CN114473870B - Grinding machine monitoring system and monitoring method - Google Patents

Grinding machine monitoring system and monitoring method Download PDF

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Publication number
CN114473870B
CN114473870B CN202210241087.6A CN202210241087A CN114473870B CN 114473870 B CN114473870 B CN 114473870B CN 202210241087 A CN202210241087 A CN 202210241087A CN 114473870 B CN114473870 B CN 114473870B
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workpiece
grinding device
control unit
generates
grinding
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CN114473870A (en
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杨智凯
赵佑升
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Syntec Technology Suzhou Co Ltd
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Syntec Technology Suzhou Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B51/00—Arrangements for automatic control of a series of individual steps in grinding a workpiece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
    • B24B49/02—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation according to the instantaneous size and required size of the workpiece acted upon, the measuring or gauging being continuous or intermittent
    • B24B49/04—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation according to the instantaneous size and required size of the workpiece acted upon, the measuring or gauging being continuous or intermittent involving measurement of the workpiece at the place of grinding during grinding operation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
    • B24B49/12—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation involving optical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
    • B24B49/14—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation taking regard of the temperature during grinding

Abstract

The invention discloses a grinding machine monitoring system and a monitoring method.A control unit is coupled with a first driving device, a second driving device, a first sensor, a second sensor, a third sensor, an input unit and a storage unit. The control unit compares the sensing signal with the machining model and generates a comparison result, and when the comparison result is different from a default range in the machining model, the control unit generates command signals which are respectively transmitted to the first driving device and the second driving device and used for controlling the grinding device to perform corresponding actions with the workpiece. Through the quantification process, the data change in the processing process is assisted to a user, the manpower consumption of manual judgment is effectively reduced, and the operation threshold of a grinding machine system is greatly reduced.

Description

Grinding machine monitoring system and monitoring method
Technical Field
The invention belongs to the technical field of grinding machine monitoring, and particularly relates to a grinding machine monitoring system and a monitoring method.
Background
A grinding machine (Grinder) is one type of machine tool. The machining operation of the grinding machine is grinding, and the grinding device is used to grind the excess amount of the workpiece to obtain the required shape, size and machining surface. Sharpening of cutting tools and precise manufacture of mechanical parts are both dependent on grinding operations; the grinding work is also a part of the precision machining, and the grinding machine is used for grinding with high precision and a relatively small rough surface, and can perform high-efficiency grinding. High-speed grinding is the most common grinding operation in grinding work, and is mainly performed by using a grinding wheel (grinding wheel), and a small part of the grinding wheel is processed by using other grinding devices or abrasives such as abrasive cloth and oilstones.
Because the grinding processing belongs to one of the precision processing, a series of processing actions are controlled by a programmed instruction, the requirements on the precision and the surface quality are very high, a rule for judging the processing quality is needed to measure whether the quality of the workpiece is suitable, the processing experience of an operator is relied on in the past, whether the workpiece is burnt or not is judged by seeing processing sparks, whether the cutting force is overlarge is judged by hearing cutting audio frequency, even whether the workpiece has a chatter mark or not is judged according to the vibration degree of a machine table, and the artificial observation modes can judge by relying on deep processing experience, so that the operation of the conventional grinding machine has the following limitations, such as: (1) The processing experience cannot be passed on by quantization/datamation, and can be saved only through spoken statement or paper and pen recording of operators, and the judgment standards of each operator are different and lack a common criterion; (2) The failure to integrate the data of the machining path, the load factor, etc. into the data of the alignment sequence means that the operator cannot know at what time point the machining problem occurs, and can only judge by experience, which is a great difficulty in troubleshooting and solving the problem.
For the above situation, although there are audio sensors, accelerometers and other devices to assist the judgment of the operator, the conventional auxiliary devices in the market are independent and difficult to integrate into the control unit, so that these data cannot be analyzed immediately and the control unit system cannot make an appropriate decision, which results in the user being unable to judge when and where the processing problem occurs. For example, without the position information matching process section, the user can only know that a problem occurs when the user takes the finished product, but does not know that the problem occurs in the process section, which makes it difficult to troubleshoot the problem. Or the existing sensor only provides a simple I/O signal, can only judge whether problems occur or not, and is difficult to monitor the change of data in the processing process.
In addition, grinding has advantages such as good surface roughness, high dimensional accuracy of a workpiece, and speediness of machining, but it is necessary to perform machining in a predetermined polishing route. Taking a surface grinder as an example, the following circumstances may bring about the disadvantages of not being economical: (1) When the workpiece is placed on the workbench at different angles, the long stroke of the grinding path appears, which results in time-consuming processing and reduced production efficiency; (2) When the appearance contour of the workpiece is irregular, the grinding path is easy to be longer, and a lot of processing time is wasted. In the above situation, the general procedure is to go to the reversing switch or to reverse automatically after the stroke limit, which causes the machine to run for a long time in the machining process, resulting in low machining efficiency.
In the past, it is an extremely demanding objective to determine the machining quality by observing the machining spark, the vibration of the touch machine, and the audio frequency of the cutting by hearing, how to integrate and quantify the experience rules and help the user to know the data change in the machining process to ensure the quality of the workpiece.
Disclosure of Invention
In view of the above, the present invention provides a grinder monitoring system and a monitoring method thereof to overcome the deficiencies of the prior art, which quantify the process, assist the user in learning the data change in the machining process, effectively reduce the manpower consumption for human judgment, and greatly reduce the operation threshold of the grinder system.
In order to achieve the purpose, the invention adopts the technical scheme that: a grinding machine monitoring system for monitoring the machining of a workpiece on a grinding machine by a grinding device controlled by a first drive and a second drive, comprising:
a first sensor coupled to the first drive or the grinding device; when the grinding device is used for processing the workpiece, the first sensor correspondingly generates a first sensing signal;
a second sensor coupled to the second drive or the grinding device; when the grinding device is used for processing the workpiece, the second sensor correspondingly generates a second sensing signal;
a third sensor coupled to the grinding device; when the grinding device is used for processing the workpiece, the third sensor correspondingly generates a third sensing signal;
the input unit is used for setting monitoring factors of grinding; the monitoring factor is associated with the first sense signal, the second sense signal, and the third sense signal;
a storage unit for storing at least one machining model for grinding the workpiece;
a control unit coupled to the first driving device, the second driving device, the first sensor, the second sensor, the third sensor, the input unit, and the storage unit;
the control unit converts the first sensing signal into the coordinate of the workpiece or the axial position of the grinding device, converts the second sensing signal into the angular position of the grinding device, and converts the third sensing signal into the vibration signal of the grinding device;
the control unit compares the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device, the vibration signal of the grinding device with the machining model according to the monitoring factors transmitted by the input unit and generates a comparison result, and when the comparison result is different from a default range in the machining model, the control unit generates a first command signal and a second command signal and transmits the first command signal and the second command signal to the first driving device and the second driving device respectively to control the grinding device to perform corresponding actions with the workpiece.
Optimally, the control unit calculates the load factor of the grinding device according to the current of the second driving device, compares the load factor of the grinding device, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device, the vibration signal of the grinding device with the machining model and generates a comparison result; the control unit judges whether the grinding device generates idle stroke according to the comparison result, and when the comparison result is different from a default range in the machining model, the control unit controls the workpiece and the grinding device to perform corresponding actions according to the difference; or/and the control unit calculates the feed amount of the grinding device, compares the feed amount of the grinding device, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates workpiece burn or workpiece vibration mark or whether the grinding device exceeds a wear value according to the comparison result, and correspondingly adjusts the feed amount of the grinding device when the control unit judges that the workpiece generates the workpiece burn or the workpiece vibration mark; or/and the control unit calculates the feed rate of the grinding device, compares the feed rate of the grinding device, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates workpiece burn or poor roundness of the workpiece according to the comparison result, and correspondingly adjusts the feed rate of the grinding device when the control unit judges that the workpiece generates workpiece burn or poor roundness of the workpiece; or/and the control unit calculates the grinding wheel rotating speed of the grinding device, compares the rotating speed of the grinding device, the workpiece coordinate, the axial position of the grinding device, the angle position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates a workpiece vibration mark according to the comparison result, and correspondingly adjusts the rotating speed of the grinding device when the control unit judges that the workpiece generates the workpiece vibration mark; or/and the control unit calculates the rotating speed of the workpiece, compares the rotating speed of the workpiece, the coordinates of the workpiece, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates a workpiece vibration mark according to the comparison result, and correspondingly adjusts the rotating speed of the workpiece when the control unit judges that the workpiece generates the workpiece vibration mark; and/or the control unit calculates the transverse moving speed of the workpiece, compares the transverse moving speed of the workpiece, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates a workpiece vibration mark according to the comparison result, and correspondingly adjusts the transverse moving speed of the workpiece when the control unit judges that the workpiece generates the workpiece vibration mark.
Optimally, the device also comprises an audio sensor, wherein the audio sensor is coupled to the grinding device and used for sensing an audio signal generated by the grinding device in the machining process, the control unit compares the audio signal, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, the control unit judges whether the workpiece generates workpiece vibration marks or grinding device stuffing according to the comparison result, and when the control unit judges that the workpiece generates the workpiece vibration marks or the grinding device stuffing, the control unit correspondingly adjusts the feed amount or the rotating speed or the transverse moving speed of the workpiece of the grinding device.
Optimally, the device also comprises a flow meter, wherein the flow meter is arranged on the cooling device of the machine tool and is used for sensing the flow change of the cutting fluid applied in the machining process to generate a flow meter signal; the control unit compares the flow meter signal, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device, the vibration signal of the grinding device with the machining model and generates a comparison result, the control unit judges whether the workpiece generates workpiece burn or the grinding device is stuffed according to the comparison result, and when the control unit judges that the workpiece generates workpiece burn or the grinding device is stuffed, the control unit correspondingly adjusts the feed rate or the feed rate of the grinding device or the flow rate of the cutting fluid of the machine tool cooling device.
Furthermore, the device also comprises a temperature sensor, wherein the temperature sensor is used for sensing the temperature of the workpiece, the control unit compares the workpiece temperature, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model to generate a comparison result, the control unit judges whether the workpiece generates workpiece burn or not according to the comparison result, and when the control unit judges that the workpiece generates workpiece burn, the control unit correspondingly adjusts the feed amount or feed rate of the grinding device or the flow rate of the cutting fluid of the machine tool cooling device.
Preferably, the control unit further converts the grinding device axial position into the grinding device axial velocity, the grinding device axial acceleration, or the grinding device axial jerk, and the control unit converts the grinding device angular position into the grinding device angular velocity or the grinding device angular acceleration.
Optimally, the control unit compares the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device, the vibration signal of the grinding device with the machining model according to the monitoring factors transmitted by the input unit, and when the comparison result is different from the default range in the machining model, the control unit sends out a warning signal, records current machining data or executes a protection mechanism, wherein the warning signal comprises sound, color or other forms capable of warning, and the protection mechanism comprises that the grinding device stops machining or the grinding device is separated from the workpiece.
Preferably, the first driving device is an axial motor or an oil pressure driving device, and the second driving device is a spindle motor.
Preferably, the first sensor is a linear encoder, a rotary encoder or an optical ruler, the second sensor is a rotary encoder, and the third sensor is an accelerometer.
Optimally, the control unit is also connected with a remote storage monitoring device through a network, and the condition of the grinding machine is monitored synchronously.
Another object of the present invention is to provide a method for monitoring a grinding machine, based on the above-mentioned system, for monitoring a workpiece processed by a grinding device controlled by a first driving device and a second driving device on the grinding machine, comprising the steps of:
(1) A user sets the monitoring factors of the grinding processing to the control unit through the input unit;
(2) The control unit judges and selects at least one required processing model from the storage unit through the monitoring factors to compare processing data;
(3) Starting to machine the workpiece, wherein when the grinding device machines the workpiece, the control unit is coupled to the first driving device or the grinding device through a first sensor to generate a first sensing signal which is converted into the coordinate of the workpiece or the axial position of the grinding device; the control unit is coupled to the second driving device through a second sensor or generates a second sensing signal which is converted into an angle position of the grinding device, and the control unit is coupled to the grinding device through a third sensor and generates a third sensing signal which is converted into a vibration signal of the grinding device;
(4) The control unit compares the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device, the vibration signal of the grinding device with the machining model according to the monitoring factors transmitted by the input unit and generates a comparison result, and when the comparison result is different from a default range in the machining model, the control unit generates a first command signal and a second command signal which are respectively transmitted to the first driving device and the second driving device and used for controlling the grinding device and the workpiece to carry out corresponding processing modes.
Optimally, the machining model is established such that when a standard workpiece is machined, the first sensor, the second sensor and the third sensor transmit sensed data of a machining process back to the control unit, and the control unit processes the data to obtain cleaner and noiseless data, and the machining model of the workpiece is described by using the data.
Optimally, the control unit calculates the load factor of the grinding device according to the current of the second driving device, compares the load factor of the grinding device, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the grinding device generates idle stroke according to the comparison result, and controls the workpiece and the grinding device to perform corresponding actions according to the difference when the comparison result is different from a default range in the machining model; or/and the control unit calculates the feed amount of the grinding device, compares the feed amount of the grinding device, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates workpiece burn or workpiece vibration mark or whether the grinding device exceeds a wear value according to the comparison result, and correspondingly adjusts the feed amount of the grinding device when the control unit judges that the workpiece generates the workpiece burn or the workpiece vibration mark; or/and the control unit calculates the feed rate of the grinding device, compares the feed rate of the grinding device, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates workpiece burn or poor roundness of the workpiece according to the comparison result, and correspondingly adjusts the feed rate of the grinding device when the control unit judges that the workpiece generates workpiece burn or poor roundness of the workpiece; or/and the control unit calculates the grinding wheel rotating speed of the grinding device, compares the rotating speed of the grinding device, the workpiece coordinate, the axial position of the grinding device, the angle position of the grinding device, the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates a workpiece vibration mark according to the comparison result, and correspondingly adjusts the rotating speed of the grinding device when the control unit judges that the workpiece generates the workpiece vibration mark; or/and the control unit calculates the rotating speed of the workpiece, compares the rotating speed of the workpiece, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates a workpiece vibration mark according to the comparison result, and correspondingly adjusts the rotating speed of the workpiece when the control unit judges that the workpiece generates the workpiece vibration mark; and/or the control unit calculates the transverse moving speed of the workpiece, compares the transverse moving speed of the workpiece, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates a workpiece vibration mark according to the comparison result, and correspondingly adjusts the transverse moving speed of the workpiece when the control unit judges that the workpiece generates the workpiece vibration mark.
Optimally, the grinding device utilizes an audio sensor to sense an audio signal generated by the grinding device in the machining process, the control unit compares the audio signal, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model to generate a comparison result, the control unit judges whether the workpiece generates workpiece vibration marks or the grinding device is stuffed according to the comparison result, and when the control unit judges that the workpiece generates the workpiece vibration marks or the grinding device is stuffed, the control unit correspondingly adjusts the feed amount, the rotating speed or the transverse moving speed of the workpiece of the grinding device.
Optimally, the machine tool cooling device of the grinding machine is used for sensing a flow meter signal generated by the change of the flow rate of cutting fluid applied in the machining process through a flow meter, the control unit compares the flow meter signal, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, the control unit judges whether the workpiece generates workpiece burn or grinding device stuffing according to the comparison result, and when the control unit judges that the workpiece generates workpiece burn or grinding device stuffing, the control unit correspondingly adjusts the feed amount and feed rate of the grinding device or the flow rate of the cutting fluid of the machine tool cooling device.
Furthermore, the grinding machine is further provided with a temperature sensor for sensing the temperature of the workpiece, the control unit compares the workpiece temperature, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model to generate a comparison result, the control unit judges whether the workpiece generates workpiece burn according to the comparison result, and when the control unit judges that the workpiece generates workpiece burn, the control unit correspondingly adjusts the feed amount and feed rate of the grinding device or the flow rate of the cutting fluid of the machine tool cooling device.
Optimally, the control unit further converts the grinding device axial position into the grinding device axial velocity, the grinding device axial acceleration or the grinding device axial jerk, and the control unit converts the grinding device angular position into the grinding device angular velocity or the grinding device angular acceleration.
Optimally, the control unit compares the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device, the vibration signal of the grinding device and the machining model according to the monitoring factors transmitted by the input unit, and when the comparison result is different from the default range in the machining model, the control unit sends out a warning signal, records current machining data or executes a protection mechanism, wherein the warning signal comprises sound, color or other forms capable of warning, and the protection mechanism comprises that the grinding device stops machining or is separated from the workpiece.
Preferably, the first driving device is an axial motor or an oil pressure driving device, and the second driving device is a spindle motor.
Preferably, the first sensor is a linear encoder or a rotary encoder or an optical scale, the second sensor is a rotary encoder, and the third sensor is an accelerometer.
Optimally, the control unit is also connected with a remote storage monitoring device through a network, and the condition of the grinding machine is synchronously monitored through the remote storage monitoring device.
Due to the application of the technical scheme, compared with the prior art, the invention has the following advantages: the system integrates a plurality of sensors into a grinding machine system, can integrate processing information such as load rate, feed amount, workpiece rotating speed, grinding wheel abrasion value, coordinate, acceleration gauge amplitude, cutting fluid flow, pressure and the like when processing is carried out, establishes a processing load model of an alignment time sequence, and establishes an intelligent monitoring system of a set of grinding machine by utilizing the model; according to the invention, through establishing the machining load model, a user can observe data change in the machining process and set up a processing mode when machining abnormity occurs, so that the quality of a workpiece is ensured, the manpower consumption of manual judgment can be effectively reduced, and the operation threshold of a grinding machine system is greatly reduced.
Drawings
FIG. 1 is a schematic diagram of a first block of a grinding machine monitoring system of the present invention;
FIG. 2 is a second block diagram of the grinder monitoring system of the present invention;
FIG. 3 is a schematic diagram of a third block of the grinder monitoring system of the present invention;
FIG. 4 is a fourth block diagram of a grinder monitoring system according to the present invention;
FIG. 5 is a schematic flow chart of a method of monitoring a grinding machine according to the present invention;
FIG. 6 is a schematic view of a process for creating a machining model according to the present invention;
FIG. 7 is a schematic diagram of a fifth block diagram of a grinding machine monitoring system according to the present invention;
FIG. 8 is a sixth block schematic diagram of a grinding machine monitoring system of the present invention;
100, grinding machine; 110. a first driving device; 120. a grinding device; 130. a second driving device; 140. a first sensor; 141. a first sensing signal; 142. a second sensing signal; 143. a third sensing signal; 150. a second sensor; 160. a third sensor; 200. an input unit; 210. monitoring factors; 300. a storage unit; 310. processing the model; 400. a control unit; 410. a first command signal; 420. a second command signal; 500. a remote storage monitoring device; 600. an audio sensor; 610. an audio signal; 700. a machine tool cooling device; 710. a flow meter; 720. a flow meter signal; 800. a temperature sensor; 810. a temperature signal.
Detailed Description
The following detailed description of preferred embodiments of the invention will be made.
The following description of the embodiments refers to the accompanying drawings, which are included to illustrate specific embodiments in which the invention may be practiced. Directional phrases used in connection with the present invention, such as "upper," "lower," "front," "rear," "left," "right," "inner," "outer," "side," and the like, refer to the orientation of the figure only. Accordingly, the directional terminology is used for purposes of illustration and understanding, and is not intended to be limiting of the present application. In addition, in the description, unless explicitly described to the contrary, the word "comprise" or "comprises" should be understood to mean that including the element, but not excluding any other elements.
Fig. 1 to 4 are block schematic diagrams of a grinding machine monitoring system, specifically: the present application provides a monitoring system for a grinding machine 100, which is controlled by a first driving device 110 and a second driving device 130, for monitoring the machining of a workpiece (not shown) by a grinding device 120. In application, the first driving device 110 is an axial motor or an oil pressure driving device, where the axial direction represents linear (left-right movement or front-back movement); the second driving device 130 is a spindle motor; the grinding device 120 includes a spindle and a grinding wheel (not shown). The grinding machine monitoring system mainly includes a first sensor 140, a second sensor 150, a third sensor 160, an input unit 200, a storage unit 300, and a control unit 400.
The first sensor 140 is coupled to the first driving device 110 (shown in fig. 1 and 3) or the grinding device 120 (shown in fig. 2 and 4). When the grinding device 120 machines a workpiece, the first sensor 140 generates a first sensing signal 141. In specific implementation, the first sensor 140 is a linear encoder, a rotary encoder or an optical ruler, and can obtain the current position information of the machine; when the first sensor 140 is coupled to the grinding apparatus 120, the first sensor 140 is connected to the spindle of the grinding apparatus 120.
The second sensor 150 is coupled to the second driving device 130 (shown in fig. 1 and 2) or the grinding device 120 (shown in fig. 3 and 4). The second sensor 150 generates the second sensing signal 142 when the grinding device 120 processes the workpiece. In practical application, the second sensor 150 is a rotary encoder, and can obtain the current rotation angle of the spindle; when the second sensor 150 is coupled to the grinding apparatus 120, the second sensor 150 is connected to the spindle of the grinding apparatus 120.
The third sensor 160 is coupled to the grinding device 120. When the grinding device 120 machines a workpiece, the third sensor 160 generates a third sensing signal 143; in a specific application, the third sensor 160 is an accelerometer for measuring the acceleration of the object (for determining the vibration amplitude of the object), and the third sensor 160 (accelerometer) measures the acceleration of the grinding device 120 and converts the acceleration into a vibration signal of the grinding device 120.
The input unit 200 is used to set the monitoring factors 210 for the grinding process of the grinding machine 100. The monitoring factor is associated with the first sensing signal 141, the second sensing signal 142, and the third sensing signal 143. The input unit 200 is not limited to an input mode, and may be an input interface on the grinding machine 100 or an external device (e.g., a notebook computer) when the application is implemented. The monitoring factor 210 is workpiece burn or workpiece chatter mark, for example, whether the workpiece in grinding process is burned or whether the workpiece generates chatter mark; the workpiece burn refers to the phenomenon that the surface tissue of the workpiece is changed due to high temperature during grinding, and the surface of the workpiece is oxidized and discolored; the workpiece chatter mark is generated on a workpiece due to the fact that vibration is usually caused by periodic change in the environment (mechanism) or in the machining during grinding, and the vibration frequency of the workpiece is matched with the resonance frequency of the workpiece. On the other hand, workpiece chatter marks may also be caused by unintended, irregular vibration frequencies that may be generated during machining under particular conditions.
The storage unit 300 is configured to store at least a machining model 310 for grinding a workpiece. The storage unit 300 may be an external storage device or a memory built in the grinding machine 100, and the machining model 310 is a machining load model obtained by machining a standard workpiece in advance, which will be described in detail later.
The control unit 400 is coupled to the first driving device 110, the second driving device 130, the first sensor 140, the second sensor 150, the third sensor 160, the input unit 200 and the storage unit 300. The control unit 400 converts the first sensing signal 141 into one of the coordinates of the workpiece or the axial position of the grinding device 120, the axial position of the grinding device 120 being the linear position (left-right movement or front-back movement) of the grinding wheel in the grinding device 120; the control unit 400 converts the second sensing signal 142 into an angular position of the grinding device 120, wherein the angular position of the grinding device 120 is a rotation angle of a grinding wheel in the grinding device 120; the control unit 400 converts the third sensing signal 143 into a vibration signal of the grinding device 120, and uses the vibration signal to obtain the acceleration of the grinding device 120 and then convert the acceleration into a vibration signal (including the vibration frequency and the vibration phase) of the grinding device 120.
The control unit 400 compares the workpiece coordinate, the axial position of the grinding device 120, the angular position of the grinding device 120, the vibration signal of the grinding device 120, and the machining model 310 according to the monitoring factors 210 transmitted from the input unit 200, and generates a comparison result, and when the comparison result is different from a default range in the machining model 310 (i.e. larger than or smaller than a preset range), the control unit 400 generates a first command signal 410 and a second command signal 420, which are respectively transmitted to the first driving device 110 and the second driving device 130, for controlling the grinding device 120 and the workpiece to perform corresponding actions (the corresponding actions may be automatic reversing of the workpiece, or corresponding actions of adjusting the grinding device 120).
Fig. 5 is a schematic flow chart of a monitoring method of the grinding machine according to the present application. Based on the grinding machine monitoring system, the grinding machine monitoring method comprises the following steps:
step S110: the user sets the monitoring factor 210 of the grinding process to the control unit 400 through the input unit 200.
Step S120: the control unit 400 determines to select the required machining model 310 from the storage unit 300 through the monitoring factor 210 for comparison of machining data.
Step S130: when the grinding device 120 processes the workpiece, the control unit 400 is coupled to the first driving device 110 or the grinding device 120 through the first sensor 140 to generate the first sensing signal 141, which is converted into the coordinate of the workpiece or the axial position of the grinding device 120; the control unit 400 is coupled to the second driving device 130 or the grinding device 120 through the second sensor 150 to generate a second sensing signal 142, which is converted into the angular position of the grinding device 120; the control unit 400 is coupled to the grinding device 120 through the third sensor 160 to generate the third sensing signal 143, which is converted into the vibration signal of the grinding device 120.
Step S140: the control unit 400 compares the workpiece coordinates, the axial position of the grinding device 120, the angular position of the grinding device 120, and the vibration signal of the grinding device 120 with the machining model 310 according to the monitoring factors 210 transmitted from the input unit 200 and generates a comparison result.
Step S150: when the comparison result is different from the default range in the machining model 310, the control unit 400 generates a first command signal 410 and a second command signal 420, which are respectively transmitted to the first driving device 110 and the second driving device 130 for controlling the grinding device 120 and the workpiece to perform corresponding processing modes.
Fig. 6 is a schematic diagram illustrating a process of establishing a machining model in the grinding machine monitoring method of the present application. The machining model 310 is established by the following steps:
step S210: and processing the standard workpiece.
Step S220: during processing, the sensing data of the first sensor 140, the second sensor 150 and the third sensor 160 during processing are transmitted back to the control unit 400.
Step S230: the control unit 400 processes the respective data to obtain cleaner and noise-free data, which are used to delineate the machining model 310 of the workpiece.
FIG. 7 is a fifth block diagram of a grinding machine monitoring system according to the present application. In practical applications, the control unit 400 is further connected to a remote storage monitoring device 500 (the embodiment is described based on the embodiment shown in fig. 1) via a network, so as to synchronize the monitoring status of the grinding machine; in practical applications, the remote storage monitoring device 500 may be a server for storing monitoring data of a plurality of grinding machines; the remote computer can be used for monitoring and recording by off-site operators, so that a remote user or a monitor can synchronously know the processing condition and warn or perform other corresponding actions when abnormality is detected in the processing process. That is, the remote storage monitoring device 500 may be a server for storing monitoring data of multiple grinding machines, or may be a remote computer for monitoring and recording by an off-site operator.
In specific implementation, the control unit 400 calculates a load factor of the grinding device 120 according to the current of the second driving device 120, where the load factor is a ratio between a current torque command of the spindle motor and a rated torque, and is simply a ratio (%) between a current load borne by the motor and a current capacity thereof, compares the load factor of the grinding device 120, coordinates of the workpiece, an axial position of the grinding device 120, an angular position of the grinding device 120, and a vibration signal of the grinding device 120 with the machining model 310 to generate a comparison result, and the control unit 400 determines whether the grinding device generates an idle stroke according to the comparison result, and when the comparison result is different from a default range in the machining model 310, the control unit 400 controls the workpiece and the grinding device 120 to perform corresponding actions according to the difference, where the corresponding actions may be automatic workpiece reversing, and parameters required for the automatic reversing are the load factor and the vibration signal (the third sensor 160 correspondingly generates the third sensing signal 143), and can more accurately monitor whether the grinding device 120 or the workpiece needs the reversing actions by calculating the load factor of the grinding device 120, so as to improve work efficiency.
When the application is implemented, the control unit 400 calculates the feed amount of the grinding device 120, wherein the feed amount is the grinding amount (mm) of the grinding wheel to the workpiece, compares the feed amount of the grinding device 120, the workpiece coordinate, the axial position of the grinding device 120, the angular position of the grinding device 120 and the vibration signal of the grinding device 120 with the processing model 310 to generate a comparison result, and judges whether the workpiece generates workpiece burn or workpiece vibration mark or not according to the comparison result or judges whether the grinding device 120 exceeds a wear value (the wear value refers to whether the grinding wheel generates wear or not); when the control unit 400 determines that the workpiece has a burn or a chatter mark, the control unit 400 adjusts the feed amount of the grinding device 120 correspondingly, or when the grinding wheel exceeds a wear value, a warning is issued to remind the user to replace the grinding wheel. In another embodiment, the wear value may refer to the wear range of the grinding wheel.
When the application is implemented, the control unit 400 calculates the feed rate of the grinding device 120, wherein the feed rate is the grinding amount (mm/min) of the grinding wheel in unit time, compares the feed rate of the grinding device 120, the workpiece coordinates, the axial position of the grinding device 120, the angular position of the grinding device 120 and the vibration signal of the grinding device 120 with the machining model 310 to generate a comparison result, and judges whether the workpiece generates workpiece burn or poor roundness of the workpiece according to the comparison result (the poor roundness of the workpiece refers to that the workpiece generates periodic radial runout during grinding, so that the workpiece generates roundness error); when the control unit 400 determines that the workpiece is burned or the roundness of the workpiece is not good, the control unit 400 correspondingly adjusts the feed rate of the grinding device 120.
When the application is implemented, the control unit 400 calculates the rotation speed of the grinding wheel of the grinding device 120, wherein the rotation speed of the grinding wheel refers to the number of revolutions per minute (rpm) of the grinding wheel, compares the rotation speed of the grinding device 120, the workpiece coordinates, the axial position of the grinding device 120, the angular position of the grinding device 120, and the vibration signal of the grinding device 120 with the machining model 310 to generate a comparison result, determines whether the workpiece generates the workpiece chatter marks according to the comparison result by the control unit 400, and when the control unit 400 determines that the workpiece generates the workpiece chatter marks, the control unit 400 correspondingly adjusts the rotation speed of the grinding device 120.
When the application is implemented, when the excircle grinding machine is applied, the control unit 400 calculates the rotating speed of the workpiece, compares the rotating speed of the workpiece, the coordinates of the workpiece, the axial position of the grinding device 120, the angular position of the grinding device 120 and the vibration signal of the grinding device 120 with the machining model 310 and generates a comparison result, the control unit 400 judges whether the workpiece generates a workpiece chatter mark according to the comparison result, and when the control unit 400 judges that the workpiece generates the workpiece chatter mark, the control unit 400 correspondingly adjusts the rotating speed of the workpiece.
When the surface grinder is applied, the control unit 400 calculates the transverse moving speed of the workpiece, compares the transverse moving speed of the workpiece, the coordinates of the workpiece, the axial position of the grinding device 120, the angular position of the grinding device 120 and the vibration signal of the grinding device 120 with the machining model 310 to generate a comparison result, judges whether the workpiece generates the vibration mark of the workpiece according to the comparison result, and when the control unit 400 judges that the workpiece generates the vibration mark of the workpiece, the control unit 400 correspondingly adjusts the transverse moving speed of the workpiece.
Fig. 8 is a schematic diagram of a sixth block of the monitoring system of the grinding machine of the present application (an embodiment is described based on the embodiment shown in fig. 1). In application, the monitoring system of the grinding machine 100 further includes an audio sensor 600, the audio sensor 600 is coupled to the grinding device 120, the audio sensor 600 is used for sensing an audio signal 610 generated by the grinding device 120 during machining, the control unit 400 compares the audio signal 610, the workpiece coordinate, the axial position of the grinding device 120, the angular position of the grinding device 120, and the vibration signal of the grinding device 120 with the machining model 310 to generate a comparison result, and the control unit 400 determines whether workpiece chatter marks or grinding device stuffing occur on the workpiece according to the comparison result, where the grinding device stuffing (wheel stuffing) refers to generation of grinding wheel chips during grinding, and the chips are easy to stuff in air holes of the grinding wheel, so that the grinding wheel gradually becomes a non-serrated plane, and cannot effectively perform grinding. When the control unit 400 determines that the workpiece has chatter marks or is jammed, the control unit 400 correspondingly adjusts the feed amount, the rotation speed, or the lateral movement speed of the grinding device 120.
When the monitoring system of the grinding machine 100 is applied, the monitoring system further comprises a flow meter 710, the flow meter 710 is installed on the machine tool cooling device 700 and is used for sensing a flow meter signal 720 generated by the flow change of the cutting fluid applied in the machining process, the control unit compares the flow meter signal 720, the workpiece coordinate, the axial position of the grinding device 120, the angular position of the grinding device 120 and the vibration signal of the grinding device 120 with the machining model 310 and generates a comparison result, the control unit 400 judges whether the workpiece generates workpiece burn or the grinding device 120 is jammed according to the comparison result, and when the control unit 400 judges that the workpiece generates workpiece burn or the grinding device 120 is jammed, the control unit 400 correspondingly adjusts the feed amount and the feed rate of the grinding device 120 or the flow amount of the cutting fluid of the machine tool cooling device 700.
When the monitoring system of the grinding machine 100 is applied, the monitoring system further includes a temperature sensor 800, the temperature sensor 800 is configured to sense a temperature of the workpiece, the control unit compares the temperature signal 810, the coordinates of the workpiece, the axial position of the grinding device 120, the angular position of the grinding device 120, and the vibration signal of the grinding device 120, which are transmitted by the temperature sensor 800, with the machining model 310 to generate a comparison result, the control unit 400 determines whether the workpiece is burned according to the comparison result, and when the control unit 400 determines that the workpiece is burned, the control unit 400 correspondingly adjusts a feed rate and a feed rate of the grinding device 120 or a flow rate of the cutting fluid of the machine tool cooling device 700.
In practice, the control unit 400 further converts the axial position of the grinding apparatus 120 into the axial speed of the grinding apparatus 120, the axial acceleration of the grinding apparatus 120, or the axial jerk of the grinding apparatus 120, and the control unit 400 converts the angular position of the grinding apparatus 120 into the angular speed of the grinding apparatus 120 or the angular acceleration of the grinding apparatus 120. The position information obtained as described above is further differentiated to obtain, for example, velocity, acceleration or jerk, using the calculation function of the control unit 400. Specifically, it is difficult to determine whether the grinding wheel has ground the workpiece by determining the change of the angular position (0 to 360 °), but it is more obvious to determine whether the grinding wheel has ground the workpiece by determining the change of the angular velocity and the angular acceleration. The angular velocity of the grinding device 120 is the rotational angular velocity of the grinding wheel in the grinding device, and the acceleration is the same; and the axial acceleration of the grinding apparatus 120 may be reconverted to an axial jerk of the grinding apparatus 120.
When the application is implemented, the control unit 400 compares the workpiece coordinate, the axial position of the grinding device 120, the angular position of the grinding device 120, the vibration signal of the grinding device 120 with the processing model according to the monitoring factors 210 transmitted from the input unit 200, and when the comparison result is different from the default range in the processing model 310, the control unit 400 sends out a warning signal, records the current processing data or executes a protection mechanism, and the same warning signal can be synchronously displayed and recorded on the remote storage monitoring device 500, wherein the warning signal comprises sound, color or other forms capable of warning; the protection mechanism includes the grinding device 120 stopping machining or the grinding device 120 disengaging from the workpiece.
When the application is implemented, the machining model 310 of the grinding machine monitoring system is integrated by each machining data, when a standard workpiece is machined, the first sensor 140, the second sensor 150 and the third sensor 160 transmit the machining data such as load rate, vibration value, feed rate, feed amount, workpiece rotating speed, grinding wheel abrasion value, coordinates, flow rate and pressure of cutting fluid and the like back to the control unit 400 through the driver, the control unit 400 performs a series of processing steps on each data such as filtering, averaging, smoothing and the like to obtain cleaner and noise interference-free data, and the data are used for drawing the machining model 310 of the workpiece; the machining model 310 includes three-dimensional or two-dimensional machining paths, a load factor analyzed by a motor current, a grinding wheel wear value calculated from a machined workpiece count and an abrasive wear characteristic, a feed rate synthesized in each axial direction, actual rotation speeds of the grinding wheel and the workpiece, a cutting fluid flow measured by a flow meter, a cutting fluid pressure measured by a pressure gauge, a machine amplitude measured by an accelerometer, and other alignment time series data, that is, different machining positions have different data such as load factors, vibration values, and feed rates.
Subsequently, when a general workpiece is processed in a subsequent batch, when the processing data is out of the set default range (or threshold), the processing action selected by the user can be responded, and the processing action can be selected according to the requirement of the user, and comprises corresponding modes of sending out an alarm, writing a file record (recording current processing data), executing a protection mechanism (such as stopping rotation of the spindle and lifting the tool bit), and the like.
In addition, the processing model 310 integrates various data in the processing process, and the data can be used as a basis for judging the processing quality, so that the empirical rule that the processing problem can be judged only depending on the operation experience of a user in the processing process of a conventional grinding machine is solved, for example, the size of sparks can cause workpiece burn. The other judgment is that the grinding sound of the harsh sound may represent the generation of chatter marks on the workpiece, and whether the chatter marks occur or not can be judged by observing the rotation speed of the grinding wheel, the rotation speed of the workpiece, the amplitude of the machine or the feed amount, and at this time, if the rotation speed of the grinding wheel is too high, the feed amount is too large or the amplitude of the machine is too large, the control unit 400 also immediately performs a processing action to prompt a user to reduce the rotation speed of the grinding wheel, reduce the feed amount or check whether the mechanisms of the grinding wheel, the bearing, the grinding wheel seat and the like are firm.
The method and the device for checking the machining process utilize model comparison to assist a user in observing changes in the machining process, quantify the machining process into visual data, and have obvious help for checking problems. In addition, the influence of the processing parameters on the processing quality can be observed through each data recorded by the processing model 310, so that a user can adjust the calling of the processing parameters according to the requirement, for example, the user hopes to obtain good surface roughness, the feed amount can be reduced, and the rotating speed of the grinding wheel can be increased; or the feed rate can be increased and the feed amount can be increased if the machining efficiency is improved; according to the application situation of the user, the model can provide the calling of a plurality of groups of processing parameters, and the user can conveniently deal with various situations.
In the application of detecting an abnormality in a machining process, by establishing the machining model 310 of the standard part, when a general batch machining is performed subsequently, all workpieces are compared in real time according to the model, and when the machining data of the workpieces is different from the machining model 310 of the standard part, the control unit 400 gives an alarm or performs other corresponding actions. For example, the user can know the position of the abnormality by processing information (such as processing path, processing type and processing time) by using the abnormality detection function, so as to help the user to clear the reason and time point of the abnormality; in addition, the change rate of the processing information, such as the change of the load factor and the amplitude of the machine table, can be further utilized to obtain the trend of data change in the processing process, thereby achieving the purpose of preventing abnormity and maintaining the processing quality of batch processing.
The abnormality detection may be performed by a single observation of the processing data (including data acquired by an external sensor) received by the control unit 400; for example, when a workpiece is machined, a data object to be observed is selected, a threshold (i.e., a default range in the machining model) is set for the data object, a window (e.g., a display screen of the input unit 200) of the simulated machining path displays different colors due to changes in data, a color section is marked by the set threshold, and when improper machining data is transmitted back, a color different from the color in the threshold is displayed, which indicates that an abnormal phenomenon occurs in the machining path; the control unit 400 may alert or guide the user to make a corresponding solution for the abnormal processing section. It should be noted that the user can adjust the threshold value (i.e. the default range in the machining model) in the input unit 200 according to the actual requirement.
In an embodiment, when the user sets one or more grinding functions (e.g., monitoring workpiece burn or monitoring workpiece chatter marks) as the monitoring factor 210 in the input unit 200, the control unit 400 automatically selects corresponding machining parameters (e.g., feed rate or feed amount) according to the one or more grinding functions for monitoring. In another embodiment, after the user sets one or more grinding functions in the input unit 200, one or more processing parameters may also be set in the input unit 200 as the monitoring factor 210 according to actual requirements, and the control unit 400 may monitor according to the one or more processing parameters.
The user can know the abnormal phenomenon on a certain position of the workpiece according to the abnormal detection function so as to further inspect the problem in the processing process, the processing mode provides the user with the ability to know the abnormal section generated in the processing process, and the abnormal section is displayed as visual data by quantifying the experience mode of manually judging the processing abnormality in the prior art, thereby helping the user avoid the influence of wrong processing conditions on the processing quality of the workpiece.
In a further application, the anomaly detection function of the grinding machine monitoring system and the anomaly detection function of the grinding machine monitoring method can be applied to a grinding machine with an intelligent reversing function in a matching way, for example, a surface grinding machine is taken as an example, a user inputs a machining program command according to the size of a workpiece to be achieved, a worktable of the grinding machine is enabled to move left and right along an X axis, a travel distance generated at the time is a fixed grinding path, a standard workpiece is machined for one time, a machining model is established by recording machining data (load rate, vibration value and coordinates), then in the rest of general machining processes, a spindle load rate generated when a grinding wheel grinds the workpiece is judged to be lower than a set threshold value (representing that the grinding wheel does not grind the workpiece and generates an idle travel) through the machining model, the grinding path can perform reversing action according to the machining model, namely, the next section of machining pass is machined, and the optimal grinding path is generated for the grinding wheel to grind the workpiece by shortening the travel distance when the worktable moves left and right along the X axis, so as to improve the working efficiency.
The above embodiments are only for illustrating the technical idea and features of the present invention, and the purpose of the present invention is to enable those skilled in the art to understand the content of the present invention and implement the present invention, and not to limit the protection scope of the present invention by this means. All equivalent changes and modifications made according to the spirit of the present invention should be covered in the protection scope of the present invention.

Claims (21)

1. A grinding machine monitoring system for monitoring the machining of a workpiece on a grinding machine by a grinding device controlled by a first drive and a second drive, comprising:
a first sensor coupled to the first drive or the grinding device; when the grinding device is used for machining the workpiece, the first sensor correspondingly generates a first sensing signal;
a second sensor coupled to the second drive device or the grinding device; when the grinding device is used for processing the workpiece, the second sensor correspondingly generates a second sensing signal;
a third sensor coupled to the grinding device; when the grinding device is used for processing the workpiece, the third sensor correspondingly generates a third sensing signal;
the input unit is used for setting monitoring factors of grinding; the monitoring factor is associated with the first sense signal, the second sense signal, and the third sense signal;
a storage unit for storing at least one machining model for grinding the workpiece;
a control unit coupled to the first driving device, the second driving device, the first sensor, the second sensor, the third sensor, the input unit, and the storage unit;
the control unit converts the first sensing signal into a workpiece coordinate or a grinding device axial position, converts the second sensing signal into a grinding device angular position, and converts the third sensing signal into a grinding device vibration signal;
the control unit compares the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device, the vibration signal of the grinding device and the machining model according to the monitoring factors transmitted by the input unit and generates a comparison result, and when the comparison result is different from a default range in the machining model, the control unit generates a first command signal and a second command signal and transmits the first command signal and the second command signal to the first driving device and the second driving device respectively to control the grinding device and the workpiece to perform corresponding actions.
2. The machine monitoring system of claim 1, wherein: the control unit calculates the load factor of the grinding device according to the current of the second driving device, compares the load factor of the grinding device, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result; the control unit judges whether the grinding device generates idle stroke according to the comparison result, and when the comparison result is different from a default range in the machining model, the control unit controls the workpiece and the grinding device to perform corresponding actions according to the difference; or/and the control unit calculates the feed amount of the grinding device, compares the feed amount of the grinding device, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates workpiece burn or workpiece vibration mark or whether the grinding device exceeds a wear value according to the comparison result, and correspondingly adjusts the feed amount of the grinding device when the control unit judges that the workpiece generates the workpiece burn or the workpiece vibration mark; or/and the control unit calculates the feed rate of the grinding device, compares the feed rate of the grinding device, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates workpiece burn or poor roundness of the workpiece according to the comparison result, and correspondingly adjusts the feed rate of the grinding device when the control unit judges that the workpiece generates workpiece burn or poor roundness of the workpiece; or/and the control unit calculates the grinding wheel rotating speed of the grinding device, compares the rotating speed of the grinding device, the workpiece coordinate, the axial position of the grinding device, the angle position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates a workpiece vibration mark according to the comparison result, and correspondingly adjusts the rotating speed of the grinding device when the control unit judges that the workpiece generates the workpiece vibration mark; or/and the control unit calculates the rotating speed of the workpiece, compares the rotating speed of the workpiece, the coordinates of the workpiece, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates a workpiece vibration mark according to the comparison result, and correspondingly adjusts the rotating speed of the workpiece when the control unit judges that the workpiece generates the workpiece vibration mark; and/or the control unit calculates the transverse moving speed of the workpiece, compares the transverse moving speed of the workpiece, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates a workpiece vibration mark according to the comparison result, and correspondingly adjusts the transverse moving speed of the workpiece when the control unit judges that the workpiece generates the workpiece vibration mark.
3. The machine monitoring system of claim 1, wherein: the control unit judges whether the workpiece generates workpiece vibration marks or the grinding device is stuffed according to the comparison result, and when the control unit judges that the workpiece generates the workpiece vibration marks or the grinding device is stuffed, the control unit correspondingly adjusts the feed amount or the rotating speed of the grinding device or the rotating speed of the workpiece or the transverse moving speed of the workpiece.
4. The machine monitoring system of claim 1, wherein: the flow meter is arranged on a machine tool cooling device and used for sensing the flow change of cutting fluid applied in the machining process to generate a flow meter signal; the control unit compares the flow meter signal, the workpiece coordinate, the axial position of the grinding device, the angle position of the grinding device, the vibration signal of the grinding device with the machining model and generates a comparison result, the control unit judges whether the workpiece generates workpiece burn or the grinding device is stuffed according to the comparison result, and when the control unit judges that the workpiece generates the workpiece burn or the grinding device is stuffed, the control unit correspondingly adjusts the feed amount or the feed rate of the grinding device or the flow rate of the cutting fluid of the machine tool cooling device.
5. A machine monitoring system as claimed in claim 4, in which: the temperature sensor is used for sensing the temperature of the workpiece, the control unit compares the workpiece temperature, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, the control unit judges whether the workpiece generates workpiece burn according to the comparison result, and when the control unit judges that the workpiece generates workpiece burn, the control unit correspondingly adjusts the feed amount or feed rate of the grinding device or the flow rate of cutting fluid of the machine tool cooling device.
6. The machine monitoring system of claim 1, wherein: the control unit also converts the axial position of the grinding device into the axial speed, the axial acceleration or the axial jerk of the grinding device, and converts the angular position of the grinding device into the angular speed or the angular acceleration of the grinding device.
7. The machine monitoring system of claim 1, wherein: the control unit compares the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device, the vibration signal of the grinding device with the machining model according to the monitoring factors transmitted by the input unit, and when the comparison result is different from the default range in the machining model, the control unit sends out a warning signal, records current machining data or executes a protection mechanism, wherein the warning signal comprises a warning form of sound or color, and the protection mechanism comprises that the grinding device stops machining or the grinding device is separated from the workpiece.
8. The machine monitoring system of claim 1, wherein: the first driving device is an axial motor or an oil pressure driving device, and the second driving device is a spindle motor.
9. The machine monitoring system of claim 1, wherein: the first sensor is a linear encoder, a rotary encoder or an optical ruler, the second sensor is a rotary encoder, and the third sensor is an accelerometer.
10. The machine monitoring system of claim 1, wherein: the control unit is also connected with a remote storage monitoring device through a network, and synchronizes the monitoring condition of the grinding machine.
11. A method for monitoring a grinding machine, which is a method for monitoring the processing of a workpiece by a grinding device controlled by a first driving device and a second driving device on the grinding machine, is characterized in that: it comprises the following steps:
(1) A user sets a monitoring factor of the grinding processing to the control unit through the input unit;
(2) The control unit judges and selects at least one required processing model from the storage unit through the monitoring factors to compare processing data;
(3) Starting to process the workpiece, wherein when the grinding device processes the workpiece, the control unit is coupled to the first driving device or the grinding device through a first sensor to generate a first sensing signal which is converted into a workpiece coordinate or a grinding device axial position; the control unit is coupled to the second driving device through a second sensor or generates a second sensing signal which is converted into a grinding device angle position, and the control unit is coupled to the grinding device through a third sensor and generates a third sensing signal which is converted into a grinding device vibration signal;
(4) The control unit compares the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device, the vibration signal of the grinding device and the machining model according to the monitoring factors transmitted by the input unit and generates a comparison result, and when the comparison result is different from a default range in the machining model, the control unit generates a first command signal and a second command signal which are transmitted to the first driving device and the second driving device respectively and used for controlling the grinding device and the workpiece to carry out corresponding processing modes.
12. A method of monitoring a grinding machine as claimed in claim 11, wherein: the machining model is established in such a way that when a standard workpiece is machined, the first sensor, the second sensor and the third sensor transmit sensing data of a machining process back to the control unit, the control unit processes all the data to obtain cleaner data without noise interference, and the machining model of the workpiece is drawn by using the data.
13. A machine monitoring method as claimed in claim 11, in which: the control unit calculates the load factor of the grinding device according to the current of the second driving device, compares the load factor of the grinding device, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the grinding device generates idle stroke according to the comparison result, and controls the workpiece and the grinding device to perform corresponding actions according to the difference when the comparison result is different from a default range in the machining model; or/and the control unit calculates the feed amount of the grinding device, compares the feed amount of the grinding device, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates workpiece burn or workpiece vibration mark or whether the grinding device exceeds a wear value according to the comparison result, and correspondingly adjusts the feed amount of the grinding device when the control unit judges that the workpiece generates the workpiece burn or the workpiece vibration mark; or/and the control unit calculates the feed rate of the grinding device, compares the feed rate of the grinding device, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates workpiece burn or poor roundness of the workpiece according to the comparison result, and correspondingly adjusts the feed rate of the grinding device when the control unit judges that the workpiece generates workpiece burn or poor roundness of the workpiece; or/and the control unit calculates the grinding wheel rotating speed of the grinding device, compares the rotating speed of the grinding device, the workpiece coordinate, the axial position of the grinding device, the angle position of the grinding device, the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates a workpiece vibration mark according to the comparison result, and correspondingly adjusts the rotating speed of the grinding device when the control unit judges that the workpiece generates the workpiece vibration mark; or/and the control unit calculates the rotating speed of the workpiece, compares the rotating speed of the workpiece, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device, the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates a workpiece chatter mark according to the comparison result, and correspondingly adjusts the rotating speed of the workpiece when the control unit judges that the workpiece generates the workpiece chatter mark; and/or the control unit calculates the transverse moving speed of the workpiece, compares the transverse moving speed of the workpiece, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, judges whether the workpiece generates a workpiece chatter mark according to the comparison result, and correspondingly adjusts the transverse moving speed of the workpiece when the control unit judges that the workpiece generates the workpiece chatter mark.
14. A machine monitoring method as claimed in claim 11, in which: the grinding device utilizes an audio sensor to sense an audio signal generated by the grinding device in machining, the control unit compares the audio signal, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model to generate a comparison result, the control unit judges whether the workpiece generates workpiece vibration marks or the grinding device is stuffed according to the comparison result, and when the control unit judges that the workpiece generates the workpiece vibration marks or the grinding device is stuffed, the control unit correspondingly adjusts the feed amount, the rotating speed or the transverse moving speed of the workpiece of the grinding device.
15. A machine monitoring method as claimed in claim 11, in which: the grinding machine is provided with a machine tool cooling device, the machine tool cooling device is used for sensing a flow meter signal generated by the change of cutting fluid flow applied in machining through a flow meter, the control unit compares the flow meter signal, the workpiece coordinate, the axial position of the grinding device, the angle position of the grinding device and the vibration signal of the grinding device with the machining model and generates a comparison result, the control unit judges whether the workpiece generates workpiece burn or grinding device stuffing according to the comparison result, and when the control unit judges that the workpiece generates the workpiece burn or the grinding device stuffing, the control unit correspondingly adjusts the feed amount and the feed rate of the grinding device or the cutting fluid flow of the machine tool cooling device.
16. A machine monitoring method as claimed in claim 15, characterised in that: the grinding machine is characterized in that the grinding machine is further provided with a temperature sensor for sensing the temperature of the workpiece, the control unit compares the workpiece temperature, the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model to generate a comparison result, the control unit judges whether the workpiece generates workpiece burn according to the comparison result, and when the control unit judges that the workpiece generates workpiece burn, the control unit correspondingly adjusts the feed amount and feed rate of the grinding device or the flow rate of cutting fluid of the machine tool cooling device.
17. A machine monitoring method as claimed in claim 11, in which: the control unit also converts the axial position of the grinding device into the axial speed, the axial acceleration or the axial jerk of the grinding device, and converts the angular position of the grinding device into the angular speed or the angular acceleration of the grinding device.
18. A method of monitoring a grinding machine as claimed in claim 11, wherein: the control unit compares the workpiece coordinate, the axial position of the grinding device, the angular position of the grinding device and the vibration signal of the grinding device with the machining model according to the monitoring factors transmitted by the input unit, and when the comparison result is different from the default range in the machining model, the control unit sends out a warning signal, records current machining data or executes a protection mechanism, wherein the warning signal comprises a warning form of sound or color, and the protection mechanism comprises that the grinding device stops machining or the grinding device is separated from the workpiece.
19. A machine monitoring method as claimed in claim 11, in which: the first driving device is an axial motor or an oil pressure driving device, and the second driving device is a spindle motor.
20. A machine monitoring method as claimed in claim 11, in which: the first sensor is a linear encoder or a rotary encoder or an optical scale, the second sensor is a rotary encoder, and the third sensor is an accelerometer.
21. A method of monitoring a grinding machine as claimed in claim 11, wherein: the control unit is also connected with a remote storage monitoring device through a network, and the condition of the grinding machine is synchronously monitored through the remote storage monitoring device.
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