CN112504331A - Performance data acquisition and analysis device for plastic forming machine tool - Google Patents
Performance data acquisition and analysis device for plastic forming machine tool Download PDFInfo
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- CN112504331A CN112504331A CN202010210255.6A CN202010210255A CN112504331A CN 112504331 A CN112504331 A CN 112504331A CN 202010210255 A CN202010210255 A CN 202010210255A CN 112504331 A CN112504331 A CN 112504331A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
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- G—PHYSICS
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- G08C—TRANSMISSION SYSTEMS FOR MEASURED VALUES, CONTROL OR SIMILAR SIGNALS
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Abstract
The invention discloses a performance data acquisition and analysis device of a plastic forming machine tool, which analyzes and evaluates the performance and the running state of the plastic forming machine tool through a sensor acquisition machine screw press, a hot die forging press, a (free forging and die forging) hydraulic press and other plastic forming machine tool performance data. Installing sensors such as hitting force, gas-liquid pressure, slide block displacement, equipment vibration and the like on the machine tool, and acquiring data related to the performance of the machine tool; transmitting and storing data; analyzing according to a certain principle and algorithm; and evaluating the performance and the running state of the equipment. The invention is used for researching the process application performance of the plastic forming machine tool, guiding the optimization of control parameters, judging the precision and the performance state of the plastic forming machine tool, and is convenient to maintain.
Description
Technical Field
The invention relates to the collection, transmission, storage and analysis evaluation of performance data of a plastic forming machine tool. The invention can realize the measurement, analysis, monitoring and alarm of the performance, precision retentivity, reliability and running state of the plastic forming machine tool; by adopting the device, the performance curve and the analysis result are obtained, so that the process personnel can reasonably exert the equipment performance, the maintenance personnel can conveniently know the equipment state according to the performance evaluation result, and the equipment manufacturer can improve the manufacturing level.
Background
The plastic forming machine tool is a machine tool device for metal plastic forming, mainly comprises a (die forging and free forging) hydraulic machine, a screw press, a crank press, a ring rolling machine, a spinning machine and the like, and is applied to die forging and free forging production in the fields of automobiles, trains, aviation, aerospace, war industry, ships and the like.
The basic feature of a plastic forming machine is to convert energy into a formed object to form a cold or hot metal or nonmetal into a desired shape and property. In the plastic forming process, the inherent properties and the shape of the material are changed, so the control of the parameters of the plastic forming process: such as the forming speed of the material, temperature change, forming resistance, energy conversion rate and the like, has important significance. Unlike cutting, which focuses primarily on the dimensional accuracy of the workpiece, plastic forming equipment focuses more on the combination of process and equipment performance, which requires, firstly, the acquisition of equipment process parameter data and, secondly, the analysis and evaluation of these performance data.
The performance data acquisition and analysis are carried out on the plastic forming equipment, and the significance of the method mainly comprises the following points: 1. evaluating the technological capability of equipment and improving the technological control process; 2. the performance of different equipment is compared, so that the equipment is better matched with the process, the equipment design is improved, and the performance characteristics are exerted; 3. and guiding a production enterprise to correctly select equipment, and better using and maintaining the equipment.
With the technical progress, at present, a control system of plastic forming equipment generally has the functions of measurement, data storage, fault analysis, display, alarm and the like, and with the development of sensor and computer technology, the technologies of remote diagnosis, data transmission and the like are also applied to the equipment control system.
The control system of the present advanced plastic forming equipment has the following functions:
1) the method comprises the steps of slider displacement detection, mold identification, material detection and real-time product thickness monitoring.
2) The servo and electro-hydraulic proportional technology is adopted, digital display and proportional control can be realized, stepless speed regulation is realized, the running speed and position of the sliding block can be controlled at will, and the balance of the sliding block can be freely adjusted.
3) The hydraulic system is provided with a pressure detection point, and the pressure sensor detects point pressure to judge faults. The control system is provided with an action button; a function changeover switch; a motor start-stop button; alarm, monitoring display, touch screen, etc. of each part; ethernet communication; and (3) screen display information: and storing the working information and the fault information of the press machine and the parameters of the die.
4) Remote data transmission and remote operation and maintenance, and diagnosis system.
5) Data acquisition and analysis;
collecting and transmitting operation data between a press control PC and a user PC, and analyzing the data;
6) connections between systems
The control system provides an automatic interface and can program an automatic continuous mode by matching with an automatic feeding system and an automatic discharging system. And performing data exchange by using the PROFINET, reserving a PROFINET interface, and performing data monitoring and modification on the equipment through the master control system. The master control system and the automatic system have integration and safety relations.
7) And (4) total control: alarming; a scanning system; a photovoltaic protection system; safety interlocking;
nevertheless, the control system of the apparatus has difficulty performing the functions of the device described herein for the following reasons:
1) the main function of the equipment control system is equipment operation control, and the key point of the function configuration is to ensure the sensitivity and reliability of equipment control. High sampling speed and data processing speed are required for performance data acquisition and analysis, and a PLC (programmable logic controller) is mostly adopted for a control system of the plastic forming equipment, so that the operation, storage and analysis capabilities are obviously insufficient.
2) The equipment control system generally collects data mainly based on switching value, and data collection contents related to the internal performance of the equipment, such as displacement, impact force, gas-liquid pressure, current and the like, are mainly used for control and fault analysis and do not have the functions of data analysis and performance evaluation.
3) The design and configuration of the device are based on the characteristic that the plastic forming equipment focuses on process control and data acquisition and traceability of the product manufacturing process, and the specially designed device suitable for performance data acquisition and analysis of the plastic forming equipment can realize performance analysis and evaluation of the equipment.
4) The device is characterized in that the data acquisition, analysis and evaluation are completely independent of an equipment control system, and the device has the functions of displaying and receiving the equipment control system data, displaying the analysis result and transmitting the data to the upper level.
Disclosure of Invention
The invention aims to provide a device which can collect performance data of a plastic forming machine tool, can evaluate the running state, the precision retentivity and the reliability of the machine tool and predict the fault of the machine tool by analyzing the data, and the device comprises functional modules of data collection, data storage, data analysis and evaluation, display, data transmission and the like. The device does not participate in the control of the machine tool, but obtains the relevant information of the machine tool performance through a sensor system independently attached to the machine tool or sensor data sent by a machine tool control system. Analyzing and evaluating the data to determine the application performance, working state, maintenance state and the like of the machine tool process; the device is independent of a machine tool control system, and only collects, analyzes and evaluates data related to machine tool performance without participating in machine tool control; the device collects sensor data related to the machine tool performance, filters and stores the data, and can evaluate the equipment performance according to an algorithm and a judgment criterion; the device is different from the existing functions of a machine tool control system in that the function of the device is focused on data acquisition and data analysis and evaluation, so that the system designed and configured by the device has high acquisition frequency and high-speed data transmission and processing capacity; the device can simultaneously display a plurality of paths of data curves in an overlapping manner according to design; the device can automatically analyze and process data aiming at different equipment according to a built-in algorithm to generate an evaluation result; the device comprises parts such as data acquisition, data storage, data analysis and evaluation, display, data transmission and the like; the device can also integrate and dispersedly arrange part of sensor data on different parts of a machine tool in a sub-station mode, such as a hydraulic station far away from a main machine, and transmit the sensor data to a main station at a high speed by a 5G technology, so that data transmission lines are reduced.
In order to achieve the purpose, the invention provides the following technical scheme:
the whole structure of the device is shown in figure 1 (figure 1)
The device of the invention has an overall system frame as shown in figure 2 (figure 2):
the functions of each part of the module are as follows:
data acquisition:
for different types of plastic forming equipment, various sensor data capable of describing the performance of the equipment are respectively collected.
Data (and sensor type, location) to be collected according to different equipment performance characteristics:
hydraulic press data acquisition (and sensor type, position) (figure 3)
Crank press (hot die forging press, punching machine and trimming press) data (and sensor type, position) (figure 4)
Screw press (Clutch type, electric screw press) data acquisition (and sensor type, position) (fig. 5)
Data storage:
the arrangement of the device is adapted to transmit data obtained from the sensor at high speed and to ensure that it is not distorted.
The storage signal has a memory with large capacity, which ensures that various data collected by the equipment in long-time working can be stored, and the data can be collected by a specially arranged sensor and also can be stored in the data transmitted by the control system.
Data analysis and evaluation:
and aiming at different equipment, a special algorithm and a rule are adopted to analyze the obtained performance data, so that the performance, reliability, precision retentivity and running state of the equipment can be evaluated.
Display and data transmission:
with a high resolution display, the data and the curves formed by the data can be displayed clearly.
The system has a data external transmission function, and can transmit data to places required by an upper level, such as an MES system.
The device of the invention can not only store and call the performance data of the equipment, but also analyze the data by using special software except the configuration of hardware.
Compared with the existing equipment control system and the performance data acquisition means thereof, the invention has the following beneficial effects: by adopting the device of the invention, the performance data of the equipment can be recorded at high speed and large capacity: the main task of the equipment control system is to realize sensitive and accurate control of the equipment, and high-speed and high-capacity data acquisition can cause the design of the control system to be complex and reduce the functions. Because this device is independent of control system, can be on the basis that does not influence control function, dispose abundanter sensor and large capacity memory, promote the ability of gathering, saving different data greatly, also promoted the data acquisition flexibility.
The professional analysis software matched with the device has stronger performance data operation and analysis capability.
Drawings
Fig. 1 shows the overall structure of the device.
FIG. 2 is a device architecture framework.
Figure 3 shows the data (and sensor type, location) collected by the hydraulic machine.
Fig. 4 shows data (and sensor types and positions) collected by a crank press (hot die forging press, punch press, and trimming press).
Fig. 5 shows data (and sensor type, position) collected by a screw press (clutch, electric screw).
FIG. 6 shows the main interface of the device.
FIG. 7 is a process parameter display interface.
FIG. 8 is a data collection and display interface.
Fig. 9 is a device information parameter display interface.
FIG. 10 is a performance curve display interface.
Fig. 11 is an abnormal data analysis display interface.
Fig. 12 is a device performance evaluation display interface.
Detailed Description
The technical solution in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In fig. 1, the device is composed of various sensors (a), an input interface (B), an output interface (C), a display (D), a memory (E), and an analysis device (F), data collected by the sensors (a) are stored in the memory (E), and are called and analyzed as needed, and the analysis result can be displayed on the display (D) or uploaded to the MES system and the superior data management system (G) through the output interface (C). The memory (E) is characterized by a large volume, and can store sensor data of high resolution for at least one week, and the analysis computer must also have a high calculation speed.
In fig. 2, the architecture of the whole set of apparatus is described, which is composed of a data acquisition part (a), a data storage part (b), a data analysis part (c), a display part (d) and a data output part (e). The data acquisition part (A) acquires corresponding performance data aiming at various sensors specially configured for different devices; the data storage part (B) is responsible for storing the acquired data, and the data is also allowed to be called externally; the data analysis part (C) reads data from the data storage part (B) according to a certain strategy to analyze; and (4) displaying the analysis result on a display or uploading the analysis result to an upper layer data management system such as an MES system.
Fig. 3 is a schematic diagram of the hydraulic machine collecting data (and sensor type, location). According to the working performance characteristics of the hydraulic machine, the basic sensors are configured to be that a high-precision displacement sensor (1) is respectively arranged at four corners of a sliding block; each loading oil cylinder on the slide block is provided with a pressure sensor (2); each main loading oil pump motor is provided with a current sensor (3); the equipment is provided with a total current sensor (4), a total voltage sensor (5) and a total power sensor (6); a vibration sensor (7) is arranged on the machine body and the key pipeline;
fig. 4 is a schematic diagram of data (and sensor types and positions) collected by a crank press (a hot die forging press, a punch press and a trimming press). The hot die forging press (trimming press and punch) adopts a crank-link mechanism to transfer force, and according to the working characteristics and performance requirements, the basic sensors are configured in such a way that four corners of a slide block are respectively provided with a high-precision displacement sensor (1); each main loading motor is provided with a current sensor (3); the equipment is provided with a total current sensor (4), a total voltage sensor (5) and a total power sensor (6); a vibration sensor (7) is arranged on the machine body and the key pipeline; a precise air pressure sensor (8) is arranged on a clutch (brake) of the press machine or an air storage tank of the clutch (brake); a hitting force sensor (9) is arranged on the upright post of the machine body;
FIG. 5 is a schematic diagram of data acquisition of a clutch screw press and an electric screw press. According to the working performance characteristics of the screw press, the basic sensors are configured to be that a high-precision displacement sensor (1) is respectively arranged at four corners of a slide block; each main motor of the electric screw press is provided with a current sensor (3); the equipment is provided with a total current sensor (4), a total voltage sensor (5) and a total power sensor (6); a vibration sensor (7) is arranged on the machine body and the key pipeline; a hitting force sensor (9) is arranged on the upright post of the machine body; a clutch oil cylinder pressure sensor (10) needs to be installed on the clutch type screw press;
FIG. 6 is a main display page of the display of the present device. The main display page shows the main functions of the data acquisition and analysis device, including the process parameters set by the equipment; performance curves (including independent curves and superimposed curves); equipment information (including equipment main parameters, data extraction (screening and extracting required data), abnormal data analysis, equipment performance evaluation and the like.
Fig. 7 is a process parameter interface showing process parameter setting data of products currently and previously produced stored in the device, and data of related products can be inquired every shift.
Fig. 8 is a data acquisition and display interface showing the data acquisition location and the actual data acquired by each sensor.
FIG. 9 shows device information parameters, including product parameters (mainly describing the start time, end time, etc. of a certain batch of products, the production volume, etc.); a device parameter; an environmental parameter;
FIG. 10 is a performance curve interface that may display a single performance data curve, an overlapping performance data curve, for use in determining the operational condition and status of the device.
Fig. 11 is an abnormal data analysis interface, and after the data analysis module analyzes the collected data, the abnormal data can be called out and the reason for the abnormality is displayed.
Fig. 12 is an apparatus performance evaluation interface. The equipment precision retentivity and the working stability can be determined after the data of the working condition and the long-term running condition of the working condition are analyzed, the equipment state is predicted through algorithm analysis, and the equipment performance is evaluated.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.
Furthermore, it should be understood that although the present description refers to embodiments, not every embodiment may contain only a single embodiment, and such description is for clarity only, and those skilled in the art should integrate the description, and the embodiments may be combined as appropriate to form other embodiments understood by those skilled in the art.
The above-mentioned embodiments are only preferred embodiments of the present invention, and all changes made by the claims of the present invention should fall within the scope of the present invention.
Claims (8)
1. A data acquisition and analysis device independent of a machine tool control system does not participate in machine tool control, but obtains machine tool performance related information through a sensor system independently attached to a machine tool or sensor data sent by the machine tool control system. The data are analyzed and evaluated, and the application performance, the working state, the maintenance state and the like of the machine tool process can be determined.
2. A data collection and analysis device according to claim 1, wherein the device is independent of the machine tool control system and collects and analyzes only data relating to machine tool performance without participating in machine tool control.
3. A data acquisition and analysis device according to claim 1, characterized in that it acquires sensor data related to the machine tool performance, filters and stores these data and makes it possible to evaluate the performance of the equipment according to algorithms and judgment criteria.
4. A measuring and evaluation device according to claim 1, characterized in that the device differs from the existing functions of the machine tool control system in that its functions are dedicated to data acquisition and analysis and evaluation of data, whereby the system is designed and configured to have a high acquisition frequency, high speed transmission and processing capacity of data.
5. The data collection and analysis device of claim 1, wherein the device is designed to simultaneously display multiple data curves in superposition.
6. The data collection and analysis device of claim 1, wherein the device can automatically analyze and process data according to a built-in algorithm and aiming at different devices to generate an evaluation result.
7. The data collection and analysis device of claim 1, wherein the device is comprised of data collection, data storage, data analysis and evaluation, display, and data transmission.
8. The data collection and analysis device of claim 1, wherein the device can integrate and distribute part of the sensor data in a sub-station manner to different parts of the machine tool, such as a hydraulic station far away from the main machine, and transmit the sensor data to the main station at high speed by using 5G technology, thereby reducing data transmission lines.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN118247079A (en) * | 2024-05-23 | 2024-06-25 | 山西永鑫生重工股份有限公司 | Forging forming system of aluminum alloy forging |
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