CN112305992A - Unattended processing method of numerical control processing equipment - Google Patents
Unattended processing method of numerical control processing equipment Download PDFInfo
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- CN112305992A CN112305992A CN202011150160.6A CN202011150160A CN112305992A CN 112305992 A CN112305992 A CN 112305992A CN 202011150160 A CN202011150160 A CN 202011150160A CN 112305992 A CN112305992 A CN 112305992A
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- 238000012545 processing Methods 0.000 title claims abstract description 52
- 238000003672 processing method Methods 0.000 title claims abstract description 9
- 238000003754 machining Methods 0.000 claims abstract description 59
- 238000000034 method Methods 0.000 claims abstract description 17
- 238000012544 monitoring process Methods 0.000 claims abstract description 17
- 230000008569 process Effects 0.000 claims abstract description 10
- 230000002159 abnormal effect Effects 0.000 claims abstract description 6
- 238000001514 detection method Methods 0.000 claims description 18
- 239000000523 sample Substances 0.000 claims description 4
- 238000005299 abrasion Methods 0.000 claims description 3
- 238000009825 accumulation Methods 0.000 claims 2
- 238000004519 manufacturing process Methods 0.000 abstract description 19
- 238000010924 continuous production Methods 0.000 abstract description 4
- 238000005520 cutting process Methods 0.000 abstract description 4
- 238000011161 development Methods 0.000 description 3
- 238000010276 construction Methods 0.000 description 2
- 238000007599 discharging Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 230000005856 abnormality Effects 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000000284 extract Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 230000004630 mental health Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
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- 238000006467 substitution reaction Methods 0.000 description 1
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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
- G05B19/406—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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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The invention provides an unattended processing method of numerical control processing equipment, wherein before unattended processing, all parts are installed in place, a cutter of a machine tool is prepared, a numerical control program is called, and continuous production is started; monitoring the load condition in real time in the production process, and stopping the machine when the cutting load of a certain point of the part is greater than a threshold value; before the hole of the part is machined, the length of a hole machining cutter is measured, and the machine is stopped when the deviation between the cutter length and the cutter length recorded by a system is greater than a set value; after part of the set part machining content is finished, measuring the machining size concerned in the part by using a measuring head in the machine tool, stopping the machine if the size exceeds a set value, and compensating a cutter if the size is within a tolerance range but deviates from a median value so as to ensure the consistency of the machining size; by monitoring the machining process, the process safety and the quality safety are ensured, and if the data monitoring of the machining process is abnormal, the machining program normally runs until the machining is finished. The invention is improved on the basis of the existing numerical control equipment, and realizes unattended processing of the numerical control equipment.
Description
Technical Field
The invention relates to the technical field of unmanned numerical control machining, in particular to an unattended machining method of numerical control machining equipment.
Background
With the rapid development of intelligent manufacturing, the numerical control machine tool is developed to high speed, high efficiency and high precision, but the price of an intelligent device or an intelligent manufacturing production line is often high, and for most enterprises, the investment of the device or the production line is difficult to support unless the intelligent device or the intelligent manufacturing production line is used for processing a specific product on a specific occasion.
Many processing units are limited to the problems of low labor cost, small product batch and multiple varieties, and the start-up rate and the effective running time of numerical control equipment are often insufficient. On the premise that manpower and material resources are not increased, prolonging the effective running time of the numerical control equipment is an optimal method for improving productivity. In order to improve the utilization rate of numerical control equipment, two or more shifts are more or less executed. Compared with the normal shift, the number of the persons in multiple shifts is large, the physical and mental health of the staff is extremely unfavorable, and the labor enthusiasm and the creativity of the staff are difficult to activate. The intelligent manufacturing is the development direction of numerous enterprises (workshops), but the introduction of intelligent manufacturing equipment or the construction price of a production line is very expensive, and most enterprises are difficult to bear.
The unattended continuous processing of the existing numerical control equipment is realized, a multi-shift system can be cancelled with small investment, the labor intensity of personnel is reduced, the effective operation time of the numerical control equipment is improved, and a foundation is laid for intelligent workshop construction.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides an unattended processing method of numerical control processing equipment, which comprises the following steps:
before unattended processing, all parts are installed in place, a cutter of a machine tool is prepared, a numerical control program is called, and continuous production is started; monitoring the load condition in real time by load monitoring equipment in the production process, and stopping a machining program when the cutting load of a certain point of a part is greater than a threshold value, and stopping the equipment; before the hole of the part is machined, measuring the length of a hole machining cutter, and stopping a machining program and stopping equipment when the deviation between the cutter length and the cutter length recorded by a system is greater than a preset value; after part of the set part machining content is finished, measuring the machining size concerned in the part by using a measuring head in the machine tool, if the size exceeds a set value, stopping a machining program and stopping the equipment, and if the size is within a tolerance range and deviates from a median value, compensating a cutter to ensure the consistency of the machining size; the process safety and the quality safety are ensured by monitoring the machining process, and if the data monitoring of the machining process is abnormal, the machining program normally runs until the machining is finished.
Advantageous effects
The invention is improved on the basis of the existing numerical control equipment, unattended processing of the numerical control equipment is realized, the effective operation time of the equipment is prolonged by 2-3 times, the labor intensity of personnel is reduced, and meanwhile, the production efficiency and the product quality are improved. The unattended processing mode of the numerical control processing equipment is an intermediate stage of development to intelligent manufacturing in the current state, fundamentally solves the problem that the processing time of the equipment is not enough, and has popularization and application values.
Additional aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
Drawings
The above and/or additional aspects and advantages of the present invention will become apparent and readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
FIG. 1: flow chart of the invention.
Detailed Description
In general, when a numerical control device is machined, an operator is beside the device and mainly responsible for detecting the size of a part, processing an abnormality, confirming a coordinate system, maintaining a cutter, shutting down the device and the like in real time. For unattended operation, the problems of relevant operation and safe production need to be solved through technical means, namely, the unattended operation processing mode needs to solve the problems of good production continuity and processing process safety.
The production continuity comprises the steps of being capable of being installed at one time to enable the numerical control equipment to have enough processing tasks at night or using automatic equipment to solve the problem of feeding and discharging of workpieces. When the processing contents of partial procedures are more, for example, the processing time of one procedure is more than 8h, the parts do not need to be frequently clamped, and the parts can be clamped by personnel in the middle process; for parts with less processing content in the process and short processing time of single products, corresponding automatic equipment is needed to replace manual work for clamping the parts in the middle process. For a numerical control lathe, a mechanical arm is generally adopted for automatic feeding and discharging, so that continuous production is ensured; the use of flexible manufacturing systems for machining centers is a good solution.
The processing safety comprises equipment safety and quality safety. The continuous processing of the equipment must solve the equipment safety and quality safety in the processing process of the equipment. The equipment is safe, and the equipment is stopped in time after abnormal processing without being attended by people, so that the equipment is not damaged; the quality safety, including not appearing in batches the out-of-tolerance or scrap in the course of working, guarantee the part size is qualified.
In order to realize the unattended processing mode, in the embodiment, aiming at the requirements of the continuity of the production and the safety of the processing process, the unattended processing method of the numerical control processing equipment is provided, and a series of technical means are used for replacing manual judgment to realize the autonomous operation of the processing program, so that the unattended processing mode is realized.
Referring to the flow chart, the implementation steps of the unattended processing mode are as follows:
a. preparing a workpiece: according to the characteristics of the product, corresponding tools are designed, and the product blanks are installed on the processing platform in batches at fixed points.
b. Preparing a cutter: and uniformly managing the machining tools, making tool backup and uniformly managing in an equipment tool magazine.
c. Designing a processing program: and compiling a workpiece machining program.
d. Monitoring the load of the machine tool: the machine tool spindle sensor monitors the spindle load condition in real time, extracts load data and compares the load data with a load set threshold, when the load data exceeds the threshold, the machining abnormity (such as over-cut, interference, cutter collision, cutter breakage and the like) is shown, and the machining program is immediately and automatically terminated and the machine is stopped.
The equipment load monitoring is to collect and display the equipment load in real time. When equipment is abnormally processed, the processing load is increased rapidly and is monitored and controlled in real time, and when the processing load exceeds a normal operation state, the machine tool can be stopped.
e. And (3) detecting the damage of the cutter: when the tool is changed in the machining process, the size of a new tool is detected on line and compared with the nominal size of the tool, when the difference between the detected size of the tool and the nominal size exceeds a set value, the tool is indicated to be damaged, the machining program is immediately stopped, or a new spare tool is replaced, and the machining is continued.
The purpose of tool damage detection is to confirm whether a tool is intact or not through an automatic program before machining, and if the tool has a problem, the program is set to stop a machine tool so as to ensure that the length or the diameter of the tool used for machining is not out of tolerance. The tool damage detection is widely applied to hole machining tools, the length of the hole machining tools is mainly detected, and machining safety is guaranteed.
f. Workpiece online detection: in the machining process, after certain set concerned dimensions are machined, a machine tool online measuring probe is used for online measuring the dimensions of the workpiece, the dimensions are compared with nominal dimensions, when the dimension difference exceeds a set value, machining abnormity (such as cutter damage, tool looseness and the like) is shown, and the machining program is immediately and automatically stopped.
The on-line detection is realized by directly installing equipment on a production line and utilizing a soft measurement technology for real-time detection and real-time feedback. For example, a machine tool is equipped with a probe, and after machining is completed, the probe is used to detect a machined portion, including detection in the depth direction and detection in the diameter direction. When the machining tool is damaged and the depth size or the diameter size of the machined part cannot be machined, the machined size cannot be obtained by measuring the workpiece, and then the equipment alarms and stops. On the other hand, the workpiece online detection can detect the machining size of the part in real time, directly compensate the abrasion of the cutter to a program, and ensure that a machined product is within a size tolerance range.
g. And (3) managing the service life of the cutter: and according to the processing time and the service life of the cutter, when the accumulated processing time of the cutter reaches a service life set value, stopping the processing program and stopping the machine, or replacing a spare cutter to continue processing.
Tool life management refers to the sum of cutting time from the time a tool is put into service to the time the tool is scrapped. The tool life may be calculated based on the actual cutting time of the tool, or may be calculated using the number of products to be machined. In continuous machining, it is necessary to clarify the use state of the tool. When the cutter is damaged, the material of the part is not removed, the rough machining amount is not removed, the finish machining cutter is very unfavorable, and the machine tool collision can be caused, so that the danger is high.
h. Tool wear compensation: according to the online detection data of the workpiece, when the online detection result of the workpiece deviates from the set value, the deviation value is added to the cutter compensation according to a certain proportion, the cutter abrasion and the machining error are compensated, and the machined size of the workpiece is ensured to be close to the theoretical value.
i. And monitoring data in the machining process without abnormity, normally running a machining program until machining is finished, and automatically stopping the equipment and turning off a power supply after the machining finishes a specified task.
The method comprises the steps of monitoring machine tool load data, cutter damage detection data, workpiece online detection data and cutter accumulated service time in a program in a circulating mode in sequence, protecting a machining process, and suspending machining and processing according to a design mode when any monitoring data is abnormal. The mode method is applied to numerical control processing equipment, can completely realize an unattended processing mode, and achieves the purpose of continuous production without rest of the equipment for people to rest.
Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention, and that variations, modifications, substitutions and alterations can be made in the above embodiments by those of ordinary skill in the art without departing from the principle and spirit of the present invention.
Claims (4)
1. An unattended processing method of numerical control processing equipment is characterized in that: the method comprises the following steps:
step 1: preparing a workpiece: designing corresponding tools according to the characteristics of the product, and installing the product blanks on a processing platform in batches at fixed points;
step 2: preparing a cutter: uniformly managing machining tools, making tool backup, and uniformly managing in an equipment tool magazine;
and step 3: designing a processing program: compiling a workpiece processing program;
and 4, step 4: processing according to a processing program, and in the processing process, circularly performing machine tool load monitoring, tool damage detection, workpiece online detection and tool service time accumulation in sequence to protect the processing process;
the machine tool load monitoring means that in the machining process, load conditions are monitored in real time through load monitoring equipment, load data are extracted and compared with a load set threshold value, when the load data exceed the threshold value, machining abnormity is shown, a machining program is automatically stopped, and numerical control machining equipment is stopped;
the tool breakage detection means that when a tool is changed in the machining process, the size of a new tool is detected on line and compared with the nominal size of the tool, when the difference between the detected size of the tool and the nominal size exceeds a set value, the tool breakage condition is indicated, the machining program is automatically stopped, the numerical control machining equipment is stopped, or a new spare tool is replaced, and the machining is continued;
the workpiece online detection means that after certain set attention dimension machining is completed in the machining process, a machine tool online measuring probe is used for measuring the attention dimension of the workpiece online and comparing the attention dimension with a nominal dimension value, when the measured dimension is out of a tolerance range, the machining is abnormal, a machining program is automatically stopped, a numerical control machining device is stopped, and when the measured dimension is in the tolerance range but deviates from a median value, tool abrasion compensation is carried out to ensure the consistency of the machined dimension;
the tool service time accumulation means that when the tool accumulated processing time reaches a service life set value according to the tool processing time and the service life, a processing program is automatically stopped, the numerical control processing equipment is stopped, or a spare tool is replaced to continue processing;
if the machining process is monitored to be abnormal, the machining program normally runs until the machining is finished, and after the machining finishes a specified task, the equipment is automatically stopped and the power supply is turned off.
2. The unattended processing method of the numerical control processing equipment according to claim 1, wherein: the load monitoring equipment is a machine tool spindle sensor and is used for monitoring the spindle load condition in real time.
3. The unattended processing method of the numerical control processing equipment according to claim 1, wherein: the tool breakage detection is used to detect the length of the hole machining tool before hole machining.
4. The unattended processing method of the numerical control processing equipment according to claim 1, wherein: the tool wear compensation means that according to the workpiece online detection data, when the workpiece online detection result deviates from the set value, the deviation value is added into the tool compensation according to a certain proportion, tool wear and machining errors are compensated, and the machining size of the workpiece is ensured to be close to the theoretical value.
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Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113483623A (en) * | 2021-07-19 | 2021-10-08 | 西门子电机(中国)有限公司 | Machine base machining size detection system |
| CN115056037A (en) * | 2022-06-22 | 2022-09-16 | 四川航天长征装备制造有限公司 | Method for improving tool measurement efficiency in numerical control machining process |
| CN115179108A (en) * | 2022-06-22 | 2022-10-14 | 四川航天长征装备制造有限公司 | Tool fool-proofing method in numerical control machining process |
| CN115509177A (en) * | 2022-09-22 | 2022-12-23 | 成都飞机工业（集团）有限责任公司 | Method, device, equipment and medium for monitoring abnormity of part machining process |
| CN116165966A (en) * | 2023-04-21 | 2023-05-26 | 沈阳精锐数控机床有限公司 | Informationized self-adaptive material regulation and control method and system for numerical control machine tool |
| CN117961645A (en) * | 2024-03-29 | 2024-05-03 | 中国矿业大学 | Cutter abrasion soft measurement method for small sample noise data |
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| CN113483623A (en) * | 2021-07-19 | 2021-10-08 | 西门子电机(中国)有限公司 | Machine base machining size detection system |
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| CN115509177A (en) * | 2022-09-22 | 2022-12-23 | 成都飞机工业（集团）有限责任公司 | Method, device, equipment and medium for monitoring abnormity of part machining process |
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| CN116165966A (en) * | 2023-04-21 | 2023-05-26 | 沈阳精锐数控机床有限公司 | Informationized self-adaptive material regulation and control method and system for numerical control machine tool |
| CN117961645A (en) * | 2024-03-29 | 2024-05-03 | 中国矿业大学 | Cutter abrasion soft measurement method for small sample noise data |
| CN117961645B (en) * | 2024-03-29 | 2024-05-28 | 中国矿业大学 | Cutter abrasion soft measurement method for small sample noise data |
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Application publication date: 20210202 |