includes information such as the location and type of the collected data, collection, service Through the winapi interface, the real-time data of the cutting machine control program is collected once per second according to the preset configuration, and the current position is recorded; the running track and running speed of the cutting machine are calculated according to the collected data, and the recording system is left for analysis.

CNC G command uses a code to control the actual operation of the cutting machine. An example of G command is shown in Figure 4, which mainly includes positioning commands (example G00), movement commands (example G01, G02), control commands (example M10), etc. Read Take the G command to judge the action and cutting path that the current cutting machine needs to execute, but because the cutting commands of the cutting machine manufacturer have their own standards, the G command acquisition program needs a lot of development work and needs to be customized when obtaining the correct cutting command. , this embodiment re-splits the command logic, extracts the key command types and benchmarks them, and uses a simple interface for users to set up, so as to achieve the function of a unified system compatible with the standards of all cutting machine manufacturers. The specific configuration interface is shown in Figure 5.

The industrial-grade wireless AP is used for signal transmission between the data acquisition system and the status monitoring system; the industrial-grade wireless AP is also used for signal transmission between the data acquisition system and the fault judgment system; the industrial-grade wireless AP can handle signals in the workshop Interference, dust and dirt.

The state monitoring system obtains the precise running state of the cutting equipment based on the collected cutting machine parameters and G commands, including: the actual cutting start time, moving/marking/cutting time, midway pause time, cutting completion time, etc. of a certain steel plate; The algorithm considers the type of trajectory (moving, scribing, and cutting) to actually confirm the effective trajectory of the current cutting machine. After the collection service summarizes the data of the cutting machine to the application server, it can provide real-time data for factory management personnel to monitor.

The specific method for the fault judgment system to judge whether the cutting machine is faulty is as follows:

Obtain the actual running trajectory of the cutting machine and the control trajectory of the cutting command, and can judge which step the actual trajectory runs to the cutting command, which is used to feed back real-time cutting information, and can also judge whether the cutting equipment is faulty; the specific algorithm is briefly described as follows: cutting The actual trajectory L1 of the machine is composed of n coordinate positions L1={A ₁ , A ₂ ,...A _i ,...A _n }, A _i is the i-th coordinate position, i=1, 2, 3, ..., n; the control trajectory of the cutting corresponding to L1 in the G command is L2, L2 is composed of Q continuous ideal coordinate points, L2={B ₁ , B ₂ ,...B _q ,...B _Q }; point B _q is the qth ideal coordinate; after simplifying the running state, only consider the trajectory of the same direction;

Two adjacent points in L2 form a line segment, then L2 is composed of Q-1 continuous line segments, and the shortest distance d between n coordinate positions and each line segment is calculated in turn; if there is I in n coordinate positions If the shortest distance between the position coordinates and any line segment is not within the range of the tolerance Range (I=10% obtained through testing, the tolerance range is [0,10], the unit is mm), then it is determined that the cutting machine is faulty. The specific calculation formula of the shortest distance is as follows:

The coordinates of B _x and B _x+1 are (x1, y1), (x2, y2) respectively, and (x1≠x2) B _x and B _x+1 belong to L2

The equation of the straight line segment composed of B _x and B _x+1 is:

(y2-y1)x-(x2-x1)y+x2y1-y2x1=0

Let the coordinates of A _i be (x0, y0), A _i ∈ L1

If the vertical foot of the vertical line composed of A _i and B _x , B _x+1 is on the line segment composed of B _x , B _x+1 , according to whether it is treated differently on the line segment of B _x and B _x+1 , Let the vertical foot coordinates be Cx=(x3, y3).

Line segment BxCx+line segment CxBx+1=line segment BxBx+1

and

The shortest distance from A _i to B _x , B _x+1 is the length of the vertical line, which is set to d:

If the foot of the vertical line composed of A _i and B _x , B _x+1 is outside the line segment composed of B _x , B _x+1 , then compare the line segment from A _i to B _x with the line segment from A _i to B _x+1 The length of the line segment. The shortest of the two line segments is the shortest distance from point A _i to B _x , and B _x+1 .

In addition, the actual movement track needs to record the cutting speed, and calculate the current real-time speed based on the current position and the recorded position and time difference of the last second.

In addition, it should be noted that the various specific technical features described in the above specific implementation manners may be combined in any suitable manner if there is no contradiction. In order to avoid unnecessary repetition, various possible combinations are not further described in the present invention.

Claims (4)

1. A method for state monitoring and fault judgment of CNC cutting equipment, applied to the automatic cutting of cutting equipment, characterized in that the method comprises the steps: Step 1. Split and analyze the G commands of all different types of cutting machines, and store all the G commands after split and analysis to the computer; the G commands after the split and analysis include positioning commands, movement commands, and control commands , to control the trajectory; Step 2. Collect the cutting parameters of the cutting machine in real time during a cutting process of the cutting machine, convert the cutting parameters of the cutting machine collected into a preset data format, and display it in the computer; the cutting The cutting parameters of the cutting machine include: the position coordinates of the cutting machine, the moving speed, and the current action; Step 3. Read the disassembled and analyzed G command of the cutting machine in real time, and display it in the computer; Step 4. According to the real-time cutting parameters and the G command after splitting and analyzing, judge which step the cutting machine is currently executing in the G command; and obtain the operating status of the cutting equipment according to the cutting parameters. The operating status includes: the actual Cutting start time, moving/marking/cutting time, midway pause time, cutting completion time; Step 5. According to the trajectory formed by the coordinate position of the cutting machine collected during the cutting and the control trajectory of the cutting in the G command, it is judged whether the cutting machine is faulty; The step 5 is specifically: the cutting machine performs a cutting, and its trajectory is L1, L1 is composed of n consecutive coordinate positions of the cutting machine, L1={A ₁ , A ₂ ,...A _i ,...A _n }, A _i is the i-th coordinate position, i=1, 2, 3,..., n; the cutting trajectory corresponding to L1 in the G command is L2, and L2 is composed of Q continuous ideal coordinate points, L2={B ₁ , B ₂ , ... B _q , ... B _Q }; point B _q is the qth ideal coordinate; Two adjacent points in L2 form a line segment, then L2 is composed of Q-1 continuous line segments, and the shortest distance between n coordinate positions and each line segment is calculated in turn; if there are I positions in n coordinate positions If the shortest distance between the coordinates and any line segment is not within the range of the preset tolerance Range, it is determined that the cutting machine is faulty. 2. A method for state monitoring and fault judgment of numerical control cutting equipment according to claim 1, characterized in that the parameters of the cutting machine collected in real time are converted into a preset data format by adopting XML configuration. 3. A method for state monitoring and fault judgment of CNC cutting equipment according to claim 1, characterized in that the range of the tolerance Range is [0,10], and the unit is mm. 4. A method for state monitoring and fault judgment of numerical control cutting equipment according to claim 1, characterized in that, I=10%.

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