CN113009885A - Digital mapping system and method for safety state of numerical control system - Google Patents

Digital mapping system and method for safety state of numerical control system Download PDF

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CN113009885A
CN113009885A CN201911323191.4A CN201911323191A CN113009885A CN 113009885 A CN113009885 A CN 113009885A CN 201911323191 A CN201911323191 A CN 201911323191A CN 113009885 A CN113009885 A CN 113009885A
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control system
numerical control
safety state
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model
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尹震宇
马跃
郭锐锋
杨东升
李明时
樊超
陈玄一
高峰
宋丹
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Shenyang Institute of Computing Technology of CAS
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Shenyang Institute of Computing Technology of CAS
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    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00Programme-control systems
    • G05B19/02Programme-control systems electric
    • G05B19/18Numerical 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
    • G05B19/414Structure of the control system, e.g. common controller or multiprocessor systems, interface to servo, programmable interface controller
    • G05B19/4147Structure of the control system, e.g. common controller or multiprocessor systems, interface to servo, programmable interface controller characterised by using a programmable interface controller [PIC]
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/30Nc systems
    • G05B2219/34Director, elements to supervisory
    • G05B2219/34013Servocontroller

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  • Manufacturing & Machinery (AREA)
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  • Numerical Control (AREA)

Abstract

The invention relates to the technical field of digital mapping of the safety state of a numerical control system, in particular to a digital mapping system and a digital mapping method for the safety state of the numerical control system; the invention comprises the following steps: the wireless data transmission device is communicated with the digital mapping device of the safety state of the numerical control system in a wireless or wired mode, acquires the safety state data of the physical entity equipment through the sensor and sends the safety state data to the digital mapping device of the safety state of the numerical control system; the digital mapping device of the numerical control system safety state receives the safety state data sent by the wireless data transmission device, and carries out storage, collection, modeling, data processing and diagnosis and prediction of the safety state; and the information display device is connected with the digital mapping device for the safety state of the numerical control system, displays the diagnosis and prediction results of the safety state, and performs visual display in a three-dimensional expression form through the simulation operation process of the final virtual mapping model. The invention has high practicability, high authenticity and good adaptability.

Description

Digital mapping system and method for safety state of numerical control system
Technical Field
The invention relates to the technical field of digital mapping of the safety state of a numerical control system, in particular to a digital mapping system and a digital mapping method for the safety state of the numerical control system.
Background
High-grade numerical control systems have become the enabling technology and the most basic equipment of emerging high and new technology industries and sophisticated industries. Functional safety relates to safety-related electromechanical control systems, safety-related technologies and other risk-reducing strategies, with the aim of ensuring correct execution of safety functions.
With the continuous improvement of the safety performance requirements of the numerical control system and the numerical control machine tool on the system, the numerical control system and related equipment are required to have a safety function, so that the protection of personnel, equipment and environment is realized, and the occurrence of safety accidents is reduced. The safety of numerical control systems and numerical control machines has become a focus of attention of numerical control manufacturers at home and abroad and an important function of the next generation of numerical control systems. The traditional numerical control system has the problems that the safety state of equipment cannot be actively predicted, the network communication transmission state is unstable, the daily maintenance is inconvenient and the like in the operation process. The digital mapping technology can effectively solve the problems and effectively promote the fusion of multi-source heterogeneous data, thereby promoting the digital construction of the safety state of the numerical control system and realizing the interactive fusion of the physical entity of the numerical control system and the information world.
Disclosure of Invention
Aiming at the problems that the traditional numerical control system cannot actively predict the safety state of equipment, the network communication transmission state is unstable, the daily maintenance is inconvenient and the like in the operation process, the invention aims to solve the problems that the digitalized mapping is combined with the traditional numerical control system, the digitalized mapping device and the digitalized mapping system for the safety state of the numerical control system are designed, the risk which possibly occurs in the operation process of the numerical control system is effectively analyzed, monitored and predicted by analyzing the current data and the historical data of the system, the safety state of the numerical control system is dynamically judged, and the operation and maintenance efficiency of the system is improved.
The technical scheme adopted by the invention for realizing the aim is to provide a numerical control system safety state digital mapping system, which comprises a wireless data transmission device, a numerical control system safety state digital mapping device and an information display device;
the wireless data transmission device is communicated with the digital mapping device of the safety state of the numerical control system in a wireless or wired mode and is used for acquiring the safety state data of the physical entity equipment through the sensor and sending the safety state data to the digital mapping device of the safety state of the numerical control system;
the digital mapping device of the safe state of the numerical control system is used for receiving the safe state data sent by the wireless data transmission device, storing, acquiring, modeling, processing the data and diagnosing and predicting the safe state;
the information display device is connected with the digital mapping device of the safety state of the numerical control system and used for displaying the diagnosis and prediction results of the safety state and carrying out visual display in a three-dimensional expression form through the simulation operation process of the digital mapping virtual comprehensive model.
The numerical control system safety state digital mapping device comprises a numerical control system physical entity subunit, a numerical control system digital model subunit, a numerical control system safety state data subunit and a numerical control system safety state service subunit;
the numerical control system physical entity subunit is used for managing the physical entity equipment connected with the numerical control system physical entity subunit and the set of the working states of the physical entity equipment; collecting safety state data sent by wireless transmission equipment; and according to the comparison result of the safety state service subunit of the numerical control system, adopting corresponding safety measures to optimize the overall operation efficiency of the system.
The numerical control system digital model subunit is used for establishing a numerical control system virtual model and virtual activities corresponding to the numerical control system virtual model, and mapping physical entity equipment by using safety state data transmitted by the numerical control system physical entity subunit in real time to obtain virtual mapping data; establishing a virtual mapping model according to the virtual mapping data;
the numerical control system safety state service subunit is used for comparing and analyzing the received safety state data of the physical entity subunit of the numerical control system and the safety state prediction result of the numerical control system digital model subunit to obtain a comparison result; when the comparison result reaches a preset value, the final safety state prediction result of the numerical control system of the virtual mapping model is sent to a physical entity subunit of the numerical control system;
the numerical control system safety state data subunit is used for storing safety state data of the numerical control system physical entity subunit, a safety state prediction result of the numerical control system digital model subunit and a comparison result of the numerical control system safety state service subunit.
The physical entity comprises a numerical control system, a servo driver, a field bus and a PLC.
The modeling comprises the following steps:
the virtual mapping data is input as a virtual mapping model, the safety state prediction result of the numerical control system is output as the model, and the virtual model is established through one of a neural network, a Markov chain and a finite state machine method.
The numerical control system safety state digital mapping method is characterized by comprising the following steps:
step 1) the wireless data transmission device sends the safety state data of the physical entity equipment to the digital mapping device of the safety state of the numerical control system;
step 2) the physical entity subunit of the numerical control system sends the safety state data of the physical entity equipment to the numerical control system digital model subunit and the numerical control system safety state data subunit;
step 3) establishing a virtual mapping model according to the safety state data;
step 4), the numerical control system digital model subunit sends the safety state prediction result of the virtual mapping model to the numerical control system safety state data subunit;
step 5) the numerical control system safety state data subunit sends the received safety state data of the physical entity subunit of the numerical control system and the safety state prediction result of the numerical control system digital model subunit to the numerical control system safety state service subunit for analysis and comparison;
step 6) the results of the analysis and comparison performed by the numerical control system safety state service subunit are respectively fed back to the numerical control system physical entity subunit and the numerical control system safety state data subunit;
step 7) returning to the step 2) until the analysis and comparison result reaches a preset value, and obtaining a final virtual mapping model closest to the real state of the physical entity equipment, so that the digital model subunit of the numerical control system truly reflects the safe operation state of the numerical control system and the connected physical equipment entity in the working process;
step 8), the physical entity subunit of the numerical control system receives the final safety state prediction result of the virtual mapping model and is used for taking corresponding measures;
and 9) visually presenting the simulation operation process of the final virtual mapping model in a three-dimensional representation form in the information display device.
The analysis and alignment in the step 6): comparing a prediction result output by using a virtual mapping model established by a digital model subunit of the numerical control system with safety state data provided by a physical entity subunit of the numerical control system to obtain a difference value between the prediction result and the safety state data, and judging whether the difference value reaches a preset value; if the preset value is reached, the establishment of the final virtual mapping model is finished; and if the preset value is not reached, the virtual mapping model is continuously optimized in an iterative mode.
The invention has the following beneficial effects and advantages:
1. the practicability is strong. The invention is based on practical application as a premise, aims at the problems that the safety state of equipment cannot be actively predicted, the network communication transmission state is unstable, the daily maintenance is inconvenient and the like in the operation process of the traditional numerical control system, combines the digital mapping with the traditional numerical control system, designs the digital mapping device and the digital mapping system for the safety state of the numerical control system, effectively analyzes, monitors and predicts the possible risks of the numerical control system in the operation process by analyzing the current data and the historical data of the system, dynamically judges the safety state of the numerical control system and improves the operation and maintenance efficiency of the system.
2. The degree of realism is high. Real-time interaction is realized through the connection established between the physical entity subunit of the numerical control system and the digital model subunit of the numerical control system, and finally, a digital mapping model completely corresponding to the physical entity of the numerical control system is established, so that integration and fusion of data among the physical entity subunit of the numerical control system, the digital model subunit of the numerical control system and the safety state service subunit of the numerical control system are realized.
3. Has good adaptability. For different numerical control system physical entity safety state data, a better digital mapping effect can be obtained only by dynamically adjusting a virtual model established by a numerical control system digital model subunit, and the method has good adaptability.
Drawings
FIG. 1 is a schematic diagram of the system of the present invention;
FIG. 2 is a schematic structural diagram of a digital mapping apparatus for the safety state of the numerical control system according to the present invention;
FIG. 3 is a schematic diagram of a digital mapping apparatus for the safety state of a numerical control system.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and examples.
As shown in fig. 1, the digital mapping system structure diagram of the safety state of the numerical control system in the embodiment of the invention mainly comprises a wireless data transmission device, a digital mapping device of the safety state of the numerical control system and an information display device.
The wireless data transmission device mainly obtains the safety state information of the target numerical control system physical equipment through the sensor, and is in communication connection with the numerical control system safety state digital mapping device in a wireless or wired mode.
In the embodiment, the wireless data transmission device is placed at the core position of the physical equipment connected with the numerical control system, and the safety state data of the equipment is continuously acquired through the set acquisition and transmission frequency. And then the acquired safety state data is sent to a digital mapping device of the safety state of the numerical control system in a wireless communication mode.
As shown in fig. 2, the digital mapping device for the safety state of the numerical control system mainly includes a physical entity subunit of the numerical control system, a digital model subunit of the numerical control system, a safety state data subunit of the numerical control system, and a safety state service subunit of the numerical control system.
The numerical control system physical entity subunit is used for managing the numerical control system and the physical equipment connected with the numerical control system, and comprises physical entities such as a numerical control system, a servo driver, a field bus, a PLC and the like, and a set of activities corresponding to the numerical control system. The system is mainly responsible for realizing the physical space of the operation of the numerical control system and collecting the data sent by the wireless data transmission device.
The numerical control system digital model subunit is used for establishing a numerical control system virtual model and virtual activities born by the numerical control system virtual model subunit correspondingly, and mapping the physical entity equipment by utilizing the safety state data transmitted by the numerical control system physical entity subunit in real time to obtain virtual mapping data; and establishing a virtual mapping model according to the virtual mapping data.
The modeling comprises the following steps: the virtual mapping data is input as a virtual mapping model, the safety state prediction result of the numerical control system is output as the model, and the virtual model is established through one of a neural network, a Markov chain and a finite state machine method.
And the numerical control system safety state data subunit is used for storing the safety state data of the numerical control system physical entity subunit, the safety state prediction result of the numerical control system digital model subunit and the comparison result of the numerical control system safety state service subunit.
The numerical control system safety state service subunit is used for comparing and analyzing the received safety state data of the physical entity subunit of the numerical control system and the safety state prediction result of the numerical control system digital model subunit to obtain a comparison result; and when the comparison result reaches a preset value, sending the final numerical control system safety state prediction result of the virtual mapping model to a physical entity subunit of the numerical control system.
The working mechanism of the numerical control system safety state digital mapping device is that four main bodies of a numerical control system physical entity subunit, a numerical control system digital model subunit, a numerical control system safety state data subunit and a numerical control system safety state service subunit are mutually connected through data ties to realize the interconnection of all the parts.
The physical entity subunit of the numerical control system mainly comprises the numerical control systems such as the numerical control system, the servo drive, the field bus, the PLC and the like, physical equipment entities connected with the numerical control systems, and an active set corresponding to the numerical control system, and simultaneously receives feedback information from the numerical control system digital model subunit and the numerical control system safety state data subunit. The physical entity subunit of the numerical control system has the main functions of (1) ensuring that the numerical control system and the physical equipment entity connected with the numerical control system complete corresponding work tasks; (2) the data sharing and inheritance are realized through the access and fusion of the multi-source heterogeneous security state data.
The numerical control system digital model subunit firstly carries out omnibearing digital modeling on numerical control system physical equipment from multiple dimensions such as geometry, physics, behavior, rules and the like, and integrates and fuses the models from two aspects of structure and function. And secondly, evaluating and verifying the model established by the numerical control system digital model subunit by using the physical equipment safety state data to form a virtual mapping comprehensive model of the numerical control system digital model subunit.
The digital model subunit of the numerical control system carries out fault diagnosis and prediction on the safety state of the numerical control system by simulating the operation of the physical entity subunit of the numerical control system, and can effectively predict the operation fault of the numerical control system so as to complete the monitoring on the operation state of the numerical control system and the connected physical equipment.
The numerical control system safety state diagnosis is to divide safety state data according to categories, compare the safety state data with thresholds set by various safety state data respectively, and feed back fault information by the device when the actual safety state data exceeds the set thresholds.
The numerical control system safety state prediction adopts a long-short term memory network LSTM to model the safety state data. Dividing the acquired safety state data into a training sample and a test sample, and performing data preprocessing on the obtained sample data, including feature extraction, normalization and calculation of mean value and variance to obtain a test data set; preprocessing a training sample to obtain a training data set, and performing LSTM training on the obtained data set to obtain a training result; correcting the original model by calculating the mean square error of the test data set and the training result, firstly calculating the mean square error value, comparing whether the mean square error exceeds a threshold value, if the mean square error exceeds the set threshold value, further optimizing and adjusting parameters of the model, and if the mean square error does not exceed the threshold value, outputting the result.
The numerical control system safety state data subunit is responsible for providing data support for the operation of the numerical control system physical entity subunit, the numerical control system digital model subunit and the numerical control system safety state service subunit. The data contained in the numerical control system safety state data subunit mainly comprises safety state data of a numerical control system physical entity subunit, a safety state prediction result of a numerical control system digital model subunit and a comparison result of a numerical control system safety state service subunit.
The main function of the numerical control system safety state service subunit is to analyze and process the numerical control system safety state data and the virtual mapping data. The numerical control system physical entity subunit continuously transmits the safety state data to the numerical control system safety state service subunit through the numerical control system safety state data subunit, and the subunit also continuously receives the prediction analysis result generated by the numerical control system digital model subunit. And the numerical control system safety state service subunit analyzes and compares the prediction analysis result with the safety state data of the numerical control system physical entity subunit, and transmits the analysis result to the numerical control system digital model subunit, and the numerical control system digital model subunit further optimizes the model according to the result and iterates repeatedly until the model is optimal. And the numerical control system safety state service subunit sends the prediction analysis result of the optimal model to the numerical control system physical entity subunit, and the numerical control system physical entity subunit takes corresponding measures according to the prediction result, so that the overall operation efficiency of the system is optimized.
As shown in fig. 3, the working process of the digital mapping device for the safety state of the numerical control system mainly includes the following steps:
and (5) collecting safety state data of the numerical control system. The wireless data transmission device sends the safety state data of the physical entity equipment to the digital mapping device of the safety state of the numerical control system, and plans, cleans and encapsulates the numerical control system with multiple types, multiple scales and multiple granularities and the connected safety state data of the physical equipment sent by the wireless data transmission device, thereby realizing the unified and standard processing of the data.
And establishing and fusing a safety state data virtual mapping model. And the numerical control system physical entity subunit sends the physical entity equipment safety state data to the numerical control system digital model subunit and the numerical control system safety state data subunit. And establishing a virtual mapping model according to the safety state data, and integrating and fusing the models from two aspects of structure and function by establishing the relation among the models of all layers. And evaluating and verifying the model established by the numerical control system digital model subunit by using the real data of the numerical control system physical entity subunit to form a numerical control system digital mapping virtual comprehensive model.
And (5) performing iterative optimization on the virtual mapping data. And the numerical control system digital model subunit sends the safety state prediction result of the virtual mapping model to the numerical control system safety state data subunit, and the numerical control system safety state data subunit sends the received safety state data of the numerical control system physical entity subunit and the safety state prediction result of the numerical control system digital model subunit to the numerical control system safety state service subunit for analysis and comparison. The results of the analysis and comparison performed by the numerical control system safety state service subunit are respectively fed back to the numerical control system physical entity subunit and the numerical control system safety state data subunit.
The specific steps of analysis and comparison are as follows: comparing a prediction result output by using a virtual mapping model established by a digital model subunit of the numerical control system with safety state data provided by a physical entity subunit of the numerical control system to obtain a difference value between the prediction result and the safety state data, and judging whether the difference value reaches a preset value; if the preset value is reached, the establishment of the final virtual mapping model is finished; and if the preset value is not reached, the virtual mapping model is continuously optimized in an iterative mode.
Meanwhile, the numerical control system physical entity subunit safety state data, the numerical control system digital model subunit model prediction data and the numerical control system safety state service subunit data are iterated, optimized and fused, and the safety state data virtual mapping model is continuously perfected, so that the numerical control system digital model subunit can truly reflect the safe running state of the numerical control system and the connected physical equipment entity in the working process.
And returning to the establishment and fusion of the safety state data virtual mapping model until the analysis and comparison result reaches a preset value, and obtaining a final virtual mapping model closest to the real state of the physical entity equipment, so that the digital model subunit of the numerical control system truly reflects the safe running state of the numerical control system and the connected physical equipment entity in the working process.
And the physical entity subunit of the numerical control system receives the final safety state prediction result of the virtual mapping model and is used for taking corresponding measures so as to optimize the overall operation efficiency of the system.
And visually displaying the safety state of the numerical control system. And visually presenting the simulation operation process of the final virtual mapping model in a three-dimensional representation form in an information display device.

Claims (6)

1. A numerical control system safety state digital mapping system is characterized by comprising a wireless data transmission device, a numerical control system safety state digital mapping device and an information display device;
the wireless data transmission device is communicated with the digital mapping device of the safety state of the numerical control system in a wireless or wired mode and is used for acquiring the safety state data of the physical entity equipment through the sensor and sending the safety state data to the digital mapping device of the safety state of the numerical control system;
the digital mapping device of the safe state of the numerical control system is used for receiving the safe state data sent by the wireless data transmission device, storing, acquiring, modeling, processing the data and diagnosing and predicting the safe state;
the information display device is connected with the digital mapping device for the safety state of the numerical control system, is used for displaying the diagnosis and prediction results of the safety state, and is visually displayed in a three-dimensional representation form through the simulation operation process of the final virtual mapping model.
2. The numerical control system safety state digital mapping system of claim 1, wherein the numerical control system safety state digital mapping device comprises a numerical control system physical entity subunit, a numerical control system digital model subunit, a numerical control system safety state data subunit, a numerical control system safety state service subunit;
the numerical control system physical entity subunit is used for managing the physical entity equipment connected with the numerical control system physical entity subunit and the set of the working states of the physical entity equipment; collecting safety state data sent by wireless transmission equipment; and taking corresponding safety measures according to the comparison result of the safety state service subunit of the numerical control system.
The numerical control system digital model subunit is used for establishing a numerical control system virtual model and virtual activities corresponding to the numerical control system virtual model, and mapping physical entity equipment by using safety state data transmitted by the numerical control system physical entity subunit in real time to obtain virtual mapping data; establishing a virtual mapping model according to the virtual mapping data;
the numerical control system safety state service subunit is used for comparing and analyzing the received safety state data of the physical entity subunit of the numerical control system and the safety state prediction result of the numerical control system digital model subunit to obtain a comparison result; when the comparison result reaches a preset value, the safety state prediction result of the numerical control system of the virtual mapping model is sent to a physical entity subunit of the numerical control system;
the numerical control system safety state data subunit is used for storing safety state data of the numerical control system physical entity subunit, a safety state prediction result of the numerical control system digital model subunit and a comparison result of the numerical control system safety state service subunit.
3. The numerical control system safety state digital mapping device according to claim 2, wherein the physical entities comprise a numerical control system, a servo drive, a field bus and a PLC.
4. The numerical control system safety state digital mapping device according to claim 2, wherein the modeling comprises the following steps:
the virtual mapping data is input as a virtual mapping model, the safety state prediction result of the numerical control system is output as the model, and the virtual model is established through one of a neural network, a Markov chain and a finite state machine method.
5. A digital mapping method for the safety state of a numerical control system is characterized by comprising the following steps:
step 1) the wireless data transmission device sends the safety state data of the physical entity equipment to the digital mapping device of the safety state of the numerical control system;
step 2) the physical entity subunit of the numerical control system sends the safety state data of the physical entity equipment to the numerical control system digital model subunit and the numerical control system safety state data subunit;
step 3) establishing a virtual mapping model according to the safety state data;
step 4), the numerical control system digital model subunit sends the safety state prediction result of the virtual mapping model to the numerical control system safety state data subunit;
step 5) the numerical control system safety state data subunit sends the received safety state data of the physical entity subunit of the numerical control system and the safety state prediction result of the numerical control system digital model subunit to the numerical control system safety state service subunit for analysis and comparison;
step 6) the results of the analysis and comparison performed by the numerical control system safety state service subunit are respectively fed back to the numerical control system physical entity subunit and the numerical control system safety state data subunit;
step 7) returning to the step 2) until the analysis and comparison result reaches a preset value, and obtaining a final virtual mapping model closest to the real state of the physical entity equipment, so that the digital model subunit of the numerical control system truly reflects the safe operation state of the numerical control system and the connected physical equipment entity in the working process;
step 8), the physical entity subunit of the numerical control system receives the final safety state prediction result of the virtual mapping model and is used for taking corresponding measures;
and 9) visually presenting the simulation operation process of the final virtual mapping model in a three-dimensional representation form in the information display device.
6. The method for digitally mapping the security state of a numerical control system according to claim 5, wherein the analysis in step 6) compares: comparing a prediction result output by using a virtual mapping model established by a digital model subunit of the numerical control system with safety state data provided by a physical entity subunit of the numerical control system to obtain a difference value between the prediction result and the safety state data, and judging whether the difference value reaches a preset value; if the preset value is reached, the establishment of the final virtual mapping model is finished; and if the preset value is not reached, the virtual mapping model is continuously optimized in an iterative mode.
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