CN112255969A - Data acquisition, analysis and display system and method of numerical control machine tool - Google Patents
Data acquisition, analysis and display system and method of numerical control machine tool Download PDFInfo
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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
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- 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
- G05B2219/31—From computer integrated manufacturing till monitoring
- G05B2219/31282—Data acquisition, BDE MDE
Abstract
The invention provides a data acquisition, analysis and display system and a data acquisition, analysis and display method for a numerical control machine tool, wherein the system comprises a data acquisition module, a sensor module, a data uploading module, a network connection system, a database system, a cloud computing platform and a digital workshop management and control cloud platform; according to the scheme, the data acquisition module is connected with the numerical control machine tool, so that data are acquired and uploaded to the cloud, the data are displayed on the digital workshop management and control cloud platform after being analyzed and processed, and in this way, basic data support can be provided for workshop management and intelligent decision making, the production efficiency is improved, and the equipment efficiency is improved.
Description
Technical Field
The invention relates to the technical field of equipment manufacturing industry, in particular to a data acquisition, analysis and display system and method of a numerical control machine tool.
Background
At present, the equipment manufacturing industry in China has the problems of weak core competitiveness, low quality and low efficiency of product production, low intelligent degree and the like. The equipment manufacturing industry belongs to the discrete manufacturing industry, has the characteristics of mainly producing various small-batch parts, and the problems of low quality and low efficiency of product production are mainly caused by the fact that part of key production equipment management and control means is backward, the management efficiency is low, and the information feedback is not timely. With the continuous update and breakthrough of intelligent technology, it is possible to solve the above problems in equipment manufacturing industry by applying digital and intelligent means. Most equipment manufacturing industries in China are seeking intelligent means to carry out enterprise intelligent transformation and upgrade so as to improve the product quality and the production efficiency.
Disclosure of Invention
The invention provides a data acquisition, analysis and display system and a data acquisition, analysis and display method for a numerical control machine tool, which mainly solve the technical problems that: the networked management and control of workshop equipment and the real-time monitoring of the running state of the equipment are realized, and the effects of improving the comprehensive efficiency of key production equipment and improving the management level of the workshop equipment are achieved.
In order to solve the technical problems, the invention provides a data acquisition, analysis and display system of a numerical control machine tool, which comprises a data acquisition module, a sensor module, a data uploading module, a network connection system, a database system, a cloud computing platform and a digital workshop management and control cloud platform;
the data acquisition module is in communication connection with the numerical control machine tool through a network cable, a serial port and a communication protocol by using software and is used for acquiring running state data of the numerical control machine tool, a machine tool program, feeding, rotating speed and load and a verification result signal for verifying whether each product is qualified or not;
the sensor module is used for acquiring digital signals of current, voltage and power of the numerical control machine tool at any moment in the machining process and off-line signals of products in real time;
the data uploading module sends data information acquired by the data acquisition module and the sensor module to the database system and the cloud computing platform by using the network connection system;
the database system is used for storing the data information acquired by the data acquisition module and the sensor module;
the cloud computing platform is used for carrying out data analysis processing according to the data information acquired by the data acquisition module and the sensor module, determining the equipment state of the numerical control machine tool, and storing the equipment state in the database system to form a time sequence event sequence; wherein the equipment state comprises operation, planned shutdown, unplanned shutdown and undefined; calculating the equipment operation efficiency, the productivity efficiency, the product percent of pass and the comprehensive efficiency of the numerical control machine; the comprehensive efficiency is the product of the equipment operation efficiency, the productivity efficiency and the product percent of pass; and sending the data analysis processing result to a digital workshop management and control cloud platform for visual display.
Optionally, the data uploading module uses a browser-based software programming tool node red, receives data information of the data acquisition module by using an Opc ua module inside the node red, then writes a program to convert the data into a json (JavaScript Object Notation) format, and finally uploads the data to the cloud computing platform by using a Message queue Telemetry Transport protocol (mqtt).
Optionally, the network connection system includes a sim (Subscriber Identity Module) card for providing network data traffic, an industrial router, a micro industrial personal computer, and a signal-enhanced antenna, and data acquisition and communication between devices are achieved through connection between components.
Optionally, the sensor module includes a mutual inductor, a multimeter and an infrared sensor to acquire digital signals of current, voltage and power of the data machine tool at any time in the machining process and off-line signals of products.
The invention also provides a data acquisition, analysis and display method based on the data acquisition, analysis and display system of the numerical control machine tool, which comprises the following steps:
collecting running state data of the numerical control machine tool, a machine tool program, feeding, rotating speed and load and a verification result signal for verifying whether each product is qualified or not through a data acquisition module;
collecting digital signals of current, voltage and power of the numerical control machine tool at any moment in the machining process and product off-line signals in real time through a sensor module;
sending data information acquired by the data acquisition module and the sensor module to a database system and a cloud computing platform;
storing data information acquired by the data acquisition module and the sensor module through a database system;
performing data analysis processing on data information acquired by the data acquisition module and the sensor module through a cloud computing platform, wherein the data analysis processing comprises determining the equipment state of the numerical control machine tool and storing the equipment state in the database system to form a time sequence event sequence; wherein the equipment state comprises operation, planned shutdown, unplanned shutdown and undefined; calculating the equipment operation efficiency, the productivity efficiency, the product percent of pass and the comprehensive efficiency of the numerical control machine; the comprehensive efficiency is the product of the equipment operation efficiency, the productivity efficiency and the product percent of pass; and sending the data analysis processing result to a digital workshop management and control cloud platform for visual display.
The invention has the beneficial effects that:
according to the data acquisition, analysis and display system and method of the numerical control machine tool, the system comprises a data acquisition module, a sensor module, a data uploading module, a network connection system, a database system, a cloud computing platform and a digital workshop management and control cloud platform; the data acquisition module is in communication connection with the numerical control machine tool through a network cable, a serial port and a communication protocol by using software and is used for acquiring running state data of the numerical control machine tool, a machine tool program, feeding, rotating speed and load and a verification result signal for verifying whether each product is qualified or not; the sensor module is used for acquiring digital signals of current, voltage and power of the numerical control machine tool at any moment in the machining process and off-line signals of products in real time; the data uploading module sends data information acquired by the data acquisition module and the sensor module to the database system and the cloud computing platform by using the network connection system; the database system is used for storing the data information acquired by the data acquisition module and the sensor module; the cloud computing platform is used for carrying out data analysis processing according to the data information acquired by the data acquisition module and the sensor module, determining the equipment state of the numerical control machine tool, and storing the equipment state in the database system to form a time sequence event sequence; wherein the equipment state comprises operation, planned shutdown, unplanned shutdown and undefined; calculating the equipment operation efficiency, the productivity efficiency, the product percent of pass and the comprehensive efficiency of the numerical control machine; the comprehensive efficiency is the product of the equipment operation efficiency, the productivity efficiency and the product percent of pass; and sending the data analysis processing result to a digital workshop management and control cloud platform for visual display. The method and the device realize key functions of networked management and control of workshop equipment, real-time monitoring of the running state of the equipment, statistics of utilization rate, early warning and the like, and achieve the effects of improving comprehensive efficiency of key production equipment and improving management level of the workshop equipment.
Drawings
Fig. 1 is a schematic structural view of a data acquisition, analysis and display system of a numerically-controlled machine tool according to a first embodiment of the present invention;
fig. 2 is a schematic structural diagram of a network connection system according to a first embodiment of the present invention;
FIG. 3 is a schematic structural diagram of a sensor module according to a first embodiment of the invention;
fig. 4 is a flowchart illustrating a data acquisition, analysis and display method of a numerically controlled machine tool according to a second embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail with reference to the following detailed description and accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
The first embodiment is as follows:
the present embodiment provides a data acquisition, analysis and display system of a numerical control machine tool, please refer to fig. 1-3, which includes a data acquisition module 10, a sensor module 20, a data upload module 30, a network connection system 40, a database system 50, a cloud computing platform 60 and a digital workshop management and control cloud platform 70;
the data acquisition module 10 is in communication connection with the numerical control machine tool through a network cable, a serial port and a communication protocol by using software, and is used for acquiring running state data of the numerical control machine tool, a machine tool program, feeding, rotating speed and load and a check result signal for checking whether each product is qualified or not;
the sensor module 20 is used for acquiring digital signals of current, voltage and power of the numerical control machine tool at any time in the machining process and product off-line signals in real time;
the data uploading module 30 transmits the data information acquired by the data acquisition module 10 and the sensor module 20 to the database system 50 and the cloud computing platform 60 by using the network connection system 40;
the database system 50 is used for storing data information acquired by the data acquisition module 10 and the sensor module 20;
the cloud computing platform 60 is configured to perform data analysis processing according to the data information acquired by the data acquisition module 10 and the sensor module 20, including determining an equipment state of the numerical control machine, and storing the data information in the database system 50 to form a time sequence event sequence; wherein the equipment state comprises operation, planned shutdown, unplanned shutdown and undefined; calculating the equipment operation efficiency, the productivity efficiency, the product percent of pass and the comprehensive efficiency of the numerical control machine; the comprehensive efficiency is the product of the equipment operation efficiency, the productivity efficiency and the product percent of pass; and sending the data analysis processing result to the digital workshop management and control cloud platform 70 for visual display.
The data uploading module 30 utilizes a browser-based software programming tool node red, receives data information of the data acquisition module 10 by using an Opc ua module inside the node red, converts the data into a json format by writing a program, and finally uploads the data to the cloud computing platform 60 by using mqtt.
The network connection system 40 comprises a sim card 41 for providing network data flow, an industrial router 42, a miniature industrial personal computer 43 and a signal enhancement antenna 44, and data acquisition and communication among devices are realized through connection among components.
The sensor module 20 comprises a mutual inductor 21, a multimeter 22 and an infrared sensor 23 to collect digital signals of current, voltage and power of the data machine tool in the machining process at any moment and off-line signals of products in real time.
The cloud computing platform 60 uses the airy cloud as a basic platform, performs data analysis and processing after receiving the data uploaded by the data uploading module 30, and sends a processing result to the database system 50 for time sequence storage and visual display of the digital workshop management and control cloud platform 70.
The cloud computing platform 60 calculates the specific routes of the device operation efficiency, the capacity efficiency, the product percent of pass and the comprehensive efficiency, including:
the production time minus the scheduled downtime, such as noon break, off duty, etc., results in the load run time. The load run time minus unplanned downtime, such as a failed shutdown, etc., yields the net production time. The percentage of net production time to load run time is the plant operating efficiency. The calculation formula is as follows:
equipment operating efficiency is net production time/load operating time 100%;
load run time-production time-planned downtime;
net production time-load run time-unplanned downtime;
the cloud computing platform 60 defines the device states as four, running, planned shutdown, unplanned shutdown, and undefined. In order to adapt to different running conditions of the field equipment, an event trigger mechanism is adopted to collect the equipment state. The user can define the event triggering the device state change and configure the triggering event and the device state association triggered by the event. Each event triggers the data acquisition module 10 to report an event code to the cloud computing platform 60, and the cloud computing platform 60 records the event to the time sequence database of the database system 50. This forms a time series of events for a particular device in the time series database. When the operation efficiency of the equipment in a certain time interval is calculated, the time sequence event sequence of the time interval is found out and converted into the corresponding equipment operation state, and then the calculation can be carried out.
For example, a shutdown event may be determined to occur when the machine program is interrupted, or the feed is interrupted, or the speed is 0, or the load is 0; specifically, whether the event is scheduled shutdown or unscheduled shutdown is judged according to preset scheduled shutdown time. Determining a planned shutdown event when at noon break (e.g., 12:00-14:00 noon), or during off-hours (e.g., 20: 00-08: 00 days of the day); and if the shutdown is carried out in the rest time period, judging that the shutdown belongs to the unplanned shutdown.
The cloud computing platform 60 may perform computing in a product count manner. The user first sets the ideal capacity of the equipment, i.e. the capacity per unit time under the ideal state. The sensor module 20 obtains the offline signal of each product, for example, an infrared sensor 23 is correspondingly arranged at the last station of the production line for monitoring the offline product, and when a certain product is offline from the station, the product can be sensed to be offline by infrared. And reporting the cloud computing platform and storing the cloud computing platform into a time sequence database. The capacity efficiency is calculated based on the operating efficiency of the equipment, so calculating the capacity efficiency in a certain time period requires first obtaining the net production time in the time period. I.e., subtracting the planned and unplanned downtime within the time period. The net production time is then multiplied by the ideal capacity to obtain the ideal yield. The percentage of the actual yield to the ideal yield in the time period counted from the time sequence database is the productivity efficiency. The formula is as follows:
capacity efficiency is actual output/ideal output net production time is 100%;
the percentage of the number of qualified products produced in a certain time period to the total number of products is the product percent of pass in the time period. The data acquisition module 10 establishes communication connection with the inspection platform of the numerical control machine tool, when the inspection platform performs quality inspection on the produced products, the data acquisition module acquires the inspection result, and reports the products qualified in quality inspection to the cloud computing platform 60, so that the qualification rate can be calculated.
The yield is the qualified product quantity/product total number 100%;
in summary, the overall efficiency (OEE) of the equipment in a specific time period is equal to the product of three percentage numbers of the operating efficiency, the productivity efficiency and the qualification rate of the equipment in the time period. The formula is as follows:
the integrated efficiency is the operating efficiency and the productivity efficiency is 100 percent;
the database system 50 uses an infiluxdb time series database, the time series data includes three important parts, namely a main part, a time point, and a measurement value, the data includes a machine tool running state, a machine tool yield, and an energy consumption condition, and the time series data is connected into a line from an observation value isolated in a time dimension, so as to reveal a state change of the machine tool.
The digital workshop management and control cloud platform 70 is a cloud management and control system specially developed for digital workshop management and control, and is used for accessing the analysis processing result of the cloud computing platform 60 into the platform, visually displaying, editing data display effect, displaying, monitoring, alarming and the like on the state, parameters, basic information and other information of the numerical control machine tool.
Optionally, the qualification rate of parts processed by the machine tool is predicted by using the BP neural network, when the parts are produced in a large scale, parts with defect risks are selected by using a production line, manual secondary detection is carried out, the qualification rate of the parts is ensured by using big data analysis, and meanwhile, the labor cost is saved. And the defects of the machine tool parts can be complied with and found through the input of the defect parts of the parts, the simulation preproduction of a processing scheme, the pre-optimization of parameters, the pre-estimation of a production result and the quick and multi-information transmission among working procedures are realized.
The data acquisition, analysis and display system of the numerical control machine tool provided by the embodiment comprises a data acquisition module, a sensor module, a data uploading module, a network connection system, a database system, a cloud computing platform and a digital workshop management and control cloud platform; the data acquisition module is in communication connection with the numerical control machine tool through a network cable, a serial port and a communication protocol by using software and is used for acquiring running state data of the numerical control machine tool, a machine tool program, feeding, rotating speed and load and a verification result signal for verifying whether each product is qualified or not; the sensor module is used for acquiring digital signals of current, voltage and power of the numerical control machine tool at any moment in the machining process and off-line signals of products in real time; the data uploading module sends data information acquired by the data acquisition module and the sensor module to the database system and the cloud computing platform by using the network connection system; the database system is used for storing the data information acquired by the data acquisition module and the sensor module; the cloud computing platform is used for carrying out data analysis processing according to the data information acquired by the data acquisition module and the sensor module, determining the equipment state of the numerical control machine tool, and storing the equipment state in the database system to form a time sequence event sequence; wherein the equipment state comprises operation, planned shutdown, unplanned shutdown and undefined; calculating the equipment operation efficiency, the productivity efficiency, the product percent of pass and the comprehensive efficiency of the numerical control machine; the comprehensive efficiency is the product of the equipment operation efficiency, the productivity efficiency and the product percent of pass; and sending the data analysis processing result to a digital workshop management and control cloud platform for visual display. The method and the device realize key functions of networked management and control of workshop equipment, real-time monitoring of the running state of the equipment, statistics of utilization rate, early warning and the like, and achieve the effects of improving comprehensive efficiency of key production equipment and improving management level of the workshop equipment.
Example two:
in this embodiment, based on the data acquisition, analysis and display system of the numerical control machine tool provided in the above embodiment, a corresponding data acquisition, analysis and display method for the numerical control machine tool is provided, please refer to fig. 4, and the method includes:
s401, collecting running state data of the numerical control machine tool, a machine tool program, feeding, rotating speed and load and a verification result signal for verifying whether each product is qualified or not through a data collection module;
s402, collecting digital signals of current, voltage and power of the numerical control machine tool at any time in the machining process and product off-line signals in real time through a sensor module;
s403, sending data information acquired by the data acquisition module and the sensor module to a database system and a cloud computing platform;
s404, storing data information acquired by the data acquisition module and the sensor module through a database system;
s405, performing data analysis processing on data information acquired by the data acquisition module and the sensor module through the cloud computing platform; determining the equipment state of the numerical control machine tool, storing the equipment state in the database system, and forming a time sequence event sequence; wherein the equipment state comprises operation, planned shutdown, unplanned shutdown and undefined; calculating the equipment operation efficiency, the productivity efficiency, the product percent of pass and the comprehensive efficiency of the numerical control machine; the comprehensive efficiency is the product of the equipment operation efficiency, the productivity efficiency and the product percent of pass;
and S406, sending the data analysis processing result to a digital workshop management and control cloud platform for visual display.
It will be apparent to those skilled in the art that the modules or steps of the invention described above may be implemented in a general purpose computing device, they may be centralized on a single computing device or distributed across a network of computing devices, and optionally they may be implemented in program code executable by a computing device, such that they may be stored on a computer storage medium (ROM/RAM, magnetic disks, optical disks) and executed by a computing device, and in some cases, the steps shown or described may be performed in an order different than that described herein, or they may be separately fabricated into individual integrated circuit modules, or multiple ones of them may be fabricated into a single integrated circuit module. Thus, the present invention is not limited to any specific combination of hardware and software.
The foregoing is a more detailed description of the present invention that is presented in conjunction with specific embodiments, and the practice of the invention is not to be considered limited to those descriptions. For those skilled in the art to which the invention pertains, several simple deductions or substitutions can be made without departing from the spirit of the invention, and all shall be considered as belonging to the protection scope of the invention.
Claims (5)
1. A data acquisition, analysis and display system of a numerical control machine tool is characterized by comprising a data acquisition module, a sensor module, a data uploading module, a network connection system, a database system, a cloud computing platform and a digital workshop management and control cloud platform;
the data acquisition module is in communication connection with the numerical control machine tool through a network cable, a serial port and a communication protocol by using software and is used for acquiring running state data of the numerical control machine tool, a machine tool program, feeding, rotating speed and load and a verification result signal for verifying whether each product is qualified or not;
the sensor module is used for acquiring digital signals of current, voltage and power of the numerical control machine tool at any moment in the machining process and off-line signals of products in real time;
the data uploading module sends data information acquired by the data acquisition module and the sensor module to the database system and the cloud computing platform by using the network connection system;
the database system is used for storing the data information acquired by the data acquisition module and the sensor module;
the cloud computing platform is used for carrying out data analysis processing according to the data information acquired by the data acquisition module and the sensor module, determining the equipment state of the numerical control machine tool, and storing the equipment state in the database system to form a time sequence event sequence; wherein the equipment state comprises operation, planned shutdown, unplanned shutdown and undefined; calculating the equipment operation efficiency, the productivity efficiency, the product percent of pass and the comprehensive efficiency of the numerical control machine; the comprehensive efficiency is the product of the equipment operation efficiency, the productivity efficiency and the product percent of pass; and sending the data analysis processing result to a digital workshop management and control cloud platform for visual display.
2. The data acquisition, analysis and display system of the numerical control machine tool according to claim 1, wherein the data uploading module uses a browser-based software programming tool node red, receives data information of the data acquisition module by using an Opc ua module inside the node red, converts the data into a json format by a program, and finally uploads the data to the cloud computing platform by using mqtt.
3. The data acquisition, analysis and display system of a numerical control machine according to claim 1, wherein the network connection system comprises a sim card providing network data traffic, an industrial router, a micro industrial personal computer, a signal enhancing antenna, data acquisition by connection between components, and communication between devices.
4. The data acquisition, analysis and display system of a numerical control machine according to claim 1, wherein the sensor module comprises a mutual inductor, a multimeter and an infrared sensor to acquire digital signals of current, voltage and power of the machine tool and off-line signals of products at any moment in the machining process in real time.
5. A data acquisition, analysis and display method based on the data acquisition, analysis and display system of the numerical control machine tool according to any one of claims 1 to 4, characterized by comprising the following steps:
collecting running state data of the numerical control machine tool, a machine tool program, feeding, rotating speed and load and a verification result signal for verifying whether each product is qualified or not through a data acquisition module;
collecting digital signals of current, voltage and power of the numerical control machine tool at any moment in the machining process and product off-line signals in real time through a sensor module;
sending data information acquired by the data acquisition module and the sensor module to a database system and a cloud computing platform;
storing data information acquired by the data acquisition module and the sensor module through a database system;
performing data analysis processing on data information acquired by the data acquisition module and the sensor module through a cloud computing platform, wherein the data analysis processing comprises determining the equipment state of the numerical control machine tool and storing the equipment state in the database system to form a time sequence event sequence; wherein the equipment state comprises operation, planned shutdown, unplanned shutdown and undefined; calculating the equipment operation efficiency, the productivity efficiency, the product percent of pass and the comprehensive efficiency of the numerical control machine; the comprehensive efficiency is the product of the equipment operation efficiency, the productivity efficiency and the product percent of pass; and sending the data analysis processing result to a digital workshop management and control cloud platform for visual display.
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