CN111308959A - Numerical control machine tool monitoring system and method based on instruction domain data synchronization - Google Patents
Numerical control machine tool monitoring system and method based on instruction domain data synchronization Download PDFInfo
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- CN111308959A CN111308959A CN202010142763.5A CN202010142763A CN111308959A CN 111308959 A CN111308959 A CN 111308959A CN 202010142763 A CN202010142763 A CN 202010142763A CN 111308959 A CN111308959 A CN 111308959A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/406—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by monitoring or safety
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/408—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by data handling or data format, e.g. reading, buffering or conversion of data
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/4155—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by programme execution, i.e. part programme or machine function execution, e.g. selection of a programme
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/45—Nc applications
- G05B2219/45136—Turning, lathe
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Abstract
The invention provides a numerical control machine tool monitoring system and method based on instruction domain data synchronization, wherein the system comprises the following steps: the numerical control machine tool supports a numerical control machine tool data acquisition protocol; the camera is arranged inside or outside the numerical control machine tool and is connected with a numerical control device of the numerical control machine tool through a communication medium; the data acquisition and synchronization device is used for acquiring various electric control data in the numerical control machine tool and video data acquired by the camera, synchronizing the various electric control data and the video data through the line number of the instruction domain data, forming a plurality of data blocks with the line number of the instruction domain data as an index, and uploading the data blocks to the cloud server; the cloud server is used for processing and storing the data uploaded by the data acquisition and synchronization device; and the terminal equipment is used for acquiring the required monitoring data from the server. The invention has the characteristic of highly synchronous monitoring data, and can assist data analysis and quickly position the machine tool.
Description
Technical Field
The invention relates to the technical field of numerical control, in particular to a numerical control machine tool monitoring system and method based on instruction domain data synchronization.
Background
Along with the popularization of automatic production lines, production links of manual monitoring become fewer and fewer, and the demand degree of unmanned monitoring brought by the production links is higher and higher. The purpose of control is in order to leave the control record of lathe, when production goes wrong, can find out the problem root and repair the problem through the record of backtracking, guarantees the normal clear of production. Typical production problems include:
1. human factors. Production problems due to worker mishandling and deliberate human destruction. For example, improper clamping by workers results in machining dimension deviation.
2. And (4) a fault outside the machine tool. The method comprises the conditions of production line manipulator failure, machine tool oil pressure and air pressure failure and the like. For example, machining lack of lubrication causes wear of machine tool guide rails.
3. Material problems. Due to the processing problems caused by unqualified quality of cutter materials, workpiece blanks and the like.
4. And (4) internal faults of the machine tool. The internal faults of the machine tool cause the deviation of the machining control of the machine tool, and the problems of unqualified machining, production accidents and the like are caused.
5. Mixing problems. The above-mentioned several conditions occur simultaneously, which brings about production problems.
Currently, there are two mainstream production monitoring methods:
1. and (5) video monitoring. Video surveillance is a relatively common surveillance method: the cameras are arranged outside and inside the machine tool, so that the running condition of the machine tool is monitored, and the video data is stored for future reference. External cameras are commonly used to monitor external conditions of the machine tool, such as: whether artificial damage exists or not, whether the feeding and discharging of the mechanical arm are abnormal or not and the like. The internal camera monitors the internal processing conditions of the machine tool, such as whether a cutter break occurs or not, whether a cooling fault occurs or not, and the like.
2. And (5) monitoring data. The method mainly extracts electric control data in the machine tool for monitoring, and the monitored data objects comprise: 1) machine tool operation log. The operating conditions of the machine tool are mainly recorded, for example:
processing was started at 8:20: 35. The cycle starts the lamp to light.
The speed of the main shaft is increased from 0 to 3000r/min at the ratio of 8:20: 37.
……
2) Machine tool operating data electrocardiogram. And (3) collecting key operation data of the machine tool at high frequency and drawing a oscillogram. The key data includes: and the running load current, speed, power and other data of each shaft of the machine tool.
3) Machine tool G code. The text and current run of the process are monitored.
The data monitoring can capture the change details of the data in the machine tool, restore the fault site from the data and quickly locate the fault reason.
The two monitoring methods have the following disadvantages in practical application:
1) if only a video monitoring mode is adopted, only the external image of the machine tool can be monitored, and the internal problems of the machine tool cannot be diagnosed. For example, the surface of the machined workpiece is not smooth, at which time the load and velocity data of the spindle need to be reviewed for additional diagnosis.
2) If only a data monitoring method is adopted, external image auxiliary diagnosis is lacked, and many faults are difficult to confirm. For example, abnormal data change conditions are found by analyzing the data records of the machine tool, and the observation and the video monitoring result is caused by improper operation of workers. If only data is analyzed, the reason is difficult to determine quickly, and manpower analysis cost is wasted.
3) If the method of video monitoring and data monitoring is adopted at the same time, a new problem exists: the synchronization between the video-monitored image data and the machine tool internal data is lacking. Machine tool faults often occur in a moment, if image data and machine tool internal data are staggered, analysis problems are not helped, and analysis can be interfered, so that analysis work is wrongly wrong.
Meanwhile, data related to data monitoring also need to be synchronized, so that the data analysis difficulty can be reduced.
4) If the method of time stamp synchronization is adopted, the effect of data synchronization can also be achieved. However, for the numerical control machining industry, the data synchronized according to the time stamp is not clear and vivid enough, and the field more hopes to see the step (instruction) of each feed, and the corresponding machine tool operation data, namely the instruction field data.
Aiming at the defects in the prior art, the invention provides a numerical control machine tool monitoring system and method based on instruction domain data synchronization.
Disclosure of Invention
The invention aims to provide a numerical control machine tool monitoring system and method based on instruction domain data synchronization, which provide accurate and synchronous data support for backtracking diagnosis of machine tool faults and help to quickly and accurately position the machine tool faults.
The invention is realized by the following steps:
in one aspect, the present invention provides a numerical control machine tool monitoring system based on instruction domain data synchronization, including:
the numerical control machine tool supports a numerical control machine tool data acquisition protocol;
the camera is arranged inside or outside the numerical control machine tool and is connected with a numerical control device of the numerical control machine tool through a communication medium;
the data acquisition and synchronization device is used for acquiring various electric control data in the numerical control machine tool and video data acquired by the camera, synchronizing the various electric control data and the video data through the line number of the instruction domain data, forming a plurality of data blocks with the line number of the instruction domain data as an index, and uploading the data blocks to the cloud server;
the cloud server is used for processing and storing the data uploaded by the data acquisition and synchronization device;
and the terminal equipment is used for acquiring the required monitoring data from the server.
Further, the numerical control machine tool data acquisition protocol supported by the numerical control machine tool is one or more of OPCUA, MTConnect and NC-LINK.
Further, the data collecting and synchronizing device comprises a processor, a memory and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the following steps:
collecting the running line number of the current G code;
collecting log data, and attaching a current line number mark to each piece of log data;
collecting various electric control data in the numerical control machine tool, and attaching a current row number mark to each piece of data;
communicating with the camera and attaching the current line number tag to the video data;
recording the current time, and adding a current line number mark;
collecting data of other machine tools, and attaching a current row number mark;
and repeatedly executing the process, and uploading the G code file to the cloud server when the program is finished.
Further, the processing of the data uploaded by the data acquisition and synchronization device by the cloud server specifically includes: and after receiving the data block, the server analyzes the G code text file, extracts the text of the line number corresponding to the data block and inserts the extracted text into the data block.
Further, the data acquisition and synchronization device is integrated into a numerical control device of a numerical control machine tool or is installed in an external device.
Further, the terminal equipment is provided with a display screen, a plurality of parallel pictures are displayed on the display screen, and all types of data acquired by the data acquisition and synchronization device are displayed synchronously.
On the other hand, the invention also provides a numerical control machine tool monitoring method based on instruction domain data synchronization, which is applied to the numerical control machine tool monitoring system based on instruction domain data synchronization and comprises the following steps:
the camera acquires video data of the numerical control machine tool;
the data acquisition and synchronization device acquires various electric control data in the numerical control machine tool and video data acquired by a camera and synchronizes the various electric control data and the video data through the line number of the instruction domain data to form a plurality of data blocks with the line number of the instruction domain data as an index and upload the data blocks to the cloud server;
the cloud server processes and stores the data uploaded by the data acquisition and synchronization device;
and the terminal equipment acquires the required monitoring data from the server.
Further, the data collecting and synchronizing device collects various electronic control data inside the numerical control machine and video data obtained by the camera and synchronizes the various electronic control data and the video data through the instruction domain data line number to form a plurality of data blocks using the instruction domain data line number as an index and upload the data blocks to the cloud server specifically includes:
collecting the running line number of the current G code;
collecting log data, and attaching a current line number mark to each piece of log data;
collecting various electric control data in the numerical control machine tool, and attaching a current row number mark to each piece of data;
communicating with the camera and attaching the current line number tag to the video data;
recording the current time, and adding a current line number mark;
collecting data of other machine tools, and attaching a current row number mark;
and repeatedly executing the process, and uploading the G code file to the cloud server when the program is finished.
Further, the processing of the data uploaded by the data acquisition and synchronization device by the cloud server specifically includes: and after receiving the data block, the server analyzes the G code text file, extracts the text of the line number corresponding to the data block and inserts the extracted text into the data block.
Furthermore, a plurality of parallel pictures are displayed on a display screen of the terminal equipment, and all types of data acquired by the data acquisition and synchronization device are displayed synchronously.
Compared with the prior art, the invention has the following beneficial effects:
the numerical control machine tool monitoring system and method based on instruction domain data synchronization provided by the invention have the characteristic of highly synchronizing monitoring data, and can assist data analysis and quickly position machine tool problems. The method provides high-synchronization review of the internal data and the video images of the machine tool, and is favorable for analyzing the faults of the unattended machine tool; all data are synchronized through the line number of the instruction field data (G code), so that an analyst of the data can clearly see the start and stop of each processing feed, the operation data and the image, and can help the analyst to analyze the data and locate the fault reason more quickly.
Drawings
Fig. 1 is a schematic structural diagram of a numerical control machine tool monitoring system based on instruction domain data synchronization according to an embodiment of the present invention;
fig. 2 is a schematic diagram of a data block according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
As shown in fig. 1, an embodiment of the present invention provides a numerical control machine monitoring system based on instruction domain data synchronization, including a numerical control machine, a camera, a data acquisition and synchronization apparatus, a cloud server, and a terminal device. The numerical control machine tool must support a general numerical control machine tool data acquisition protocol, wherein the numerical control machine tool data acquisition protocol refers to a network-based data acquisition protocol and is not a numerical control machine tool bus communication protocol. Currently, common communication protocols of numerical control machine tools such as OPCUA, MTCONNECT, NC-LINK and the like support one or more of the common protocols. The camera is installed in the inside or the outside of digit control machine tool, including inside and outside simultaneous installation, the camera passes through the communication medium to be connected with the numerical control device of digit control machine tool, can be network cable communication, usb line communication or other data communication media. The data acquisition and synchronization device is used for acquiring various electric control data in the numerical control machine tool and video data acquired by the camera and synchronizing the various electric control data and the video data through the instruction domain data line number to form a plurality of data blocks taking the instruction domain data line number as an index and upload the data blocks to the cloud server, and the synchronization mode is that the synchronization is carried out through the instruction domain data, namely the G code line number. And the cloud server is used for processing and storing the data uploaded by the data acquisition and synchronization device. The terminal equipment is used for acquiring the required monitoring data from the server.
In a refinement of the above embodiment, the data acquisition and synchronization apparatus includes a processor, a memory, and a computer program stored in the memory and executable on the processor, and the processor implements the following steps when executing the computer program:
1) collecting the running line number of the current G code;
2) collecting log data, and attaching a current line number mark to each piece of log data;
3) collecting various electric control data in the numerical control machine tool, including data such as load current, speed, position and the like, and attaching a current row number mark to each piece of data;
4) communicating with the camera and attaching the current line number tag to the video data;
5) recording the current time, and adding a current line number mark;
6) collecting data of other machine tools, and attaching a current row number mark;
7) and repeatedly executing the process, and uploading the G code file to the cloud server when the program is finished.
It should be noted that the above steps 1) to 6) are performed synchronously, not sequentially.
Through the above processing, the acquired data may form individual data blocks with the instruction field data line number, i.e., the G code line number, as an index, and the schematic diagram of the data blocks is shown in fig. 2, and the data blocks are uploaded to the cloud server for storage.
The data acquisition and synchronization device can be integrated into a numerical control device of a numerical control machine tool and can also be installed into external equipment. When integrated into a numerical control device, the corresponding computer program may simply be embedded into the numerical control device, employing the processor and memory of the numerical control device. The external device, such as a production line master controller (industrial personal computer) or a common computer, may only embed a corresponding computer program into the external device, and use a processor and a memory of the external device. If the device is installed on the external equipment, the external equipment and the numerical control device need to be connected through a network cable to keep data communication.
The processing of the data uploaded by the data acquisition and synchronization device by the cloud server specifically comprises: and after receiving the data block, the server analyzes the G code text file, extracts the text of the line number corresponding to the data block and inserts the extracted text into the data block. Meanwhile, the server also provides a data reading function, namely when the terminal equipment needs to check data, the server can provide the specified data blocks for the terminal.
The terminal device can be a computer, a smart phone, a tablet and other devices with an operating system, monitoring software is operated on the terminal device, and the monitoring software provides visualization of monitoring data. The terminal equipment is provided with a display screen, and under the control of the monitoring software, a plurality of parallel pictures are displayed on the display screen, and all types of data acquired by the data acquisition and synchronization device are synchronously displayed. And dragging any one picture, and switching all pictures to the corresponding data blocks for display according to the data synchronization relationship.
Correspondingly, an embodiment of the present invention further provides a numerical control machine tool monitoring method based on instruction domain data synchronization, which is applied to the numerical control machine tool monitoring system based on instruction domain data synchronization of the above embodiments, and includes the following steps:
the camera acquires video data of the numerical control machine tool;
the data acquisition and synchronization device acquires various electric control data in the numerical control machine tool and video data acquired by a camera and synchronizes the various electric control data and the video data through the line number of the instruction domain data to form a plurality of data blocks with the line number of the instruction domain data as an index and upload the data blocks to the cloud server;
the cloud server processes and stores the data uploaded by the data acquisition and synchronization device;
and the terminal equipment acquires the required monitoring data from the server.
Further, the data collecting and synchronizing device collects various electronic control data inside the numerical control machine and video data obtained by the camera and synchronizes the various electronic control data and the video data through the instruction domain data line number to form a plurality of data blocks using the instruction domain data line number as an index and upload the data blocks to the cloud server specifically includes:
collecting the running line number of the current G code;
collecting log data, and attaching a current line number mark to each piece of log data;
collecting various electric control data in the numerical control machine tool, and attaching a current row number mark to each piece of data;
communicating with the camera and attaching the current line number tag to the video data;
recording the current time, and adding a current line number mark;
collecting data of other machine tools, and attaching a current row number mark;
and repeatedly executing the process, and uploading the G code file to the cloud server when the program is finished.
Further, the processing of the data uploaded by the data acquisition and synchronization device by the cloud server specifically includes: and after receiving the data block, the server analyzes the G code text file, extracts the text of the line number corresponding to the data block and inserts the extracted text into the data block.
Furthermore, a plurality of parallel pictures are displayed on a display screen of the terminal equipment, and all types of data acquired by the data acquisition and synchronization device are displayed synchronously.
In summary, the numerical control machine tool monitoring system and method based on instruction domain data synchronization provided by the embodiments of the present invention have the characteristic of highly synchronizing monitoring data, and can assist data analysis and quickly locate machine tool problems. The method provides high-synchronization review of the internal data and the video images of the machine tool, and is favorable for analyzing the faults of the unattended machine tool; all data are synchronized through the line number of the instruction field data (G code), so that an analyst of the data can clearly see the start and stop of each processing feed, the operation data and the image, and can help the analyst to analyze the data and locate the fault reason more quickly.
Those of ordinary skill in the art will appreciate that all or part of the steps of the various methods of the embodiments may be implemented by associated hardware as instructed by a program, which may be stored on a computer-readable storage medium, which may include: a Read Only Memory (ROM), a Random Access Memory (RAM), a magnetic or optical disk, or the like.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (10)
1. A numerical control machine tool monitoring system based on instruction domain data synchronization is characterized by comprising:
the numerical control machine tool supports a numerical control machine tool data acquisition protocol;
the camera is arranged inside or outside the numerical control machine tool and is connected with a numerical control device of the numerical control machine tool through a communication medium;
the data acquisition and synchronization device is used for acquiring various electric control data in the numerical control machine tool and video data acquired by the camera, synchronizing the various electric control data and the video data through the line number of the instruction domain data, forming a plurality of data blocks with the line number of the instruction domain data as an index, and uploading the data blocks to the cloud server;
the cloud server is used for processing and storing the data uploaded by the data acquisition and synchronization device;
and the terminal equipment is used for acquiring the required monitoring data from the server.
2. The numerical control machine tool monitoring system based on instruction domain data synchronization of claim 1, wherein: the numerical control machine tool data acquisition protocol supported by the numerical control machine tool is one or more of OPCUA, MTConnect and NC-LINK.
3. The system for monitoring a numerically controlled machine tool based on instruction domain data synchronization according to claim 1, wherein the data collection and synchronization device comprises a processor, a memory, and a computer program stored in the memory and executable on the processor, the processor implementing the following steps when executing the computer program:
collecting the running line number of the current G code;
collecting log data, and attaching a current line number mark to each piece of log data;
collecting various electric control data in the numerical control machine tool, and attaching a current row number mark to each piece of data;
communicating with the camera and attaching the current line number tag to the video data;
recording the current time, and adding a current line number mark;
collecting data of other machine tools, and attaching a current row number mark;
and repeatedly executing the process, and uploading the G code file to the cloud server when the program is finished.
4. The numerical control machine tool monitoring system based on instruction domain data synchronization of claim 3, wherein the processing of the data uploaded by the data acquisition and synchronization device by the cloud server specifically comprises: and after receiving the data block, the server analyzes the G code text file, extracts the text of the line number corresponding to the data block and inserts the extracted text into the data block.
5. The numerical control machine tool monitoring system based on instruction domain data synchronization of claim 1, wherein: the data acquisition and synchronization device is integrated into a numerical control device of a numerical control machine tool or is installed in an external device.
6. The numerical control machine tool monitoring system based on instruction domain data synchronization of claim 1, wherein: the terminal equipment is provided with a display screen, a plurality of parallel pictures are displayed on the display screen, and all types of data acquired by the data acquisition and synchronization device are synchronously displayed.
7. A numerical control machine tool monitoring method based on instruction domain data synchronization, which is applied to the numerical control machine tool monitoring system based on instruction domain data synchronization according to any one of claims 1 to 6, and is characterized by comprising the following steps:
the camera acquires video data of the numerical control machine tool;
the data acquisition and synchronization device acquires various electric control data in the numerical control machine tool and video data acquired by a camera and synchronizes the various electric control data and the video data through the line number of the instruction domain data to form a plurality of data blocks with the line number of the instruction domain data as an index and upload the data blocks to the cloud server;
the cloud server processes and stores the data uploaded by the data acquisition and synchronization device;
and the terminal equipment acquires the required monitoring data from the server.
8. The numerical control machine tool monitoring method based on instruction domain data synchronization of claim 7, wherein the data collecting and synchronizing device collects various electric control data and video data obtained by a camera inside the numerical control machine tool and synchronizes the various electric control data and the video data through an instruction domain data line number, and the forming of a plurality of data blocks with the instruction domain data line number as an index and the uploading to the cloud server specifically comprises:
collecting the running line number of the current G code;
collecting log data, and attaching a current line number mark to each piece of log data;
collecting various electric control data in the numerical control machine tool, and attaching a current row number mark to each piece of data;
communicating with the camera and attaching the current line number tag to the video data;
recording the current time, and adding a current line number mark;
collecting data of other machine tools, and attaching a current row number mark;
and repeatedly executing the process, and uploading the G code file to the cloud server when the program is finished.
9. The numerical control machine tool monitoring method based on instruction domain data synchronization of claim 7, wherein the processing of the data uploaded by the data acquisition and synchronization device by the cloud server specifically comprises: and after receiving the data block, the server analyzes the G code text file, extracts the text of the line number corresponding to the data block and inserts the extracted text into the data block.
10. The numerical control machine tool monitoring method based on the instruction domain data synchronization of claim 7, wherein a plurality of parallel pictures are displayed on a display screen of the terminal device, and all types of data collected by the data collection and synchronization device are displayed synchronously.
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