CN111638081A - Tool magazine system reliability test method - Google Patents
Tool magazine system reliability test method Download PDFInfo
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- CN111638081A CN111638081A CN202010518181.2A CN202010518181A CN111638081A CN 111638081 A CN111638081 A CN 111638081A CN 202010518181 A CN202010518181 A CN 202010518181A CN 111638081 A CN111638081 A CN 111638081A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M99/00—Subject matter not provided for in other groups of this subclass
- G01M99/008—Subject matter not provided for in other groups of this subclass by doing functionality tests
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
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Abstract
The invention provides a method for testing the working reliability of a tool magazine system, which is used for testing the reliability of the tool magazine system. And performing parallel cycle test on each module in the tool magazine system to be tested, and providing an adaptive calculation method to calculate the average fault interval times, wherein when the average fault interval times is greater than the target interval times, the tool magazine system is qualified in reliability, and otherwise, the tool magazine system is unqualified. The invention adopts a parallel cycle mode in the tool magazine system working reliability test, greatly shortens the time for the tool magazine system reliability test, reduces the test cost, reduces the energy consumption and reduces the labor cost.
Description
Technical Field
The invention belongs to the technical field of mechanical equipment, and particularly relates to a tool magazine system reliability test method.
Background
The tool magazine system is one of core functional components of a machining center, and the reliability level of the tool magazine system directly influences the reliability level of the whole machine. The current domestic tool magazine system is comparable to the similar foreign products in the aspects of tool changing speed and positioning accuracy, but has a larger gap in the aspect of reliability, and the international competitiveness of the domestic processing center is severely restricted. The reliability test is an important way for rapidly acquiring fault data and performing targeted correction to improve the reliability of the tool magazine system. The patent provides a test method for the reliability of a tool magazine system, particularly a chain type tool magazine system.
In the prior art, as shown in fig. 1, a serial cycle manner of a tool magazine system is adopted for a reliability test method of the tool magazine system, the method includes that each module of the tool magazine system of a prototype is matched with each other to simulate a tool changing process, associated data is recorded once every other period of time, an average fault interval number is obtained through calculation after the total cycle number is reached, and then a target interval number is set to be compared with the average fault interval number to obtain whether the reliability of the tool magazine system is qualified or not.
In order to make the reliability test result more accurate, the tool magazine system needs to perform more than 100 ten thousand cycles, and it takes nearly 1 year. Therefore, the existing reliability test method of the tool magazine system has the defects of long test period and overhigh test cost.
Disclosure of Invention
The invention provides a reliability test method for a tool magazine system, in particular to a chain-type tool magazine system, each module of the tool magazine system to be tested is subjected to split parallel cycle test, in the test process, a single module does not need to wait for other modules matched with the single module to complete the action any more, the test period is greatly shortened, the reliability test for the same tool magazine system is completed only by 4-6 months, the test cost is reduced, the energy consumed by the test is reduced, and the labor cost is reduced.
In order to achieve the technical purpose, the invention adopts the following specific technical scheme:
a tool magazine system reliability test method comprises the following steps:
1) simulating and circulating operation M of the ith module in the 1 st prototype tool changer system according to the splitting action of the single tool changing flow of the prototypeiMeasuring and recording the 1 st model machine in the simulation cycle operationThe associated data of the ith module;
wherein, i is 1,2, 3;
2) comparing all the associated data with the respective corresponding operation standard value data, and counting one failure of the module of the prototype every time one associated data in one module exceeds the operation standard value;
3) circularly operating the step 1) to the step 2) for N times;
4) respectively operating the step 1) to the step 3) on the 2 nd to the n th sample machines;
5) and the MTBF was obtained by the following calculation methodn(mean number of fault intervals):
wherein, the MTBFnMTBF as mean time between failuresn(mz-i)The tool changing times of the mean fault interval of the ith module in n sample machines are obtained, and k is the necessary operation times of the ith module in the single tool changing process of the sample machine; t is tijIs the total number of times of operation of the jth sample ith type module, rijThe total number of the faults of the ith module of the jth prototype is shown; when in use
When the temperature of the water is higher than the set temperature,
6) setting target MTBFnValue, target MTBFnThe number of tool changes with a mean time between failures expected to be reachable by the tool magazine system, according to the MTBFnDetermining the overall reliability of the tool magazine system of the batch sampler, e.g. MTBFnAchieving target MTBFnIf no fault occurs, the knife of the sample machine is judgedQualification of the overall reliability of the library system, e.g. MTBFnNot reaching the target MTBFnAnd if so, judging that the overall reliability of the tool magazine system of the prototype of the batch of the specification is unqualified.
Further, the tool magazine system comprises a chain type tool magazine module, a reverse tool module and an automatic tool exchange module, and the associated data comprises:
simulating the temperature change data of the servo motor of the chain type tool bin module, the temperature change data of the controller box of the automatic tool exchange module and the temperature change data of the servo motor of the automatic tool exchange module during circulating operation,
immediately recording servo motor current data of the chain type tool magazine module, noise sound pressure level data of the chain type tool magazine module, vibration effective value data of the chain type tool magazine module, tool reversing position precision data of the tool reversing module, noise sound pressure level data of the tool reversing module, tool changing position precision data of the automatic tool changing module, controller tool changing process current data of the automatic tool changing module and controller vibration effective value data of the automatic tool changing module after simulation circulation operation is finished.
Further, M N is the target MTBFn3-5 times the value.
Further, the association failure does not include: faults caused by defects in the device, faults caused by operation exceeding experimental regulations, and faults caused by operation exceeding design conditions.
Further, the associating the fault further includes: and carrying out the fault caused in the preventive maintenance process according to the design index of the prototype.
Further, the temperature change data of the servo motor of the chain type tool magazine module is a temperature value and a temperature rise curve of the servo motor of the chain type tool magazine module; the temperature change data of the servo motor of the automatic cutter exchange module is the temperature value and the temperature rise curve of the servo motor of the automatic cutter exchange module.
Further, still include chain tool magazine module idle running step before the chain tool magazine module circulation operation:
idling the chain type knife bin module of the prototype for 1.5m times;
wherein m is the tool capacity of the tool magazine module.
Further, the mode of arranging the cutters on the chain type tool magazine module is as follows: the distribution center line of each tool bin of the tool bin module is used as a distribution center line, and the tools are fully distributed on one side of the distribution center line.
Further, the test cutters arranged in the chain type cutter bin module comprise at least one cutter with the maximum allowable weight, at least one cutter with the maximum allowable diameter, at least one cutter with the maximum allowable length and at least one cutter with the maximum allowable gravity moment; the test cutter is a real cutter or a simulation cutter.
Further, the step 1), the step 3), the step 4) and the idling step are all carried out on a reliability test platform.
By adopting the technical scheme, the invention has the following beneficial effects:
1. a parallel circulation mode is adopted in the tool magazine system work reliability test, and a new calculation method is provided, so that the time for the tool magazine system reliability test is greatly shortened, the test cost is reduced, the test energy consumption is reduced, and the labor cost is reduced.
2. Parallel cycle is relative to serial cycle, has avoided the loss to other modules except that each module of tool magazine system.
Drawings
FIG. 1 is a flow chart of a method for testing the reliability of a chain-type tool magazine in the prior art;
fig. 2 is a flowchart of a chain tool magazine reliability testing method of the present invention.
Wherein, ATC module-automatic tool exchange module.
Detailed Description
The present invention will now be described in detail with reference to the drawings attached hereto.
In an embodiment of the invention, a tool magazine system reliability test method is provided, which is used for testing the reliability of tool magazine systems of machining centers of the same batch and the same specification on a reliability test bench, so as to obtain the overall reliability of the tool magazine system of the machining center of the batch. The reliability experiment platform is designed independently, modules in the tool magazine system can run circularly on the reliability experiment platform, and the reliability experiment platform can measure the associated data of each module in the tool magazine system. The tool magazine system includes: chain tool magazine module, back sword module and automatic tool exchange module. The test comprises the following steps:
1) after arranging cutters on the chain type cutter bin module of the 1 st prototype, simulating and circulating the chain type cutter bin module in the 1 st prototype cutter bin system according to the splitting action of the single cutter changing flow of the prototype1And measuring and recording the associated data of the chain type knife cabin module of the 1 st prototype during the simulation cycle operation, wherein the data recording and detection are completed by the reliability experiment platform.
Simulating and circularly operating the reverse tool module in the 1 st prototype tool magazine system according to the splitting action of the single tool changing process of the prototype2And measuring and recording the relevant data of the back tool module of the 1 st prototype during the simulation cycle operation, wherein the data recording and detection are completed by a reliability experiment platform.
Simulating and circulating the automatic cutter exchange module in the 1 st prototype tool magazine system according to the splitting action of the single tool changing flow of the prototype3And measuring and recording the associated data of the reverse automatic tool exchange module of the 1 st prototype during the simulation cycle operation, wherein the data recording and detection are completed by a reliability experiment platform.
The associated data is the data that can influence chain tool magazine module, back tool module and manipulator module normal operating and influence its reliability, includes: and the temperature change data of the servo motor of the chain type tool bin module, the temperature change data of the controller box of the automatic tool exchange module and the temperature change data of the servo motor of the automatic tool exchange module are simulated during circulating operation. The servo motor temperature change data comprises a temperature value and a temperature rise curve thereof for comparison with a standard temperature value and a temperature rise curve in subsequent steps.
After the simulation cycle operation is finished, immediately measuring and recording servo motor current data of the chain type tool magazine module, noise sound pressure level data of the chain type tool magazine module, vibration effective value data of the chain type tool magazine module, tool reversing position precision data of the tool reversing module, noise sound pressure level data of the tool reversing module, tool changing position precision data of the automatic tool changing module, tool changing process current data of a controller of the automatic tool changing module and vibration effective value data of the controller of the automatic tool changing module.
And simulating the circulating operation, wherein the temperature change data of the servo motor of the chain type tool magazine module is a temperature value and a temperature rise curve.
And after the circulation operation is finished, measuring and recording servo motor current data of the chain type tool magazine module, noise sound pressure level data of the chain type tool magazine module, vibration effective value data of the chain type tool magazine module, tool reversing position precision data of the tool reversing module, noise sound pressure level data of the tool reversing module, tool changing position precision data of the automatic tool changing module, controller tool changing process current data of the automatic tool changing module and controller vibration effective value data of the automatic tool changing module.
Wherein the content of the first and second substances,
the chain type tool magazine module in the single tool changing process only operates once, namely
In the same way, the method for preparing the composite material,
in the same way, the method for preparing the composite material,
and M is 20 w.
2) Comparing all the associated data with the respective corresponding operation standard value data, and counting one failure of the module of the prototype every time one associated data in one module exceeds the operation standard value;
3) circularly operating the step 1) to the step 2) for N times; taking N as 5-8;
4) respectively operating the step 1) to the step 3) on the 2 nd to the n th sample machines;
5) and the MTBF was obtained by the following calculation methodn(mean number of fault intervals):
wherein, MTBFn(mz-i)The method comprises the steps that the tool changing times of the mean fault interval of the ith module in n sample machines are obtained, k is the necessary operation times of the ith module in the single tool changing process of the sample machine, and 1 is taken here; t is tijIs the total number of times of operation of the jth sample ith type module, rijThe total number of the faults of the ith module of the jth prototype is shown; when in use
When the temperature of the water is higher than the set temperature,
6) setting target MTBFnValue (number of tool changes for mean failure interval expected to be reachable by the tool magazine system, according to the MTBF)nDetermining the overall reliability of the tool magazine system of the batch sampler, e.g. MTBFnAchieving target MTBFnIf no fault occurs, judging that the overall reliability of the tool magazine system of the batch of prototype is qualified, such as MTBFnNot reaching the target MTBFnAnd if so, judging that the overall reliability of the tool magazine system of the prototype of the batch of the specification is unqualified.
Wherein the target MTBFnValue of expectationThe specific number of the tool changing times of the average fault interval which can be reached by the tool magazine system is determined by a manufacturer according to a prototype system of the manufacturer, the specific number is usually more than 50w, and the higher the numerical value is, the higher the reliability requirement on the tool magazine system is.
In the embodiment, a parallel cycle test mode is adopted, and compared with a serial cycle test mode adopted in the prior art, the time consumed by the coordination waiting among modules is saved, the time consumed by a single cycle process of a single module is shorter, and more than half of time can be saved in specific application. Because the reliability test of the tool magazine system needs more than 100w cycles to obtain more effective results, the test needs more than 1 year, but the test method of the invention can obtain the results only in 4-6 months.
In one embodiment of the present invention, in order to avoid the influence of the destructive fault on the calculation result, the association fault does not include: faults caused by defects in the device, faults caused by operation exceeding experimental regulations, and faults caused by operation exceeding design conditions.
In an embodiment of the present invention, in order to sufficiently ensure the accuracy of the reliability result, the associating fault further includes: and carrying out the fault caused in the preventive maintenance process according to the design index of the prototype.
In an embodiment of the present invention, before the parallel circulation of the chain type magazine modules, the method further comprises a module idling step:
idling the model machine knife bin module for 1.5m times; wherein m is the tool capacity of the tool magazine module. After 1.5m idle runs, the knife house module rotates 540 degrees, and preparation actions before circulation are carried out.
In an embodiment of the present invention, a targeted design is performed according to fatigue resistance of an existing chain type tool magazine in China, and in an embodiment of the present invention, an arrangement manner of arranging tools on a tool magazine module in step 1) is as follows: the distribution center line of each tool bin of the tool bin module is used as a distribution center line, and the tools are fully distributed on one side of the distribution center line.
The test cutters arranged in the chain type cutter bin module comprise at least one cutter with the maximum allowable weight, at least one cutter with the maximum allowable diameter, at least one cutter with the maximum allowable length and at least one cutter with the maximum allowable gravity moment; the test cutter is a real cutter or a simulation cutter.
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 and improvements made within the spirit and principle of the present invention are intended to be included within the scope of the present invention. The above description is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, several modifications and variations can be made without departing from the technical principle of the present invention, and these modifications and variations should also be regarded as the protection scope of the present invention.
Claims (10)
1. A tool magazine system reliability test method is characterized by comprising the following steps:
1) simulating and circulating operation M of the ith module in the 1 st prototype tool changer system according to the splitting action of the single tool changing flow of the prototypeiMeasuring and recording the associated data of the ith module of the 1 st prototype during the simulation cycle operation;
wherein, i is 1,2, 3;
2) comparing all the associated data with the respective corresponding operation standard value data, and counting one failure of the module of the prototype every time one associated data in one module exceeds the operation standard value;
3) circularly operating the step 1) to the step 2) for N times;
4) respectively operating the step 1) to the step 3) on the 2 nd to the n th sample machines;
5) and the MTBF was obtained by the following calculation methodn(mean number of fault intervals):
wherein, the MTBFnMTBF as mean time between failuresn(mz-i)The tool changing times of the mean fault interval of the ith module in n sample machines are obtained, and k is the necessary operation times of the ith module in the single tool changing process of the sample machine; t is tijIs the total number of times of operation of the jth sample ith type module, rijThe total number of the faults of the ith module of the jth prototype is shown; when in use
When the temperature of the water is higher than the set temperature,
6) setting target MTBFnValue, target MTBFnThe number of tool changes with a mean time between failures expected to be reachable by the tool magazine system, according to the MTBFnDetermining the overall reliability of the tool magazine system of the batch sampler, e.g. MTBFnAchieving target MTBFnIf no fault occurs, judging that the overall reliability of the tool magazine system of the batch of prototype is qualified, such as MTBFnNot reaching the target MTBFnAnd if so, judging that the overall reliability of the tool magazine system of the prototype of the batch of the specification is unqualified.
2. The assay method of claim 1, wherein: the tool magazine system comprises a chain type tool magazine module, a tool reversing module and an automatic tool exchange module, and the associated data comprise:
simulating the temperature change data of the servo motor of the chain type tool bin module, the temperature change data of the controller box of the automatic tool exchange module and the temperature change data of the servo motor of the automatic tool exchange module during circulating operation,
the automatic tool changing system comprises servo motor current data of a chain type tool bin module, noise sound pressure level data of the chain type tool bin module, vibration effective value data of the chain type tool bin module, tool reversing position precision data of the tool reversing module, noise sound pressure level data of the tool reversing module, tool changing position precision data of the automatic tool changing module, controller tool changing process current data of the automatic tool changing module and controller vibration effective value data of the automatic tool changing module, wherein the servo motor current data of the chain type tool bin module, the noise sound pressure level data of the chain type tool bin module, the vibration effective value data of the chain type tool bin module, the tool reversing position precision data of.
3. The test method according to claim 2, characterized in that: the M is the target MTBFn3-5 times the value.
4. The test method according to claim 2, characterized in that: the association failure does not include: faults caused by defects in the device, faults caused by operation exceeding experimental regulations, and faults caused by operation exceeding design conditions.
5. The test method according to claim 2, characterized in that: the associated fault further comprises: and carrying out the fault caused in the preventive maintenance process according to the design index of the prototype.
6. The test method according to claim 2, characterized in that: the temperature change data of the servo motor of the chain type tool magazine module are the temperature value and the temperature rise curve of the servo motor of the chain type tool magazine module; the temperature change data of the servo motor of the automatic cutter exchange module is the temperature value and the temperature rise curve of the servo motor of the automatic cutter exchange module.
7. The testing method according to claim 2, wherein the idling step of the chain type tool magazine module is further included before the circulating operation of the chain type tool magazine module:
idling the chain type knife bin module of the prototype for 1.5m times;
wherein m is the tool capacity of the tool magazine module.
8. The test method according to claim 2, characterized in that: the mode of arranging the cutters on the chain type cutter bin module is as follows: the distribution center line of each tool bin of the tool bin module is used as a distribution center line, and the tools are fully distributed on one side of the distribution center line.
9. The assay method of claim 8, wherein: the test cutters arranged in the chain type cutter bin module comprise at least one cutter with the maximum allowable weight, at least one cutter with the maximum allowable diameter, at least one cutter with the maximum allowable length and at least one cutter with the maximum allowable gravity moment; the test cutter is a real cutter or a simulation cutter.
10. Test method according to claim 1 or 7, characterized in that: the step 1), the step 3), the step 4) and the idling step are all carried out on a reliability test platform.
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2020
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