CN115847187B - 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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- CN115847187B CN115847187B CN202310169770.8A CN202310169770A CN115847187B CN 115847187 B CN115847187 B CN 115847187B CN 202310169770 A CN202310169770 A CN 202310169770A CN 115847187 B CN115847187 B CN 115847187B
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Abstract
The invention relates to a real-time monitoring system for deep and narrow groove turning, which belongs to the technical field of machine manufacturing and comprises an acquisition module, wherein the acquisition module is used for acquiring information of the deep and narrow groove turning; a processing module; the acquisition module is provided with a cutter image acquisition unit, and the cutter image acquisition unit is used for acquiring cutter images of deep and narrow groove turning and transmitting the cutter images 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 extracting unit, and the processing module has the beneficial effects that the working condition of the cutter head is judged according to the temperature rising rate of the cutter head, so that the probability of cutter 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 a deep narrow groove, and particularly relates to a real-time monitoring system for deep narrow groove turning.
Background
The unavoidable phenomenon accompanied with cutter abrasion and even breakage in the metal cutting process, particularly the processing of deep narrow grooves, has more challenges, and cutter striking and breaking phenomena are very easy to occur when the deep narrow groove parts are processed, on one hand, the cutter and the parts are very easy to damage because the hardness of the materials of the parts is high, the strength is high, the heat conductivity coefficient of the materials of the parts is low, the heat conductivity is very poor, the cutting heat is concentrated near the cutter point during turning, the cutter is not easy to be dispersed, the service life of the cutter can be shortened at high temperature, and the processed parts are damaged. On the other hand, because of the special shape of the deep narrow groove, the closer the cutter head is to the root of the deep narrow groove, the more difficult the scrap iron is to be discharged, the cutter head is easy to crush due to extrusion among the cutter head, the scrap iron and the parts, so that the parts are scrapped, and the extra expense is obviously greatly increased for the parts producer.
For example, the high pressure turbine outer ring assembly of a certain model of engine is an important part of the turbine unit and also a replacement. The high-pressure turbine outer ring assembly is assembled in a high-pressure turbine unit and works in a high-temperature and high-pressure environment, the structure of the high-pressure turbine outer ring assembly is an 8-degree 34' sector block, the cross section of the structure is shown in figure 1, the size of an annular deep narrow groove on the end face is very strict, the groove width is required to be 1.85+/-0.05 mm, the groove depth is required to be 5.3+/-0.1 mm, the material is nickel-based precipitation hardening type equiaxial crystal casting superalloy K465, the alloy has low heat conductivity coefficient and poor heat conductivity, cutting heat is concentrated near a cutter point and is not easy to scatter, so that the cutting temperature is high, the hardness and strength of the alloy are high, and the cutting force is very large, and is a difficult-to-process material.
It is counted that approximately 20% of machine downtime is due to tool breakage, while the cost of the tool itself and the tool change account for 3% -12% of the total cost of the product. Therefore, in order to reduce the cost of the cutter and the cutter changing, the real-time monitoring system for 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 above purpose, the technical scheme adopted by the invention is as follows: the 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 cutter images of deep and narrow groove turning and transmitting the cutter images 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 extracting unit, the preprocessing unit is used for preprocessing an image of the cutter, the characteristic extracting unit is used for extracting RGB pixel values of the cutter from the preprocessed image information, the judging unit is used for judging the change rate A of the RGB pixel values of the cutter and is used for outputting a first-level dangerous signal when A1 is less than A2, the judging unit is used for outputting a second-level dangerous signal when A is more than A2, A1 is a first change threshold value, and A2 is a second change threshold value.
Preferably, the tool image acquisition unit has a camera with a green filter.
Preferably, the processing module further comprises a counting unit, wherein the counting unit is used for calculating the sum B of pixel points with the green value exceeding 150 of the cutter at a certain moment; the judging unit judges B, when B is larger than B1, the judging unit outputs a first-level dangerous signal, when B is larger than B2, the judging unit outputs a second-level dangerous 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 further provided with a calculating unit, wherein the calculating unit is used for calculating the area change rate C of a critical pixel point of the cutter in a fixed time period, and the critical pixel point comprises a pixel point with a green value greater than 140; the judging unit judges the area change rate C of the critical pixel point of the cutter in a fixed time period, when C is more than C1, the judging unit outputs a first-level dangerous signal, when C is more than C2, the judging unit outputs a second-level dangerous signal, C1 is a first area change threshold value, C2 is a second area change threshold value, and C1 is less than C2.
Preferably, the processing module is provided with a first screening unit and a second screening unit; the first screening unit screens a pixel point coordinate set with a green value of a cutter image at (140, 160) from the preprocessed image information, and the second screening unit is used for screening a straight line with the maximum number of pixels passing through the pixel point coordinate set from a parallel straight line system perpendicular to a cutter feeding direction as a temperature indication line; the judging unit judges the change rate of the temperature indication line of the cutter, and if the change rate of the temperature indication line is larger than the safety change threshold value, the judging unit outputs a secondary dangerous signal.
Preferably, 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 cutter image in the preprocessed image information is a high inverse value, the green value at the coordinate is stored as 210, and otherwise, the original green value and the coordinate corresponding to the original green value are stored; and storing the pixel points with the green value larger than 210 in the current coordinate of the cutter, wherein the pixel value with the green value smaller than 210 in the current coordinate of the cutter is a high inverse value.
Preferably, the processing module is provided with an identification unit, the identification unit is used for detecting whether the cutter is replaced, if so, the content stored in the storage unit is cleared, and otherwise, the content stored in the storage unit is reserved.
Preferably, the tool image acquisition unit is provided with a thermal infrared imager, and the thermal infrared imager acquires temperature image information of the deep and narrow groove turning tool and transmits the temperature image information to the processing module.
Preferably, the temperature data detected by the infrared thermal imager is H, h=kx (s0×h0)/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 judging unit outputs a first-level danger signal.
Preferably, the acquisition module is provided with a linkage assembly and a support assembly, wherein the linkage assembly is used for receiving the movement instruction, and the support assembly is used for preventing the infrared thermal imager from shaking, and the infrared thermal imager and the cutter move synchronously in the same movement track.
Preferably, the acquisition module is provided with an acoustic wave acquisition unit, and the acoustic wave acquisition unit acquires acoustic wave information processed by the deep and narrow groove vehicle and transmits the acoustic wave information to the processing module; the processing module is provided with a sound processing unit, the sound processing unit processes the sound wave information to obtain sound wave frequency information L, the judging unit judges the sound wave frequency information L, and when L is more than L1, the judging unit outputs a first-level dangerous signal, and L1 is a frequency threshold.
Preferably, the processing module further includes a sound calculating unit, where the sound calculating unit is configured to calculate a similarity S between the sound frequency information L and the abnormal audio, and the judging unit judges the similarity S, and if S is greater than 70%, the judging unit outputs a first-stage danger signal, and if S is greater than 75%, the judging unit outputs a second-stage 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 of a 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 pixel difference P between RGB pixel values of the cutter and RGB pixel values 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 first-level dangerous signal.
Preferably, the display module is used for the operating condition of cutter, and the display screen is green and shows that the cutter is normal, and the display screen is orange and shows that the cutter is unusual and judging unit output first-level danger signal, and the display screen is red and shows that the cutter is dangerous and judging unit output second-level danger signal.
Preferably, the power module and the transmission port; the power module is used for providing power for the deep and narrow groove machining real-time monitoring system, and the transmission port is used for providing an interface for data transmission of the judging unit.
The invention has the beneficial effects of providing a real-time monitoring system for deep and narrow groove turning. The invention has the beneficial effects that firstly, the working condition of the cutter head can be judged through the RGB value change rate at the cutter head, so that the probability of cutter breakage is greatly reduced, and the processing cost of the deep narrow groove is reduced; secondly, the working condition of the cutter is judged through the change rate D of the temperature indication line of the cutter, so that the accuracy of the 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 shows a schematic diagram of a tool, (a) is obtained after processing at an initial time, and (b) is obtained after processing at an end time;
FIG. 3 is a block diagram of another real-time monitoring system for deep slot turning;
fig. 4 is a frame diagram of a real-time monitoring system for deep narrow groove turning.
Description of the embodiments
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1-4, the following is a specific embodiment of the present invention.
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 cutter images of deep and narrow groove turning and transmitting the cutter images 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 extracting unit, the preprocessing unit is used for preprocessing an image of the cutter, the characteristic extracting unit is used for extracting RGB pixel values of the cutter from the preprocessed image information, the judging unit is used for judging the change rate A of the RGB pixel values of the cutter and is used for outputting a first-level dangerous signal when A1 is less than A2, the judging unit is used for outputting a second-level dangerous signal when A is more than A2, A1 is a first change threshold value, and A2 is a second change threshold value.
Because of the specificity of the deep narrow groove, the width of the deep narrow groove to be processed is smaller (generally 1mm-2 mm), the ratio of the depth to the width is larger, the scrap iron is more difficult to discharge when the cutter head is closer to the root of the deep narrow groove, the cutter head, the extrusion of the scrap iron and the part groove can easily crush or shift the cutter head, the shifted cutter head further causes part damage and even part rejection, and the cutter head crush or shift not only reduces the production efficiency of the part, but also increases the production cost of the part. On the other hand, because the hardness of the part material to be processed is high, the strength is high, the heat conductivity coefficient of the part material is low, the heat conductivity is poor, the cutting heat is concentrated near the cutter point during turning, the cutting heat is not easy to be dissipated, the service life of the cutter can be shortened at high temperature, and the cutter head and the part are easy to be damaged during processing of deep and narrow grooves. The deep narrow groove machining becomes a machining difficulty, and the real-time monitoring system for deep narrow groove turning is very 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, including 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 cutter images of deep and narrow groove turning and transmitting the cutter images 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, wherein the image processing unit is provided with a preprocessing unit and a feature extraction unit, and the preprocessing unit is used for preprocessing images of the cutter. In one embodiment, the image preprocessing may include obtaining contour information of the tool through gray level transformation and edge extraction of the acquired image information, and obtaining RGB images of only the tool according to the contour information of the tool. The collected image information can be subjected to feature extraction, image segmentation, matching and recognition to eliminate information irrelevant to the tool bit.
In the process of cutting steel, the relation between the color of the cut material and the cutting temperature can be as follows: about < 200 ℃ or less; pale yellow: about 220 ℃; deep blue: about 300 ℃; light grey: about 400 ℃; dark purple black: about > 500 ℃. In addition, the relation between the cutting temperature and the cutting color of different materials is different, and the invention needs to be stated that the processed parts are not limited to the nickel-based precipitation hardening type equiaxed crystal casting superalloy K465, but also include deep and narrow groove processing of other materials with high hardness and low heat conductivity coefficient.
The color of the cutter head is changed into cyan and green along with the temperature rise when the cutter head is used for cutting deep and narrow grooves, and finally the cutter is changed into red along with the temperature rise, so that the cutter is extremely easy to break and break when the cutter is changed into red, namely the cutter is extremely easy to break or break, the color of the cutter is monitored in real time, the trend of reddening the cutter is monitored to mean that the cutter is in a dangerous working state, and the machining strategy is not timely modified. The invention judges the change rate A of RGB pixel values of the cutter through the judging unit, and meets the requirement that when A1 is less than A < A2, the judging unit outputs a first-level dangerous signal, when A is more than A2, the judging unit outputs a second-level dangerous signal, A1 is a first change threshold value, and A2 is a second change threshold value. In this embodiment, the change rate A of the RGB pixel values can be defined as the sum of the change 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 regulates and controls the processing machine tool 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 deep and narrow groove turning, so that the damage of a cutter head is effectively avoided, and the production efficiency of the deep and narrow groove is improved.
Example 2
In one embodiment, the invention monitors the green component in the cutter image in real time, judges the green change rate of the RGB pixel value of the cutter, wherein A= (G2-G1)/T1, G1 is the median value of the green component in the RGB pixel value of the cutter at the initial moment in the fixed time period T1, G2 is the median value of the green component in the RGB pixel value of the cutter at the end moment in the fixed time period T1, and A is the green change rate of the cutter in the fixed time period T1; and it is satisfied that when A1 is less than A < A2, the judging unit outputs a first-level dangerous signal, when A is more than A2, the judging unit outputs a second-level dangerous signal, A1 is a first green change threshold value, and A2 is a second change threshold value. In the normal machining period, the faster the green value changes at the initial time and the green value changes at the final time, the faster the temperature changes, and the working condition of the tool bit is judged by judging the relation between the green change rate A of the tool bit and the relation between the green change rate A, the green change rate A1 and the green change rate A2 of the tool bit.
In one embodiment, A1 has a value of 5/s, A2 has a value of 13/s, RGB represents the colors of three channels of red, green and blue, each channel has a color value of 256 levels, and the color values are expressed by numbers from 0, 1, 2, 3, and 255, for example, the value with the most number of the same green values in the green channel of the RGB image of the tool at the initial time is taken as the median value 34 of the green component, the value with the most number of the same green values in the green channel of the RGB image of the tool after 5s is taken as the median value 63 of the green component, a= (63-34)/5=5.8/s, which indicates that the tool temperature is abnormal during the period, and the judging unit outputs a first-level hazard signal. According to the invention, the work of the processing machine tool is controlled by the real-time monitoring system for deep and narrow groove turning, so that the damage of a cutter head 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, and the camera is provided with a green filter.
In the embodiment, as 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 monitoring result is very easy to interfere, the cutter image acquisition unit provided by the invention is provided with the camera, and the camera is provided with the green filter which is used for filtering non-green image information, so that the monitoring accuracy of the cutter can be effectively improved.
Example 4
The processing module is provided with a counting unit which is used for calculating the sum B of pixel points with the green value exceeding 150 of the cutter at a certain moment; the judging unit judges B, when B is larger than B1, the judging unit outputs a first-level dangerous signal, when B is larger than B2, the judging unit outputs a second-level dangerous signal, B1 is a first pixel point threshold value, B2 is a second pixel point threshold value, and B2 is larger than B1.
In the actual machining process, the cutter turns green before turning red, the green turning range is gradually increased, when the green area is increased to a certain degree, the cutter is turned red after continuously heating, therefore, the judgment of the cutter can be realized by monitoring the sum of pixels of the green component of the cutter, the judgment unit judges the sum B of the pixels of which the green value exceeds 150 at a certain moment, when B is larger than B1, the judgment unit outputs a first-level dangerous signal, when B is larger than B2, the judgment unit outputs a second-level dangerous signal, B1 is a first pixel threshold, B2 is a second pixel threshold, and B2 is larger than B1.
Example 5
The processing module is provided with a calculating unit, wherein 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 the critical pixel point of the cutter in a fixed time period, when C is more than C1, the judging unit outputs a first-level dangerous signal, when C is more than C2, the judging unit outputs a second-level dangerous signal, C1 is a first area change threshold value, C2 is a second area change threshold value, and C1 is less than C2.
In this embodiment, the determining unit determines the area change rate C of the critical pixel point of the tool in the fixed time period T2, when the area change rate C is too high, it indicates that the tool is in a dangerous state with too fast temperature change, and when the area change rate C is too low, it indicates that the tool is in a low temperature change, and the tool is in a safe working state with high probability. The judging unit judges the area change rate C of the critical pixel point of the cutter in the fixed time period T2, wherein C= (Q2-Q1)/T2, Q1 is the total area of the critical pixel point of the cutter at the initial moment in the fixed time period T2, Q2 is the total area of the critical pixel point of the cutter at the end moment in the fixed time period T2, and the critical pixel point comprises a pixel point with a green value larger than 140; when C is larger than C1, the judging unit outputs a first-level dangerous signal, when C is larger than C2, the judging unit outputs a second-level dangerous signal, C1 is a first area change threshold value, C2 is a second area change threshold value, and C1 is smaller than C2.
In one embodiment, the value of C1 is 60/s, the value of C2 is 100/s, the total critical pixel area of the tool, that is, the total critical pixel number of the tool, is 221 at the initial time in a period of time, the total critical pixel area of the tool, that is, the total critical pixel number of the tool after 5s is 573, and c= (573-221)/5=70.4/s, which means that the temperature of the tool is abnormal in the period of time, and the judging unit outputs a first-stage dangerous signal.
Example 6
The processing module is provided with a first screening unit and a second screening unit; the first screening unit screens a pixel point coordinate set with a green value of a cutter image at (140, 160) from the preprocessed image information, and the second screening unit is used for screening a straight line with the maximum number of pixels passing through the pixel point coordinate set from a parallel straight line system perpendicular to a cutter feeding direction as a temperature indication line; the judging unit judges the change rate of the temperature indication line of the cutter, and if the change rate of the temperature indication line is larger than the safety change threshold value, the judging unit outputs a secondary dangerous signal.
In this embodiment, the real-time monitoring system for deep and narrow groove turning is used for monitoring deep and narrow groove machining, and the deep and narrow groove is characterized by being narrow and deep, so that cutting heat is concentrated near a cutter point during turning, is not easy to be dissipated, and the temperature of a cutter near the root of the groove is higher. When the cutter normally works, a temperature indication line is arranged in the direction perpendicular to the feeding direction, the temperature indication line in normal work is taken as a basic line, the temperature of the cutter is higher when the cutter is closer to the root of the groove in the direction facing the deep narrow groove, and the temperature of the cutter is lower when the cutter is farther from the basic line in the direction facing the deep narrow groove. When the cutter normally works, the temperature indication line fluctuates near the basic line, but the fluctuation amplitude is smaller, but when the temperature of the cutter continuously rises, the temperature indication line moves towards the direction far away from the root of the groove, when the distance between the temperature indication line and the basic line gradually increases, the temperature of the cutter continuously increases, and the faster the temperature indication line is far away from the basic line, the cutter is rapidly warmed up, and the cutter is extremely easy to damage, so that the monitoring system capable of detecting the change of the temperature indication 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 a pixel point coordinate set with a green value of a cutter image at (140, 160) from the preprocessed image information, and the second screening unit is used for screening a straight line with the maximum number of pixels passing through the pixel point coordinate set from a parallel straight line system perpendicular to a cutter feeding direction as a temperature indication line; the judging unit judges the change rate of the temperature indication line of the cutter, and if the change rate of the temperature indication line is larger than the safety change threshold value, the judging unit outputs a secondary dangerous signal.
As shown in fig. 2, 1 is a tool, the left image is a schematic diagram of the tool obtained after processing at an initial time, where y1 is a line with the greatest distribution of pixels with green values (140, 160) perpendicular to the feeding direction, the right image is a line with the greatest distribution of pixels with green values (140, 160) perpendicular to the feeding direction, and the right image is a schematic diagram of the tool obtained after processing at an end time. The invention judges through the change rate of the temperature indication line of the cutter, thereby improving the accuracy of cutter detection.
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 cutter image in the preprocessed image information is a high inverse value, the green value at the coordinate is stored as 210, and otherwise, the original green value and the coordinate corresponding to the original green value are stored; and storing the pixel points with the green value larger than 210 in the current coordinate of the cutter, wherein the pixel value with the green value smaller than 210 in the current coordinate of the cutter is a high inverse value.
In the actual machining process, when the temperature of the tool bit is raised to a certain extent and the green value of the RGB pixel value is larger than 210, the temperature is still increased at the next moment, but the green value of the RGB pixel value of the tool bit is slightly reduced to cause the condition of 210, but the actual temperature of the tool bit is not reduced at the moment, and if the pixel point is not counted as a critical pixel point, the area change rate C of the green value is smaller than the actual value, and the phenomenon of tool bit breakage is caused with great probability.
In this embodiment, the storage module has a storage unit, where the storage unit is configured to store the preprocessed image information, store the green value at the coordinate as 210 when the green value of the tool image in the preprocessed image information is a high inverse value, and otherwise store the original green value and the coordinate corresponding to the original green value; and storing the pixel points with the green value larger than 210 in the current coordinate of the cutter, wherein the pixel value with the green value smaller than 210 in the current coordinate of the cutter is a high inverse value. The accuracy of real-time monitoring of the cutter can be improved.
Example 8
The processing module is provided with an identification unit which is used for detecting whether the cutter is replaced, if so, the content stored in the storage unit is cleared, and otherwise, the content stored in the storage unit is reserved.
In the processing process of a part, tool changing is often encountered, when the tool is changed, the data stored before are all invalid data, in this 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 acquires temperature image information of the cutter machined by the deep narrow groove and transmits the temperature image information to the processing module.
In this embodiment, the tool image acquisition unit has a thermal infrared imager that acquires temperature image information of the deep narrow groove turning tool and transmits it to the processing module. The thermal infrared imager is a device which converts an image of temperature distribution of a calibration object into a visible image by utilizing an infrared thermal imaging technology, detecting infrared radiation of the calibration object, and applying means such as signal processing, photoelectric conversion and the like. The thermal infrared imager precisely quantifies the actually detected heat, and images the whole object in real time in a planar mode, so that the suspected fault area which is heating can be accurately identified. An operator preliminarily judges the temperature condition through the image color and the hot spot tracking display function displayed on the screen, so that the high efficiency and the high accuracy are embodied on the problem of confirming the temperature.
Example 10
The temperature data detected by the infrared thermal imager is H, H=K× (S0×H20)/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 between the infrared thermal imager and the cutter is the standard distance, H0 is the same as the actual temperature of the cutter, and K is an energy coefficient; when H is more than 700 ℃, the judging unit outputs a first-level danger signal.
Since the infrared thermal imager detects that the monitored temperature is related to the distance between the detected objects, the detection result is inaccurate if the distance between the infrared thermal imager and the detected objects is not considered. Therefore, the temperature data detected by the infrared thermal imager is H, H=K× (S0×H20)/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 judging unit outputs a first-level dangerous signal, and the temperature information of the cutter can be acquired more accurately.
Example 11
The acquisition module is provided with a linkage assembly and a support assembly, the linkage assembly is used for receiving the movement instruction, and the support assembly is used for preventing the infrared thermal imaging instrument from shaking, and the infrared thermal imaging instrument and the movement track of the cutter move synchronously.
Because the cutter can do feeding action in the course of working, because the image of cutter that the removal of cutter was shot changes, and have very big relevance to the temperature detection on the cutter and the image of shooing, for this reason in this embodiment, the collection module has linkage subassembly and supporting component, linkage subassembly is used for receiving the motion instruction, and supporting component is used for preventing the infrared thermal imaging appearance shake, and the infrared thermal imaging appearance is the same and synchronous motion with the motion trail of cutter. The invention can shoot the accurate cutter image in real time and provide accurate cutter state identification.
Example 12
The acquisition module is provided with an acoustic wave acquisition unit, and the acoustic wave acquisition unit acquires acoustic wave information processed by the deep narrow groove vehicle and transmits the acoustic wave information to the processing module; the processing module is provided with a sound processing unit, the sound processing unit processes the sound wave information to obtain sound wave frequency information L, the judging unit judges the sound wave frequency information L, and when L is more than L1, the judging unit outputs a first-level dangerous signal, and L1 is a frequency threshold.
The processing module is provided with a sound calculation unit, the sound calculation unit is used for calculating the similarity S of the sound wave frequency information L and the abnormal audio, the judgment unit judges the similarity S, if S is more than 70%, the judgment unit outputs a first-level dangerous signal, and if S is more than 75%, the judgment unit outputs a second-level dangerous signal.
In the deep and narrow groove turning process, cutting sounds change in a period of time before the cutter head is abnormal, the sounds become sharp from muddy sounds until the sharp sounds become harsher sounds, and the harsher sounds accompany the breaking of the cutter, so that the occurrence of the sharp sounds becomes particularly important when the cutter head is found, the working mode of the cutter head needs to be adjusted or the cutter head needs to be replaced in time after the cutter head is found, the cutter head is prevented from breaking, and the monitoring of the cutting sounds in the machining process is very valuable. Therefore, the working condition of the cutter can be judged in an assisted manner through the collected acoustic wave information, and in one embodiment, the collecting module is provided with an acoustic wave collecting unit, and the acoustic wave collecting unit is used for collecting the acoustic wave information of deep and narrow groove turning and transmitting the acoustic wave information to the processing module; the processing module is provided with a sound processing unit, the sound processing unit can filter the sound wave information to obtain sound wave frequency information, the judging unit judges the sound wave frequency information, when L is more than L1, the judging unit outputs a first-level dangerous 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, where the sound calculating unit is configured to calculate a similarity S between the sound frequency information L and the abnormal audio, the judging unit judges the similarity S, if S > 70%, the judging unit outputs a first-level hazard signal, and if S > 75%, the judging unit outputs a second-level hazard signal.
Example 13
The acquisition module is provided with a part image acquisition unit, and the part image acquisition unit is used for acquiring image information of a 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 pixel difference P between RGB pixel values of the cutter and RGB pixel values 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 first-level dangerous signal.
Because the difference of the machined parts is that the heat dissipation of the same cutting part is possibly different, the working condition of the cutter head during the real-time monitoring of the machining can achieve a certain monitoring effect, but the heat dissipation condition of the whole part is not clear, when the cutter head is monitored to be at a certain temperature, the cutter head is stopped immediately if the temperature continues to increase, otherwise, the cutter head is extremely easy to break, but if the cutter head is always at the temperature which is equal to or lower than the temperature, the normal use of the cutter head is not affected, and the cutter head does not need to be stopped or replaced suddenly, so that the detection for judging the temperature rise or the temperature drop of the cutter head is very valuable.
In this embodiment, the acquisition module is provided with a part image acquisition unit, and the part image acquisition unit is used for acquiring image information of 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 pixel difference P between RGB pixel values of the cutter and RGB pixel values 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 first-level dangerous signal.
The part image acquisition unit specifically comprises a single-lens reflex camera, a double-lens reflex camera, a paraxial view camera, a miniature camera head and the like.
Example 14
The display module is used for 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, the display screen is red to indicate that the cutter is dangerous and the judging unit outputs a second-level danger signal.
Example 15
The power module and the transmission port; as shown in fig. 3-4, the power module is used for providing power for the deep and narrow groove machining real-time monitoring system, and the transmission port is used for providing an interface for the judging unit to transmit data.
In describing embodiments of the present invention, it is to be understood that terms "upper", "lower", "front", "rear", "left", "right", "inner", "outer", "inside", "outside", and the like indicate an azimuth or a positional relationship. "-" indicates a range where two values are the same, and the range includes 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 understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein 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 cutter image acquisition unit, and the cutter image acquisition unit is used for acquiring cutter images of deep and narrow groove turning and transmitting the cutter images 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 extracting unit, the preprocessing unit performs image preprocessing on the cutter image, the characteristic extracting 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 less than A2, the judging unit outputs a first-level dangerous signal, when A is more than A2, the judging unit outputs a second-level dangerous signal, 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 as claimed in claim 1, wherein,
the cutter image acquisition unit is provided with a camera, and the camera is provided with a green filter.
3. The deep narrow groove turning real-time monitoring system of claim 2, further comprising,
the processing module is provided with a counting unit which is used for calculating the sum B of pixel points with the green value exceeding 150 of the cutter at a certain moment;
the judging unit judges B, when B is larger than B1, the judging unit outputs a first-level dangerous signal, when B is larger than B2, the judging unit outputs a second-level dangerous 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 deep narrow groove turning real-time monitoring system of claim 2, further comprising,
the processing module is provided with a calculating unit, wherein 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 the critical pixel point of the cutter in a fixed time period, when C is more than C1, the judging unit outputs a first-level dangerous signal, when C is more than C2, the judging unit outputs a second-level dangerous signal, C1 is a first area change threshold value, C2 is a second area change threshold value, and C1 is less than C2.
5. The deep slot car tooling real-time monitoring system according to 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 with a green value of 140-160 of the cutter image from the preprocessed image information, and the second screening unit is used for screening out a straight line with the maximum number of pixels passing through the pixel point coordinate set from a parallel straight line system perpendicular to the cutter feeding direction as a temperature indication line;
the judging unit judges the change rate of the temperature indication line of the cutter, and if the change rate of the temperature indication line is larger than the safety change threshold value, the judging unit outputs a secondary dangerous signal.
6. The real-time monitoring system for deep and narrow groove turning as set forth in claim 5, wherein,
the memory module has a memory unit which,
the storage unit is used for storing the preprocessed image information, when the green value of the cutter image in the preprocessed image information is a high inverse value, the green value at the coordinate is stored as 210, and otherwise, the original green value and the coordinate corresponding to the original green value are stored;
and storing the pixel points with the green value larger than 210 in the current coordinate of the cutter, wherein the pixel value with the green value smaller than 210 in the current coordinate of the cutter is a high inverse value.
7. The real-time monitoring system for deep and narrow groove turning as set forth in claim 6, wherein,
the processing module is provided with an identification unit which is used for detecting whether the cutter is replaced, if so, the content stored in the storage unit is cleared, and otherwise, the content stored in the storage unit is reserved.
8. The deep slot car tooling real-time monitoring system of claim 7, further comprising,
the cutter image acquisition unit is provided with an infrared thermal imager, and the infrared thermal imager acquires temperature image information of the cutter machined by the deep narrow groove and transmits the temperature image information to the processing module.
9. The real-time monitoring system for deep and narrow groove turning as set forth in claim 8, wherein,
the temperature data detected by the infrared thermal imager is H, H=K× (S0×H20)/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 between the infrared thermal imager and the cutter is the standard distance, H0 is the same as the actual temperature of the cutter, and K is an energy coefficient;
when H is more than 700 ℃, the judging unit outputs a first-level danger signal.
10. The real-time monitoring system for deep and narrow groove turning as set forth in claim 9, wherein,
the acquisition module is provided with a linkage assembly and a support assembly, the linkage assembly is used for receiving the movement instruction, and the support assembly is used for preventing the infrared thermal imaging instrument from shaking, and the infrared thermal imaging instrument and the movement track of the cutter move synchronously.
11. The real-time monitoring system for deep and narrow groove turning as set forth in claim 10, wherein,
the acquisition module is provided with an acoustic wave acquisition unit, and the acoustic wave acquisition unit acquires acoustic wave information processed by the deep narrow groove vehicle and transmits the acoustic wave information to the processing module;
the processing module is provided with a sound processing unit, the sound processing unit processes the sound wave information to obtain sound wave frequency information L, the judging unit judges the sound wave frequency information L, and when L is more than L1, the judging unit outputs a first-level dangerous signal, and L1 is a frequency threshold.
12. The deep slot car tooling real-time monitoring system of claim 11, further comprising,
the processing module is provided with a sound calculation unit, the sound calculation unit is used for calculating the similarity S of the sound wave frequency information L and the abnormal audio, the judgment unit judges the similarity S, if S is more than 70%, the judgment unit outputs a first-level dangerous signal, and if S is more than 75%, the judgment unit outputs a second-level dangerous signal.
13. The deep narrow groove turning real-time monitoring system according to claim 12, wherein,
the acquisition module is provided with a part image acquisition unit, and the part image acquisition unit is used for acquiring image information of a 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 pixel difference P between RGB pixel values of the cutter and RGB pixel values 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 first-level dangerous signal.
14. The deep and narrow groove turning real-time monitoring system according to claim 13, wherein,
the display module is used for 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, the display screen is red to indicate that the cutter is dangerous and the judging unit outputs a second-level danger signal.
15. The deep and narrow groove turning real-time monitoring system of claim 14, wherein,
the power module and the transmission port;
the power module is used for providing power for the deep and narrow groove machining real-time monitoring system according to claim 14, and the transmission port is used for providing an interface for the judging unit to transmit data.
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