CN115847187A - Real-time monitoring system for deep and narrow groove turning - Google Patents
Real-time monitoring system for deep and narrow groove turning Download PDFInfo
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- CN115847187A CN115847187A CN202310169770.8A CN202310169770A CN115847187A CN 115847187 A CN115847187 A CN 115847187A CN 202310169770 A CN202310169770 A CN 202310169770A CN 115847187 A CN115847187 A CN 115847187A
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Abstract
The invention discloses a real-time monitoring system for deep and narrow groove turning, which belongs to the technical field of mechanical manufacturing and comprises an acquisition module; a processing module; the acquisition module is provided with a tool image acquisition unit, and the tool image acquisition unit is used for acquiring a tool image of deep and narrow groove turning and transmitting the tool image to the processing module; the processing module is provided with an image processing unit and a judging unit, the image processing unit is provided with a preprocessing unit and a feature extraction unit, and the processing module has the beneficial effects that the working condition of the tool bit is judged according to the temperature rising rate of the tool bit, the probability of tool breakage is reduced to a great extent, and the processing cost of deep and narrow grooves is reduced.
Description
Technical Field
The invention belongs to the technical field of machine manufacturing, relates to a part machining technology with deep and narrow grooves, and particularly relates to a real-time monitoring system for deep and narrow groove turning.
Background
The metal cutting process is inevitably accompanied with the phenomenon of cutter abrasion and even damage, especially the processing of deep narrow grooves has larger challenge, when processing deep narrow groove parts, the phenomena of cutter beating and cutter breaking are very easy to occur, on one hand, because the parts have high material hardness and high strength, the heat conductivity coefficient of the parts is low, the heat conductivity is very poor, the cutting heat is concentrated near the cutter point during the turning process, the cutting heat is not easy to be dispersed, the service life of the cutter can be shortened due to high temperature, the processed parts can be damaged, and therefore the cutter and the parts are very easy to be damaged. On the other hand, because of the special shape of dark narrow groove, the tool bit is close to the root in dark narrow groove more, and iron fillings are just more difficult to discharge, and the extrusion between tool bit and iron fillings, the part three makes the tool bit breakage very easily, causes the part to scrap, to the part producer, has undoubtedly greatly increased extra spending.
For example, the outer ring assembly of a high pressure turbine of a certain type of engine is an important part of the turbine unit and is also a necessary replacement. The high-pressure turbine outer ring component is assembled in a high-pressure turbine unit, works in a high-temperature and high-pressure environment, is structurally an 8-degree 34' fan-shaped block, and is structurally characterized in that the sectional view of the structure is shown in figure 1, the size of an annular deep narrow groove on the end face is very strict, the requirement on the groove width is 1.85 +/-0.05 mm, the groove depth is 5.3 +/-0.1 mm, the high-pressure turbine outer ring component is made of nickel-based precipitation hardening type isometric crystal casting high-temperature alloy K465, the alloy is low in heat conductivity coefficient, poor in heat conductivity, cutting heat is concentrated near a cutter point and is not easy to dissipate, the cutting temperature is high, the hardness and the strength of the high-pressure turbine outer ring component are high, and the high-pressure turbine outer ring component belongs to a difficult-processing material.
Statistically, approximately 20% of machine tool down time is due to tool breakage, and the cost of the tool itself and tool change accounts for 3% -12% of the total product cost. Therefore, in order to reduce the cost of the cutter and the cutter changing, the real-time monitoring system for the deep and narrow groove turning is very valuable.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides a real-time monitoring system for deep and narrow groove turning.
In order to achieve the purpose, the invention adopts the technical scheme that: the real-time monitoring system for the turning of the deep and narrow groove comprises an acquisition module; a processing module; the acquisition module is provided with a tool image acquisition unit, and the tool image acquisition unit is used for acquiring a tool image of deep and narrow groove turning and transmitting the tool image to the processing module; the processing module is provided with an image processing unit and a judging unit, the image processing unit is provided with a preprocessing unit and a feature extraction unit, the preprocessing unit carries out image preprocessing on a cutter image, the feature extraction unit extracts RGB pixel values of the cutter from preprocessed image information, the judging unit judges the change rate A of the RGB pixel values of the cutter and meets the requirement, when A1 is larger than A and smaller than A2, the judging unit outputs a primary danger signal, when A is larger than A2, the judging unit outputs a secondary danger signal, A1 is a first change threshold, and A2 is a second change threshold.
Preferably, the tool image acquisition unit has a camera with a green filter.
Preferably, the processing module is provided with a counting unit, and the counting unit is used for calculating the sum B of pixel points of which the green value of the tool exceeds 150 at a certain moment; the judging unit judges B, when B is larger than B1, the judging unit outputs a primary danger signal, when B is larger than B2, the judging unit outputs a secondary danger signal, B1 is a first pixel point threshold value, B2 is a second pixel point threshold value, and B2 is larger than B1.
Preferably, the processing module is provided with a calculating unit, the calculating unit is used for calculating the area change rate C of critical pixel points of the cutter in a fixed time period, and the critical pixel points comprise pixel points with green values larger than 140; the judging unit judges the area change rate C of critical pixel points of the cutter in a fixed time period, when C is larger than C1, the judging unit outputs a first-level danger signal, when C is larger than C2, the judging unit outputs a second-level danger signal, C1 is a first area change threshold value, C2 is a second area change threshold value, and C1 is smaller than C2.
Preferably, the processing module is provided with a first screening unit and a second screening unit; the first screening unit screens out a pixel point coordinate set of which the green value of the cutter image is (140, 160) from the preprocessed image information, and the second screening unit is used for screening out a straight line which passes through the pixel point coordinate set and has the largest number of pixel points in a parallel straight line system perpendicular to the cutter feeding direction to serve as a temperature indicating line; the judging unit judges the change rate of the temperature indicating line of the cutter, and if the change rate of the temperature indicating line is larger than a safety change threshold value, the judging unit outputs a secondary danger signal.
Preferably, the storage module has a storage unit, wherein the storage unit is configured to store the preprocessed image information, and when a green value of the tool image in the preprocessed image information is a high inverse value, the green value at the coordinate is stored as 210, otherwise, the original green value and the corresponding coordinate are stored; and storing pixel points with green values larger than 210 under the current coordinate of the cutter, wherein the pixel values with the green values smaller than 210 at this time under the current coordinate of the cutter are high-negative values.
Preferably, the processing module has an identification unit, and the identification unit is configured to detect whether the tool is replaced, and if the tool is replaced, clear the content stored in the storage unit, otherwise, retain the content stored in the storage unit.
Preferably, the tool image acquisition unit is provided with an infrared thermal imager, and the infrared thermal imager acquires temperature image information of the tool machined by the depth narrow groove lathe and transmits the temperature image information to the processing module.
Preferably, the temperature data detected by the infrared thermal imager is H, H = K × (S0 × H0)/S1, S0 is the standard distance between the infrared thermal imager and the tool, S1 is the actual distance between the infrared thermal imager and the tool, H0 is the temperature detected when the standard distance is between the infrared thermal imager and the tool, H0 is the same as the actual temperature of the tool, and K is the energy coefficient; when H is more than 700 ℃, the judgment unit outputs a first-level danger signal.
Preferably, the acquisition module is provided with a linkage assembly and a support assembly, the linkage assembly is used for receiving the movement instruction, the support assembly is used for preventing the infrared thermal imager from shaking, and the infrared thermal imager and the cutter move synchronously along the same movement track.
Preferably, the acquisition module is provided with a sound wave acquisition unit, and the sound wave acquisition unit acquires sound wave information of deep and narrow groove turning and transmits the sound wave information to the processing module; the processing module is provided with a sound processing unit, the sound processing unit processes sound wave information to obtain sound wave frequency information L, the judging unit judges the sound wave frequency information L, when L is larger than L1, the judging unit outputs a first-level danger signal, and L1 is a frequency threshold value.
Preferably, the processing module further comprises a sound calculating unit, the sound calculating unit is used for calculating the similarity S between the sound wave frequency information L and the abnormal audio, the judging unit judges the similarity S, if S > 70%, the judging unit outputs a primary danger signal, and if S > 75%, the judging unit outputs a secondary danger signal.
Preferably, the acquisition module is provided with a part image acquisition unit, and the part image acquisition unit is used for acquiring image information at the deep and narrow groove of the processed part and transmitting the image information to the processing module; the processing module is provided with a comparison unit, the comparison unit is used for calculating a pixel difference P between the RGB pixel value of the cutter and the RGB pixel value of the deep and narrow groove of the processed part, the judgment unit judges the pixel difference P, and if P is smaller than P1, the judgment unit outputs a primary danger signal.
Preferably, the display module is used for displaying the working state of the cutter, the display screen is green to indicate that the cutter is normal, the display screen is orange to indicate that the cutter is abnormal and the judging unit outputs the first-level danger signal, and the display screen is red to indicate that the cutter is dangerous and the judging unit outputs the second-level danger signal.
Preferably, the power supply module and the transmission port; the power module is used for providing power for the real-time monitoring system for deep and narrow groove turning, and the transmission port is used for providing an interface for the judgment unit to transmit data.
The invention has the beneficial effect that the real-time monitoring system for the turning processing of the deep and narrow groove is provided. The invention has the beneficial effects that firstly, the working condition of the tool bit can be judged according to the change rate of RGB values at the tool bit, the probability of tool breakage is reduced to a great extent, and the processing cost of deep and narrow grooves is reduced; secondly, the working condition of the cutter is judged according to the change rate D of the temperature indicating line of the cutter, so that the accuracy of a real-time detection system is improved.
Drawings
FIG. 1 is a schematic cross-sectional view of a high pressure turbine outer ring assembly;
FIG. 2 is a schematic diagram of a tool, (a) is a schematic diagram of a tool obtained after an initial time processing, and (b) is a schematic diagram of a tool obtained after a final time processing;
FIG. 3 is a block diagram of another real-time monitoring system for deep and narrow groove turning;
fig. 4 is a frame diagram of a real-time monitoring system for deep and narrow groove turning.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without making any creative effort based on the embodiments in the present invention, belong to the protection scope of the present invention.
Referring to fig. 1-4, embodiments of the present invention are shown as follows.
Example 1:
a real-time monitoring system for deep and narrow groove turning comprises an acquisition module; a processing module; the acquisition module is provided with a cutter image acquisition unit, and the cutter image acquisition unit is used for acquiring a cutter image of the deep and narrow groove turning and transmitting the cutter image to the processing module; the processing module is provided with an image processing unit and a judging unit, the image processing unit is provided with a preprocessing unit and a feature extraction unit, the preprocessing unit carries out image preprocessing on a cutter image, the feature extraction unit extracts RGB pixel values of the cutter from preprocessed image information, the judging unit judges the change rate A of the RGB pixel values of the cutter and meets the requirement, when A1 is larger than A and smaller than A2, the judging unit outputs a primary danger signal, when A is larger than A2, the judging unit outputs a secondary danger signal, A1 is a first change threshold, and A2 is a second change threshold.
Due to the particularity of the deep narrow groove, the width of the deep narrow groove to be processed is small (generally 1mm-2 mm), the ratio of the depth to the width is large, the scrap iron is more difficult to discharge when the tool bit is closer to the root of the deep narrow groove, the tool bit is broken or displaced easily due to the extrusion of the tool bit, the scrap iron and the groove of the part, the part is further damaged or even scrapped when the tool bit is displaced, the production efficiency of the part is reduced when the tool bit is broken or displaced, and the production cost of the part is increased. On the other hand, due to the fact that the to-be-machined part material is high in hardness and strength, low in heat conductivity coefficient and poor in heat conductivity, cutting heat is concentrated near a cutter point during machining, the cutting heat is not easy to dissipate, the service life of the cutter is shortened due to high temperature, and the cutter head and parts are extremely prone to being damaged during machining of deep and narrow grooves. The deep and narrow groove turning real-time monitoring system is valuable, and the phenomenon of cutter breakage is avoided by monitoring the working condition of the cutter head in real time.
In this embodiment, a real-time monitoring system for deep and narrow groove turning is provided, which includes an acquisition module; a processing module; the acquisition module is provided with a tool image acquisition unit, and the tool image acquisition unit is used for acquiring a tool image of deep and narrow groove turning and transmitting the tool image to the processing module; in this embodiment, the tool image capturing unit may be a high-definition camera, a miniature camera, or the like. The processing module is provided with an image processing unit and a judging unit, the image processing unit is provided with a preprocessing unit and a feature extracting unit, and the preprocessing unit is used for preprocessing the image of the cutter. In one embodiment, the image preprocessing may include performing gray scale transformation and edge extraction on the acquired image information to obtain profile information of the tool, and then obtaining an RGB image of only the tool according to the profile information of the tool. And the information irrelevant to the tool bit can be eliminated by performing feature extraction, image segmentation, matching and identification on the acquired image information.
In the process of cutting steel, the relationship between the color of a cutting material and the cutting temperature can be as follows: less than about < 200 ℃; light yellow: about 220 ℃; dark blue: about 300 ℃; light gray: about 400 ℃; dark purple black: about > 500 ℃. The invention also needs to claim that the parts processed by the invention are not limited to nickel-based precipitation hardening type isometric crystal casting superalloy K465, but also comprise deep and narrow groove processing of other materials with high hardness and low heat conductivity coefficient.
The color of the tool bit is different along with the change of the cutting temperature, when the tool bit cuts deep and narrow grooves, the color of the tool is changed into cyan and green along with the temperature rise, and finally the tool is changed into red along with the temperature rise, the phenomena of tool breaking and tool beating are easily caused when the tool is changed into red, namely the tool is easily broken or the tool is easily broken, therefore, the real-time monitoring of the color of the tool is important, the monitoring of the trend that the tool turns red means that the tool is close to a dangerous working state, and if the processing strategy is not modified in time, the processing strategy is not compensated. The change rate A of the RGB pixel values of the cutter is judged by the judging unit, and the condition that when A1 is larger than A and smaller than A2, the judging unit outputs a primary danger signal is met, when A is larger than A2, the judging unit outputs a secondary danger signal, A1 is a first change threshold value, and A2 is a second change threshold value. In this embodiment, the variation rate a of the RGB pixel values can be defined as the sum of the respective variation rates of the three primary colors (red, green, and blue), the value range of A1 is 15/s-20/s, and the value range of A2 is 25/s-30/s. The invention can transmit the output signal of the judging unit to the processing machine tool, the processing machine tool can regulate and control the output signal of the judging unit according to the output signal of the judging unit, and the work of the processing machine tool is controlled by the real-time monitoring system for turning the deep and narrow groove, thereby effectively avoiding the damage of a tool bit and improving the production efficiency of the deep and narrow groove.
Example 2:
in one embodiment, the invention monitors the green component in the tool image in real time, and judges the green change rate of the RGB pixel values of the tool, where a = (G2-G1)/T1, G1 is the median value of the green component in the RGB pixel values of the tool at the initial time within the fixed time period T1, G2 is the median value of the green component in the RGB pixel values of the tool at the end time within the fixed time period T1, and a is the green change rate of the tool within the fixed time period T1; and when A1 is more than A and less than A2, the judging unit outputs a first-level danger signal, and when A is more than A2, the judging unit outputs a second-level danger signal, wherein A1 is a first green change threshold, and A2 is a second change threshold. Namely, in a period of normal machining, the faster the change of the green value at the initial time and the green value at the tail time indicates the faster the temperature change, and the working condition of the cutter head is judged by judging the relationship between the green change rate A of the cutter and the green change rates A1 and A2.
In one embodiment, A1 is 5/s, A2 is 13/s, RGB represents colors of three channels of red, green and blue, color values of each channel have 256 levels, and are numerically represented as 0, 1, 2, 3,.. And 255, for example, a value with the same number of green color values in a green channel of an RGB image of a tool at an initial time is a green component median value 34, and a value with the same number of green color values in a green channel of an RGB image of a tool after 5s is a green component median value 63, a = (63-34)/5 =5.8/s, which indicates that the temperature of the tool is abnormal in the time period, and the determining unit outputs a primary danger signal. According to the invention, the work of the processing machine tool is controlled by the deep and narrow groove turning real-time monitoring system, so that the damage of a tool bit is effectively avoided, and the production efficiency of the deep and narrow groove is improved.
Example 3:
the cutter image acquisition unit is provided with a camera which is provided with a green light filter.
In the embodiment, because the processing environment is complex, the workload of directly preprocessing the acquired image to remove information irrelevant to the cutter is large, the preprocessing effect is limited, and the interference on the monitoring result is very easy to cause.
Example 4:
the processing module is provided with a counting unit, and the counting unit is used for calculating the sum B of pixel points of which the green value of the tool exceeds 150 at a certain moment; the judgment unit judges B, when B is larger than B1, the judgment unit outputs a primary danger signal, when B is larger than B2, the judgment unit outputs a secondary danger signal, B1 is a first pixel point threshold value, B2 is a second pixel point threshold value, and B2 is larger than B1.
Because in the actual course of working, the cutter can turn green earlier before turning red, and the scope of turning green increases gradually, when green area increases to a certain extent, the cutter will turn red if continuing to heat up, for this reason, the judgement to the cutter can be realized to the pixel sum of monitoring the green weight of cutter, the judgement unit judges the sum B of the pixel that the green value of cutter exceeds 150 at a certain moment, when B > B1, the judgement unit outputs the primary danger signal, when B > B2, the judgement unit outputs the secondary danger signal, B1 is the threshold value of first pixel, B2 is the threshold value of second pixel, B2 > B1.
Example 5:
the processing module is provided with a calculating unit, the calculating unit is used for calculating the area change rate C of critical pixel points of the cutter in a fixed time period, and the critical pixel points comprise pixel points with green values larger than 140; the judging unit judges the area change rate C of critical pixel points of the cutter in a fixed time period, when C is larger than C1, the judging unit outputs a first-level danger signal, when C is larger than C2, the judging unit outputs a second-level danger signal, C1 is a first area change threshold value, C2 is a second area change threshold value, and C1 is smaller than C2.
In this embodiment, the determining unit determines an area change rate C of a critical pixel of the tool in a fixed time period T2, and when the area change rate C is too high, it indicates that the tool is in a state of too fast temperature change, and when the area change rate C is too low, it indicates that the tool is in a state of too slow temperature change, and when the area change rate C is too low, it indicates that the tool is in a state of safe operation. The judging unit judges the area change rate C of critical pixel points of the cutter in a fixed time period T2, wherein C = (Q2-Q1)/T2, Q1 is the total area of the critical pixel points of the cutter at the initial moment in the fixed time period T2, Q2 is the total area of the critical pixel points of the cutter at the tail moment in the fixed time period T2, and the critical pixel points comprise pixel points with green values larger than 140; when C is larger than C1, the judging unit outputs a primary danger signal, when C is larger than C2, the judging unit outputs a secondary danger signal, C1 is a first area change threshold, C2 is a second area change threshold, and C1 is smaller than C2.
In an embodiment, the value of C1 is 60/s, the value of C2 is 100/s, the total critical pixel area, i.e., the total critical pixel number, of the tool at the initial time within a period of time is 221, the total critical pixel area, i.e., the total critical pixel number, of the tool after 5s is 573, and C = (573-221)/5 =70.4/s, which indicates that the temperature of the tool is abnormal within the period of time, and the determination unit outputs a primary danger signal.
Example 6:
the processing module is provided with a first screening unit and a second screening unit; the first screening unit screens out a pixel point coordinate set of which the green value of the cutter image is (140, 160) from the preprocessed image information, and the second screening unit is used for screening out a straight line which passes through the pixel point coordinate set and has the largest number of pixel points in a parallel straight line system perpendicular to the cutter feeding direction to serve as a temperature indicating line; the judging unit judges the change rate of the temperature indicating line of the cutter, and if the change rate of the temperature indicating line is larger than a safety change threshold value, the judging unit outputs a secondary danger signal.
In this embodiment, since the real-time monitoring system for turning of a deep and narrow groove of the present invention monitors the turning of the deep and narrow groove, the deep and narrow groove is characterized by being narrow and deep, so that the cutting heat is concentrated near the tool tip during turning, and is not easy to dissipate, and the temperature of the tool is higher as the tool approaches the root of the groove. When the cutter normally works, a temperature indicating line is arranged in the direction vertical to the cutting feed direction, the temperature indicating line in the normal work is a basic line, the cutter temperature is higher when the cutter is closer to the root part of the groove in the direction towards the deep narrow groove, and the cutter temperature is lower when the cutter is farther from the basic line in the direction away from the deep narrow groove. When the cutter normally works, the temperature indicating line fluctuates near the basic line, but the fluctuation amplitude is small, but when the temperature of the cutter continuously rises, the temperature indicating line moves towards the direction far away from the root of the groove, when the distance between the temperature indicating line and the basic line gradually increases, the temperature of the cutter is also continuously increased, and the speed of the temperature indicating line far away from the basic line is faster, the cutter is rapidly heated, the cutter damage condition is very easy to occur, and therefore, the monitoring system capable of detecting the change of the temperature indicating line is very valuable.
In this embodiment, the processing module has a first screening unit and a second screening unit; the first screening unit screens out a pixel point coordinate set of which the green value of the cutter image is (140, 160) from the preprocessed image information, and the second screening unit is used for screening out a straight line which passes through the pixel point coordinate set and has the largest number of pixel points in a parallel straight line system perpendicular to the cutter feeding direction to serve as a temperature indicating line; the judging unit judges the change rate of the temperature indicating line of the cutter, and if the change rate of the temperature indicating line is larger than a safety change threshold value, the judging unit outputs a secondary danger signal.
As shown in fig. 2, 1 is a tool, the left image is processed at the initial time to obtain a tool schematic diagram, where y1 is a straight line where the pixel points with green values (140, 160) are most distributed in the direction perpendicular to the feeding direction, the right image is processed at the end time to obtain a tool schematic diagram, and y2 is a straight line where the pixel points with green values (140, 160) are most distributed in the direction perpendicular to the feeding direction. The cutter detection accuracy is improved by judging the change rate of the temperature indicating line of the cutter.
Example 7:
the storage module is provided with a storage unit, wherein the storage unit is used for storing the preprocessed image information, when the green value of the tool image in the preprocessed image information is a high inverse value, the green value at the coordinate is stored as 210, otherwise, the original green value and the corresponding coordinate are stored; and storing pixel points with green values larger than 210 under the current coordinate of the cutter, wherein the pixel values with the green values smaller than 210 at this time under the current coordinate of the cutter are high-negative values.
Because in actual course of working, after the green value that its RGB image numerical value of tool bit heaied up to a certain extent is greater than 210, the temperature still is increasing at next moment, but the green value of its RGB image numerical value of cutter takes place the circumstances that the small amplitude descends and lead to appearing in 210, but the actual temperature of cutter this moment does not reduce, if this pixel statistics does not become critical pixel point and will cause the area rate of change C of green value to be less than actual value this moment, there is very big probability to lead to the broken phenomenon of cutter.
In this embodiment, the storage module has a storage unit, where the storage unit is configured to store the preprocessed image information, and when a green value of a tool image in the preprocessed image information is a high-negative value, the green value at the coordinate is stored as 210, otherwise, the original green value and a coordinate corresponding to the original green value are stored; and storing pixel points with green values larger than 210 under the current coordinate of the cutter, wherein the pixel values with the green values smaller than 210 at this time under the current coordinate of the cutter are high-negative values. The accuracy of real-time monitoring of the cutter can be improved.
Example 8:
the processing module is provided with an identification unit, the identification unit is used for detecting whether the cutter is replaced, if the cutter is replaced, the content stored in the storage unit is cleared, otherwise, the content stored in the storage unit is reserved.
In the machining process of a part, tool changing is often performed, after tool changing is performed, previously stored data are changed into invalid data, in the embodiment, the processing module is provided with an identification unit, the identification unit is used for detecting whether the tool is changed, if the tool is changed, the content stored in the storage unit is cleared, otherwise, the content stored in the storage unit is reserved, and the accuracy of monitoring the tool in real time can be guaranteed.
Example 9:
the cutter image acquisition unit is provided with an infrared thermal imager, and the infrared thermal imager is used for collecting temperature image information of the cutter machined by the narrow groove turning machine and transmitting the temperature image information to the processing module.
In this embodiment, the tool image acquisition unit has an infrared thermal imager, the infrared thermal imager collects the temperature image information of the tool for the depth narrow groove turning and transmits the temperature image information to the processing module. An infrared thermal imager is a device which converts an image of temperature distribution of a calibration object into a visible image by means of infrared radiation detection of the calibration object, signal processing, photoelectric conversion and the like by using an infrared thermal imaging technology. The thermal infrared imager accurately quantifies the actually detected heat and images the whole of the target object in a surface form in real time, so that the suspected fault area which is generating heat can be accurately identified. The temperature condition is preliminarily judged by an operator through the image color displayed on the screen and the hot spot tracking display function, so that high efficiency and high accuracy are embodied in the problem of temperature confirmation.
Example 10:
the temperature data detected by the infrared thermal imager is H, H = K x (S0 xH 0)/S1, S0 is the standard distance between the infrared thermal imager and the cutter, S1 is the actual distance between the infrared thermal imager and the cutter, H0 is the temperature detected when the standard distance is between the infrared thermal imager and the cutter, H0 is the same as the actual temperature of the cutter, and K is an energy coefficient; when H is more than 700 ℃, the judgment unit outputs a first-level danger signal.
Because the temperature detected and monitored by the infrared thermal imaging camera is related to the distance between the detected objects, if the distance between the infrared thermal imaging camera and the detected objects is not considered, the detection result is inaccurate. Therefore, the temperature data detected by the infrared thermal imager is H, H = K x (S0 xH 0)/S1, S0 is the standard distance between the infrared thermal imager and the cutter, S1 is the actual distance between the infrared thermal imager and the cutter, H0 is the temperature detected when the standard distance is between the infrared thermal imager and the cutter, H0 is the same as the actual temperature of the cutter, and K is an energy coefficient; when H is higher than 700 ℃, the judgment unit outputs a first-level danger signal, and the temperature information of the cutter can be more accurately acquired.
Example 11:
the acquisition module is provided with a linkage assembly and a supporting assembly, the linkage assembly is used for receiving a movement instruction, the supporting assembly is used for preventing the infrared thermal imager from shaking, and the infrared thermal imager and the cutter move synchronously along the same movement track.
Because the cutter can do the action of feeding in the course of working, because the removal of cutter is shot the image of cutter and is changed, and has very big relevance to the temperature detection on the cutter with the image of shooing, for this reason in this embodiment, the collection module has linkage assembly and supporting component, the linkage assembly is used for receiving the motion instruction, and the supporting component is used for preventing the shake of infrared thermal imager, and the infrared thermal imager is the same and simultaneous movement with the motion track of cutter. The invention can shoot accurate cutter images in real time and provide accurate cutter state identification.
Example 12:
the acquisition module is provided with a sound wave acquisition unit which acquires sound wave information of deep and narrow groove turning and transmits the sound wave information to the processing module; the processing module is provided with a sound processing unit, the sound processing unit processes sound wave information to obtain sound wave frequency information L, the judging unit judges the sound wave frequency information L, when L is larger than L1, the judging unit outputs a first-level danger signal, and L1 is a frequency threshold value.
The processing module is provided with a sound calculating unit, the sound calculating unit is used for calculating the similarity S between the sound wave frequency information L and the abnormal audio, the judging unit judges the similarity S, if S is larger than 70%, the judging unit outputs a primary danger signal, and if S is larger than 75%, the judging unit outputs a secondary danger signal.
In the deep and narrow groove turning process, the cutting sound changes within a period of time before the cutter head is abnormal, the sound changes from muddy sound to sharp sound until the sharp sound changes into harsh sound, and the harsh sound is accompanied with the breaking of the cutter. Therefore, the working condition of the cutter can be judged by the aid of collected sound wave information, in one embodiment, the collecting module is provided with a sound wave collecting unit, and the sound wave collecting unit is used for collecting sound wave information of deep and narrow groove turning and transmitting the sound wave information to the processing module; the processing module is provided with a sound processing unit, the sound processing unit can filter sound wave information to obtain sound wave frequency information, the judging unit judges the sound wave frequency information, when L is larger than L1, the judging unit outputs a first-level danger signal, L is the frequency of the sound wave frequency information at a certain moment, and L1 is a frequency threshold value.
In another embodiment, the processing module has a sound calculating unit, the sound calculating unit is configured to calculate a similarity S between the sound frequency information L and the abnormal audio, the determining unit determines the similarity S, and if S > 70%, the determining unit outputs a primary danger signal, and if S > 75%, the determining unit outputs a secondary danger signal.
Example 13:
the acquisition module is provided with a part image acquisition unit which is used for acquiring image information at the deep and narrow groove of the processed part and transmitting the image information to the processing module; the processing module is provided with a comparison unit, the comparison unit is used for calculating a pixel difference P between the RGB pixel value of the cutter and the RGB pixel value of the deep and narrow groove of the processed part, the judgment unit judges the pixel difference P, and if P is smaller than P1, the judgment unit outputs a primary danger signal.
Due to the difference of machined parts, heat dissipation of the same cutting tool can be different, the working condition of the tool bit during machining is monitored in real time, the temperature of the tool bit can be monitored in real time, the machining heat dissipation condition of the whole part is not clear, when the temperature of the tool bit is monitored to be at a certain temperature, the tool bit is stopped immediately if the temperature is continuously increased, otherwise the tool bit is extremely prone to break, but if the temperature of the tool bit is always equal to or lower than the temperature, normal use of the tool bit is not affected, the tool bit does not need to be stopped or changed urgently, and therefore the tool bit temperature rising or falling detection method is very valuable.
In this embodiment, the collecting module has a part image collecting unit, and the part image collecting unit is used for collecting image information at the deep and narrow groove of the machined part and transmitting the image information to the processing module; the processing module is provided with a comparison unit, the comparison unit is used for calculating a pixel difference P between the RGB pixel value of the cutter and the RGB pixel value of the deep and narrow groove of the processed part, the judgment unit judges the pixel difference P, and if P is smaller than P1, the judgment unit outputs a primary danger signal.
The part image acquisition unit specifically comprises a single-lens reflex camera, a double-lens reflex camera, a paraxial view-finding camera, a miniature camera and the like.
Example 14:
the display module is used for displaying the working state of the cutter, the display screen is green to indicate that the cutter is normal, the display screen is orange to indicate that the cutter is abnormal and the judging unit outputs a first-level danger signal, and the display screen is red to indicate that the cutter is dangerous and the judging unit outputs a second-level danger signal.
Example 15:
a power module and a transmission port; as shown in fig. 3 to 4, the power module is configured to provide a power supply for the real-time monitoring system for deep and narrow groove turning, and the transmission port is configured to provide an interface for the determination unit to transmit data.
In the description of the embodiments of the present invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "inner", "outer", and the like indicate orientations or positional relationships. "-" indicates a range where two values are the same, and the range includes the endpoints. For example, "A-B" means a range greater than or equal to A and less than or equal to B.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (15)
1. A real-time monitoring system for deep and narrow groove turning is characterized by comprising,
an acquisition module;
a processing module;
the acquisition module is provided with a tool image acquisition unit, and the tool image acquisition unit is used for acquiring a tool image of deep and narrow groove turning and transmitting the tool image to the processing module;
the processing module is provided with an image processing unit and a judging unit, the image processing unit is provided with a preprocessing unit and a characteristic extraction unit, the preprocessing unit carries out image preprocessing on the cutter image, the characteristic extraction unit extracts RGB pixel values of the cutter from the preprocessed image information, the judging unit judges the change rate A of the RGB pixel values of the cutter and meets the requirement,
when A1 is larger than A and smaller than A2, the judging unit outputs a first-level danger signal, and when A is larger than A2, the judging unit outputs a second-level danger signal, wherein A1 is a first change threshold value, and A2 is a second change threshold value.
2. The real-time monitoring system for deep and narrow groove turning of claim 1,
the cutter image acquisition unit is provided with a camera which is provided with a green light filter.
3. The real-time monitoring system for deep and narrow groove turning of claim 2, further comprising,
the processing module is provided with a counting unit, and the counting unit is used for calculating the sum B of pixel points of which the green value of the tool exceeds 150 at a certain moment;
the judging unit judges B, when B is larger than B1, the judging unit outputs a primary danger signal, when B is larger than B2, the judging unit outputs a secondary danger signal, B1 is a first pixel point threshold value, B2 is a second pixel point threshold value, and B2 is larger than B1.
4. The real-time monitoring system for deep and narrow groove turning of claim 2, further comprising,
the processing module is provided with a calculating unit, the calculating unit is used for calculating the area change rate C of critical pixel points of the cutter in a fixed time period, and the critical pixel points comprise pixel points with green values larger than 140;
the judging unit judges the area change rate C of critical pixel points of the cutter in a fixed time period, when C is larger than C1, the judging unit outputs a first-level danger signal, when C is larger than C2, the judging unit outputs a second-level danger signal, C1 is a first area change threshold value, C2 is a second area change threshold value, and C1 is smaller than C2.
5. The real-time monitoring system for deep and narrow groove turning in claim 3 or 4, further comprising,
the processing module is provided with a first screening unit and a second screening unit;
the first screening unit screens out a pixel point coordinate set of which the green value of the cutter image is (140, 160) from the preprocessed image information, and the second screening unit is used for screening out a straight line which passes through the pixel point coordinate set and has the largest number of pixel points in a parallel straight line system perpendicular to the cutter feeding direction to serve as a temperature indicating line;
the judging unit judges the change rate of the temperature indicating line of the cutter, and if the change rate of the temperature indicating line is larger than the safety change threshold value, the judging unit outputs a secondary danger signal.
6. The real-time monitoring system for deep and narrow groove turning of claim 5,
the memory module is provided with a memory unit,
the storage unit is used for storing the preprocessed image information, when the green value of the tool image in the preprocessed image information is a high inverse value, the green value at the coordinate is stored as 210, otherwise, the original green value and the corresponding coordinate are stored;
and storing pixel points with green values larger than 210 under the current coordinate of the cutter, wherein the pixel values with the green values smaller than 210 at this time under the current coordinate of the cutter are high-negative values.
7. The real-time monitoring system for deep and narrow groove turning machining according to claim 6,
the processing module is provided with an identification unit, the identification unit is used for detecting whether the cutter is replaced, if the cutter is replaced, the content stored in the storage unit is cleared, otherwise, the content stored in the storage unit is reserved.
8. The real-time monitoring system for deep and narrow groove turning of claim 7, characterized by further comprising,
the cutter image acquisition unit is provided with an infrared thermal imager, and the infrared thermal imager is used for collecting temperature image information of the cutter machined by the narrow groove turning machine and transmitting the temperature image information to the processing module.
9. The real-time monitoring system for deep and narrow groove turning of claim 8,
the temperature data detected by the infrared thermal imager is H, H = K x (S0 xH 0)/S1, S0 is the standard distance between the infrared thermal imager and the cutter, S1 is the actual distance between the infrared thermal imager and the cutter, H0 is the temperature detected when the standard distance is between the infrared thermal imager and the cutter, H0 is the same as the actual temperature of the cutter, and K is an energy coefficient;
when H is more than 700 ℃, the judgment unit outputs a first-level danger signal.
10. The real-time monitoring system for deep and narrow groove turning of claim 9,
the acquisition module is provided with a linkage assembly and a supporting assembly, the linkage assembly is used for receiving a movement instruction, the supporting assembly is used for preventing the infrared thermal imager from shaking, and the infrared thermal imager and the cutter move synchronously along the same movement track.
11. The real-time monitoring system for deep and narrow groove turning of claim 10,
the acquisition module is provided with a sound wave acquisition unit which acquires sound wave information of deep and narrow groove turning and transmits the sound wave information to the processing module;
the processing module is provided with a sound processing unit, the sound processing unit processes sound wave information to obtain sound wave frequency information L, the judging unit judges the sound wave frequency information L, when L is larger than L1, the judging unit outputs a first-level danger signal, and L1 is a frequency threshold value.
12. The real-time monitoring system for deep narrow groove turning machining according to claim 11, further comprising,
the processing module is provided with a sound calculating unit, the sound calculating unit is used for calculating the similarity S between the sound wave frequency information L and the abnormal audio, the judging unit judges the similarity S, if S is larger than 70%, the judging unit outputs a first-level danger signal, and if S is larger than 75%, the judging unit outputs a second-level danger signal.
13. The real-time monitoring system for deep and narrow groove turning of claim 12,
the acquisition module is provided with a part image acquisition unit which is used for acquiring image information at the deep and narrow groove of the processed part and transmitting the image information to the processing module;
the processing module is provided with a comparison unit, the comparison unit is used for calculating a pixel difference P between the RGB pixel value of the cutter and the RGB pixel value of the deep and narrow groove of the processed part, the judgment unit judges the pixel difference P, and if P is smaller than P1, the judgment unit outputs a primary danger signal.
14. The real-time monitoring system for deep and narrow groove turning of claim 13,
the display module is used for displaying the working state of the cutter, the display screen is green to indicate that the cutter is normal, the display screen is orange to indicate that the cutter is abnormal and the judging unit outputs a first-level danger signal, and the display screen is red to indicate that the cutter is dangerous and the judging unit outputs a second-level danger signal.
15. The real-time monitoring system for deep and narrow groove turning of claim 14,
a power module and a transmission port;
the power module is used for providing power for the deep narrow groove turning real-time monitoring system as claimed in any one of claims 1 to 14, and the transmission port is used for providing an interface for the judgment unit to transmit data.
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