CN112255967A - Real-time monitoring system, device and method for broken cutter in machining process of numerical control machine tool - Google Patents
Real-time monitoring system, device and method for broken cutter in machining process of numerical control machine tool Download PDFInfo
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- CN112255967A CN112255967A CN202011173832.5A CN202011173832A CN112255967A CN 112255967 A CN112255967 A CN 112255967A CN 202011173832 A CN202011173832 A CN 202011173832A CN 112255967 A CN112255967 A CN 112255967A
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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
- G05B19/4065—Monitoring tool breakage, life or condition
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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
- G05B2219/37—Measurements
- G05B2219/37616—Use same monitoring tools to monitor tool and workpiece
Abstract
The invention discloses a real-time monitoring system, a device and a method for broken knives in the machining process of a numerical control machine tool. The judging method is simple and reliable, and has high judging accuracy; additional sensors are not needed, hardware cost is reduced, and the integration with a machine tool is facilitated.
Description
[ technical field ] A method for producing a semiconductor device
The invention belongs to the technical field of processing machines, and particularly relates to a real-time monitoring system, a real-time monitoring device and a real-time monitoring method for broken tools in the processing process of a numerical control machine tool.
[ background of the invention ]
In the machining process of the numerical control machine tool, due to the reasons of unreasonable feed path, unstable cutting force, poor cutter consistency, uneven workpiece material, cutter aging, stress fatigue and the like, cutter breakage is easy to occur, and the numerical control machine tool is most common in high-speed machining of small-diameter cutters due to low strength. In addition, after the cutter is broken, due to the influences of small size, small cutting amount, cutting fluid and the like of the cutter, whether the cutter is in a healthy state at present or not can not be judged by observing with naked eyes through manual work or by the change of cutting sound, the subsequent processing flow is influenced, a large amount of processing time is wasted, and particularly the semi-finishing or finishing process with long processing time is adopted. In addition, along with the increasing automation degree of the machine tool, the number of numerical control machining field personnel is less and less, and one machine tool is considered, so that the energy is insufficient, the cutter breakage is difficult to find at the first time, and the machine tool does useless work.
Even if the broken cutter can be found, the accurate time cannot be judged, and the residual processing procedures cannot be reasonably arranged. More importantly, the continuous rise of scientific technology leads the automation technology to be more and more mature, the automatic processing production line is put into practical use, and once the broken knife generated in the automatic production process is not processed in place, the whole batch of products are lost. The existing monitoring process has the following schemes:
(1) process interruption measurement
The technology of contact tool setting gauge, laser tool setting gauge or laser broken tool monitoring, industrial camera image recognition and the like is used for detecting the tool when the tool is not in a cutting state or a path is specially left before, during and after machining; the mode is non-real-time monitoring, the cutter is required to be processed and moved back and forth to a specified position to test whether the cutter is broken or not, time is additionally increased, the cutter breakage in the processing process cannot be judged in real time, instantaneity is poor, and production efficiency is reduced.
(2) Real-time monitoring
The cutter breaking is detected by monitoring sudden changes of certain characteristic quantities in the machining process, such as main shaft load, feed shaft load, force measuring cutter handle and other characteristic quantities in real time, for example, the scheme of detecting the cutter breaking by using the sudden changes of the main shaft load exists at present abroad; the technique for detecting the knife break through the main shaft current load and the like comprises the following steps: when the small cutter is subjected to high-speed semi-precision or fine machining, due to the small cutting amount, the current of a motor of a main shaft or a frequency converter before and after the cutter is broken does not have obvious stable change, namely the sensitivity is not high, the cutter breaking phenomenon cannot be effectively judged, and the scheme is suitable for a machining scene with a large cutter diameter or a large cutting amount.
(3) The technology for detecting the cutting force through the force measuring knife handle comprises the following steps: when the small cutter is subjected to high-speed semi-precision or fine machining, due to the small cutting amount, the change of cutting force is very small, the sensitivity is extremely low, in addition, the force measuring cutter handle is expensive, the use difficulty is high, and the large-scale preparation is difficult to realize at present.
Therefore, the prior art lacks a method for monitoring the cutter breaking condition of the cutter in real time to solve the cutter breaking problem in the machining process.
[ summary of the invention ]
The invention aims to overcome the defects of the prior art and provides a real-time monitoring system, a real-time monitoring device and a real-time monitoring method for the broken cutter in the machining process of a numerical control machine tool, so as to solve the technical problems that the prior art lacks a real-time monitoring method and a cutter breakage monitoring method with high sensitivity is lack.
In order to achieve the purpose, the invention adopts the following technical scheme to realize the purpose:
a real-time monitoring method for broken cutter in the machining process of a numerical control machine tool comprises the following steps:
step 1, collecting accumulated pulse number of a grating ruler;
step 2, converting the accumulated pulse number after differential processing into time domain data, converting the time domain data into frequency domain data after Fourier transformation, and storing the amplitude of the characteristic frequency in the frequency domain data;
and 3, comparing the reserved amplitude with a reference threshold, and judging the cutter breaking when the characteristic frequency of the third time is less than the threshold.
The invention is further improved in that:
preferably, in step 1, the number of accumulated pulses in 1 second is collected.
Preferably, the characteristic frequency is a frequency corresponding to the product of the spindle rotation speed and the number of tool edges.
Preferably, the reference threshold is the accumulated pulse number of the grating ruler when the machine tool runs in idle.
Preferably, in step 3, when the amplitude of the characteristic frequency is greater than the reference threshold, the amplitude of the characteristic frequency is discarded.
Preferably, in step 3, after the knife is broken, a warning process is further included.
Preferably, in step 1, the acquisition frequency is greater than 10 KHz.
The utility model provides a digit control machine tool course of working disconnected sword real-time monitoring system, includes:
the acquisition module is used for acquiring the accumulated pulse number of the grating ruler;
the conversion module is used for converting the accumulated pulse number into time domain data after differential processing, converting the time domain data into frequency domain data after Fourier transformation, and storing the amplitude of the characteristic frequency in the frequency domain data;
and the comparison module is used for comparing the reserved amplitude value with a reference threshold value, and judging the cutter breaking when the characteristic frequency of three times is less than the threshold value.
The utility model provides a digit control machine tool course of working disconnected sword real-time monitoring device, includes: the base is fixedly arranged on the machine tool, two parallel guide rails are fixedly arranged on the base, a workbench is erected on the two parallel guide rails, a cutter is arranged above the workbench and fixedly connected to a main shaft, and the main shaft is connected to the machine tool;
a grating ruler is arranged between the parallel guide rail and the workbench and connected with an upper computer.
Preferably, the grating ruler is connected with a servo driver, the servo driver is connected with a dynamic signal acquisition card, and the dynamic signal acquisition card is connected with an upper computer.
Compared with the prior art, the invention has the following beneficial effects:
the invention discloses a real-time monitoring method for cutter breakage in the machining process of a numerical control machine tool, which comprises the steps of acquiring accumulated pulse numbers acquired by a grating ruler, carrying out differential processing to obtain time domain data, carrying out Fourier transformation on the time domain data and then converting the time domain data into frequency domain data, extracting amplitude of characteristic frequency from the frequency domain data, comparing the amplitude with a reference threshold value, and judging whether the cutter is short or not so as to realize real-time and high-sensitivity monitoring of the cutter breakage condition in the machining process. The judging method is simple and reliable, and has high judging accuracy; additional sensors are not needed, hardware cost is reduced, and the integration with a machine tool is facilitated.
The invention also discloses a real-time monitoring system for the broken cutter in the machining process of the numerical control machine tool, the system realizes the acquisition and comparison of data through the acquisition module, the conversion module and the comparison module, has the characteristic of high resolution, can judge the health state of the cutter under the state of small cutting amount of the small cutter, and solves the problem that the health of the cutter is difficult to judge due to the small cutting amount.
The invention also discloses a real-time monitoring device for the broken cutter in the machining process of the numerical control machine tool, which transmits the grating ruler signal to the upper computer, and judges the acquired signal through the upper computer. The invention has high integration level, reduces the difficulty of integration of the high-speed machine and the machine tool by acquiring the dynamic signal of the grating ruler used for axis positioning of the high-speed machine without adding a sensor, and can be integrated with the machine tool into a whole conveniently.
Furthermore, the grating ruler belongs to a precise device, and the servo driver and the like belong to high-reliability equipment, so that the signal stability is very high, the judgment accuracy is improved, and whether the cutter breakage occurs to the machining cutter can be accurately judged.
[ description of the drawings ]
FIG. 1 is a schematic diagram of the apparatus of the present invention;
FIG. 2 is a monitoring flow diagram of the present invention.
Wherein: 1-a motor, 2-a front support, 3-a workbench, 4-a guide rail, 5-a base, 6-a rear support, 7-a grating ruler, 8-a servo driver, 9-a grating ruler dynamic signal acquisition card and 10-an upper computer; 11-a machine tool; 12-a cutter; 13-a main shaft; 14-lead screw.
[ detailed description ] embodiments
The invention is described in further detail below with reference to the accompanying drawings:
in the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, and are only for convenience of description and simplicity of description, but do not indicate or imply that the device or element being referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus, should not be construed as limiting the present invention; the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance; furthermore, unless expressly stated or limited otherwise, the terms "mounted," "connected," and "connected" are to be construed broadly and encompass, for example, both fixed and removable connections; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Referring to fig. 2, the invention discloses a real-time monitoring system, a real-time monitoring device and a real-time monitoring method for broken knives in the machining process of a numerical control machine tool, and referring to fig. 2, the real-time monitoring system comprises a high-resolution grating ruler 7, a servo driver 8, a high-frequency grating ruler dynamic signal acquisition card 9 and an upper computer 10, wherein a control system is installed in the upper computer 10. The base 5 is fixed to be set up on lathe 11, and fixed guide rail 4, preceding support 2, back support 6 and the grating chi 7 that are provided with two parallels on the base 5, and guide rail 4 of two parallels is symmetrical for the central axis, and preceding support 2 and back support 6 all fix and set up in central axis department, are provided with lead screw 14 between preceding support 2 and the back support 6, and the place ahead of preceding support 2 is provided with motor 1, and motor 1's output and lead screw 14 are connected. A grating ruler 7 is arranged between one guide rail 4 and the lead screw 14, the two guide rails 4 are provided with the working table 3 on the upper frame, and the working table 3 can move along the guide rails 4. A main shaft 13 is fixedly connected to the machine tool 11, and a coaxial tool 12 is fixedly connected to the lower portion of the main shaft 13.
The grating ruler 7 is an important device used for positioning of the machine tool 11, real-time dynamic signals of the grating ruler are input into a servo driver 8 of the machine tool, a high-frequency grating ruler dynamic signal acquisition card 9 acquires dynamic signals of the grating ruler through the servo driver 8, and the grating ruler dynamic signal acquisition card 9 is connected with an upper computer 10 in a RS 485-USB (Universal Serial bus) conversion mode. The control system in the upper computer 10 may be a computer independent of an industrial personal computer of the numerical control machine, or the control system in the upper computer 10 may be directly integrated into the numerical control system. Referring to fig. 1, the entire control method includes the steps of:
(1) calibration: in order to judge whether the cutter is in a cutting state, firstly, acquiring a dynamic signal in a no-operation state as a comparison reference, and setting a reference threshold according to the result, wherein the dynamic signal is the accumulated pulse number of a machine tool grating ruler 7 read by a numerical control machine servo driver 8;
(2) collecting: a machine tool 11 collects a grating ruler dynamic signal read by a servo driver 8 in the normal machining process, and transmits the grating ruler dynamic signal to an upper computer 10 through a dynamic signal collection card 9, wherein the dynamic signal is the accumulated pulse number;
(3) and (3) treatment: the upper computer 10 firstly performs differential processing on the received accumulated pulse number, then performs fast Fourier transform on the time domain data after the differential processing to convert the time domain data into a frequency domain, and saves the amplitude at the characteristic frequency;
firstly, carrying out differential processing on the accumulated pulse number within 1 second collected from a numerical control machine tool servo driver 8, namely calculating the actual movement distance of the machine tool between the two pulse numbers to obtain displacement variation data generated along with the time variation of the machine tool within 1 second, converting the accumulated pulse number into time domain data after splitting processing, converting the time domain data into frequency domain data by using Fast Fourier Transform (FFT), simultaneously setting a frequency point corresponding to the product of the rotating speed of a current spindle 13 and the number of edges of a cutter as a selected characteristic frequency capable of representing whether the cutter breaks, and storing the amplitude at the characteristic frequency; for example, the obtained frequency domain data is data between 0 and 1000Hz, and if the rotation speed of the spindle 13 per second is 100r/s, and the number of the knife edges is 4, what characterizes the knife breaking is that the product 100 × 4 of the rotation speed of the spindle and the number of the knife edges is 400Hz, that is, the corresponding amplitude value at 400Hz represents whether the knife breaking occurs;
(4) and (3) judging: comparing the amplitude at the characteristic frequency with a set reference threshold value during the idle running, and if the amplitude is greater than the reference threshold value, discarding the amplitude acquired at this time; if the value is smaller than the reference threshold value, recording the value, and if the values are smaller than the threshold value after three continuous comparisons in the processes (2) to (4), judging that the cutter is broken;
(5) warning: and sending a warning signal to the machine tool to give an alarm to the machine tool, reminding a craftsman of the occurrence of cutter breakage and timely replacing the cutter.
In the process, the frequency of the dynamic signal acquisition of the grating ruler is high enough to be more than 10kHz, and enough data can be provided for fast Fourier transform; firstly, carrying out differential processing on the acquired dynamic signals of the grating ruler, and then carrying out fast Fourier transform; the characteristic frequency of the broken cutter can be indicated, the amplitude at the characteristic frequency is larger than a threshold value obtained in no-load operation in a normal cutting state, when the detected amplitude is continuously judged to be smaller than the threshold value for three times, the broken cutter is judged to be generated, and whether the broken cutter is generated is judged by using the amplitude change of the characteristic frequency;
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 real-time monitoring method for broken cutter in the machining process of a numerical control machine tool is characterized by comprising the following steps:
step 1, collecting accumulated pulse number of a grating ruler;
step 2, converting the accumulated pulse number after differential processing into time domain data, converting the time domain data into frequency domain data after Fourier transformation, and storing the amplitude of the characteristic frequency in the frequency domain data;
and 3, comparing the reserved amplitude with a reference threshold, and judging the cutter breaking when the characteristic frequency of the third time is less than the threshold.
2. The real-time monitoring method for the broken cutter in the machining process of the numerical control machine tool according to claim 1, wherein in the step 1, the accumulated number of pulses in 1 second is collected.
3. The real-time monitoring method for the broken cutter in the machining process of the numerical control machine tool according to claim 1, characterized in that the characteristic frequency is a frequency corresponding to the product of the rotating speed of the main shaft (13) and the number of edges of the cutter (12).
4. The real-time monitoring method for the broken tool in the machining process of the numerical control machine tool according to claim 1, characterized in that the reference threshold is the accumulated pulse number of the grating ruler when the machine tool (12) runs idle.
5. The method for monitoring the real-time broken tool in the machining process of the numerical control machine tool according to claim 1, wherein in the step 3, when the amplitude of the characteristic frequency is greater than a reference threshold value, the amplitude of the characteristic frequency is discarded.
6. The real-time monitoring method for the broken cutter in the machining process of the numerical control machine tool according to claim 1, wherein in the step 3, after the cutter is broken, a warning process is further included.
7. The real-time monitoring method for the broken cutter in the machining process of the numerical control machine tool according to claim 1, wherein in the step 1, the acquisition frequency is more than 10 KHz.
8. The utility model provides a digit control machine tool course of working real-time monitoring system that cuts, its characterized in that includes:
the acquisition module is used for acquiring the accumulated pulse number of the grating ruler;
the conversion module is used for converting the accumulated pulse number into time domain data after differential processing, converting the time domain data into frequency domain data after Fourier transformation, and storing the amplitude of the characteristic frequency in the frequency domain data;
and the comparison module is used for comparing the reserved amplitude value with a reference threshold value, and judging the cutter breaking when the characteristic frequency of three times is less than the threshold value.
9. The utility model provides a digit control machine tool course of working real-time supervision device that cuts, its characterized in that includes: the automatic cutting machine comprises a base (5), wherein the base (5) is fixedly arranged on a machine tool (11), two parallel guide rails (4) are fixedly arranged on the base (5), a workbench (3) is erected on the two parallel guide rails (4), a cutter (12) is arranged above the workbench (3), the cutter (12) is fixedly connected onto a main shaft (13), and the main shaft (13) is connected onto the machine tool (11);
a grating ruler (7) is arranged between the parallel guide rail (4) and the workbench (3), and the grating ruler (7) is connected with an upper computer (10).
10. The device for monitoring the real-time broken tool in the machining process of the numerical control machine tool according to claim 9, wherein the grating ruler (7) is connected with a servo driver (8), the servo driver (8) is connected with a dynamic signal acquisition card (9), and the dynamic signal acquisition card (9) is connected with an upper computer (10).
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Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103363920A (en) * | 2012-04-09 | 2013-10-23 | 鸿富锦精密工业（深圳）有限公司 | Cutter detection system and method |
| US9983776B1 (en) * | 2016-06-30 | 2018-05-29 | Bentley Systems, Incorporated | Software system for dynamic feature extraction for structural health monitoring |
| CN108536094A (en) * | 2017-03-01 | 2018-09-14 | 沈机（上海）智能系统研发设计有限公司 | Machine tool capability detecting system, method and numerically-controlled machine tool |
| CN109753632A (en) * | 2018-11-01 | 2019-05-14 | 北京理工大学 | A kind of surface roughness monitoring model and construction method based on data mining |
| CN111958321A (en) * | 2020-08-09 | 2020-11-20 | 西北工业大学 | Numerical control machine tool cutter wear degree identification method based on deep neural network |
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2020
- 2020-10-28 CN CN202011173832.5A patent/CN112255967B/en active Active
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103363920A (en) * | 2012-04-09 | 2013-10-23 | 鸿富锦精密工业（深圳）有限公司 | Cutter detection system and method |
| US9983776B1 (en) * | 2016-06-30 | 2018-05-29 | Bentley Systems, Incorporated | Software system for dynamic feature extraction for structural health monitoring |
| CN108536094A (en) * | 2017-03-01 | 2018-09-14 | 沈机（上海）智能系统研发设计有限公司 | Machine tool capability detecting system, method and numerically-controlled machine tool |
| CN109753632A (en) * | 2018-11-01 | 2019-05-14 | 北京理工大学 | A kind of surface roughness monitoring model and construction method based on data mining |
| CN111958321A (en) * | 2020-08-09 | 2020-11-20 | 西北工业大学 | Numerical control machine tool cutter wear degree identification method based on deep neural network |
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