CN116037705A - Real-time monitoring system for working state of cold stamping die - Google Patents
Real-time monitoring system for working state of cold stamping die Download PDFInfo
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- CN116037705A CN116037705A CN202310027968.2A CN202310027968A CN116037705A CN 116037705 A CN116037705 A CN 116037705A CN 202310027968 A CN202310027968 A CN 202310027968A CN 116037705 A CN116037705 A CN 116037705A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/10—Die sets; Pillar guides
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D55/00—Safety devices protecting the machine or the operator, specially adapted for apparatus or machines dealt with in this subclass
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention discloses a real-time monitoring system for working states of a cold stamping die, which relates to the technical field of stamping die monitoring and aims at solving the problems that a conventional mode is used for carrying out on-condition maintenance and periodical maintenance on the die, and failure of the die cannot be timely found, and the failure can be often found only through reduction of quality level of a workpiece and damage of the die, so that maintenance cost is increased, and serious die loss and product qualification rate loss are caused. According to the invention, the shutdown loss of the cold stamping production line caused by the condition-based maintenance and the periodic maintenance in the operation process of the traditional cold stamping die is avoided, the shutdown time of the cold stamping production line caused by the maintenance of the cold stamping die is effectively shortened, the occurrence of serious damage or even scrapping of the cold stamping die with high price is avoided, the rapid identification of the fault of the cold stamping die is realized, and the production efficiency is improved.
Description
Technical Field
The invention relates to the technical field of stamping die monitoring, in particular to a real-time monitoring system for working states of a cold stamping die.
Background
The mold is the basic process equipment for industrial production, and is called the "master of industry". In recent years, the mold industry in China is rapidly developed, and the mold technology is widely applied in various fields. The mold is the root of the manufacturing industry, and the level of the mold industry is a national manufacturing level marker post. From the technical point of view, the technology of design, processing and manufacturing of the Chinese die is overtaking the international level, and the enterprise management technology is on the way of the international level, but the enterprise of the Chinese die industry still needs to improve the level of intelligence, informatization and modernization. Thus, digital twinning technology provides new ideas and tools for the innovation and development of current manufacturing industries. Establishing a corresponding digital twin system around each field of the die industry is an important technology for improving the level of the die industry in China.
The service life of the cold stamping die is generally more than 10 ten thousand cold stamping products, in the long service process, the die is analyzed from the aspect of maintenance of the cold stamping die, the traditional method is to maintain the die according to conditions and maintain regularly, but the method can not find out that the die has faults in time, and the faults can be found only through the reduction of the quality level of the product and the damage of the die, so that the maintenance cost is increased, and the significant die loss and the product yield loss are caused.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides a real-time monitoring system for the working state of a cold stamping die, which avoids the shutdown loss of a cold stamping production line caused by the condition-dependent maintenance and the periodical maintenance in the operation process of the traditional cold stamping die, effectively shortens the shutdown time of the cold stamping production line caused by the maintenance of the cold stamping die, avoids the serious damage or even scrapping of the cold stamping die with high price, realizes the rapid identification of the faults of the cold stamping die, improves the production efficiency, overcomes the defects of the prior art, effectively solves the problems that the conventional mode can not timely find the faults of the die due to the condition-dependent maintenance and the periodical maintenance of the die, and often can be found through the screening of the reduction of the quality level of a manufactured piece and the damage of the die, thereby increasing the maintenance cost and leading to the serious die loss and the product percent of pass loss.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
the cold stamping die working state real-time monitoring system comprises a physical entity module, a sensor and communication module, a data analysis and processing module and a data display and control module;
the physical entity module is a cold stamping die implemented on a cold stamping production site;
the sensor and communication module is used for collecting, storing, researching and transmitting key parameters of a cold stamping die which is set in the physical entity module implementation and is in a working state on a stamping production line in real time and reliably;
the data analysis and processing module is used for realizing real-time monitoring of the working state of the physical entity module working state real-time monitoring system, intelligent diagnosis of the operation fault of the die and real-time verification of cold stamping process requirements;
the data display and control module is used for visually displaying each key parameter, the working state history data and the real-time data of the cold stamping die, and simultaneously, the control module is used for stopping the physical entity module under an abnormal state.
Preferably, the sensor comprises a pressure sensor for collecting stamping die closing pressure of the cold stamping die, a strain sensor for collecting deformation degree of the cold stamping die, a vibration sensor for collecting vibration condition of the cold stamping die and a sound sensor for collecting sound during stamping die closing of the cold stamping die.
Preferably, the data display and control module is a computer installed on the physical entity module.
Preferably, the data display and control module establishes each mathematical model for the data acquired by the sensor by using software and algorithm modeling as a basis for judging whether the working state of the cold stamping die is normal.
Preferably, the data display and control module is installed on the data analysis and processing module, and the data display and control module comprises interface development, data display and calling and data evaluation.
Preferably, the interface development is used for developing a required data display and control interface, so that the computer terminal displays key parameters, historical data and real-time data of the working state of the cold stamping die, and displays whether the cold stamping die is in a normal working state or a state requiring shutdown maintenance due to abnormal key parameters.
Preferably, the data display and call are used for calling historical data and real-time data of each key parameter stored in the computer storage device, and visual display is performed on a display interface.
Preferably, the data evaluation is used for displaying normal and abnormal on a display interface after the working state of the real-time data collected by the sensor channel is judged by a mathematical model; and for the abnormal state, a control signal is fed back to the press of the physical entity module, and the press is controlled to stop automatically, so that the cold stamping die enters a state of stopping and maintaining.
The beneficial effects of the invention are as follows:
1. the system is based on advanced technologies such as sensing, modeling, data analysis and the like, can realize comprehensive monitoring targets such as real-time monitoring of working states of the cold stamping dies, intelligent diagnosis of operation faults of the dies, real-time verification of the achievement of cold stamping process requirements and the like, reduces unscheduled downtime of a cold stamping production line caused by unpredictable die faults and accidents in the long (10-30 ten thousand cold stamping) working process of the cold stamping dies, and avoids shutdown loss of the cold stamping production line caused by condition-based maintenance and periodic maintenance in the operation process of the traditional cold stamping dies.
2. Overcomes the defect of the traditional empirical method for indirectly judging the working state of the cold stamping die according to the quality fluctuation of the cold stamping product. Therefore, the downtime of the cold stamping production line caused by the maintenance of the cold stamping die is effectively shortened, the occurrence of serious damage or even scrapping of the cold stamping die with high price is avoided, the rapid identification of the faults of the cold stamping die is realized, the production efficiency is improved, the quality stability of cold stamping products produced in a large scale is ensured, the intelligent health management of the running state of the cold stamping die is realized, and the method has remarkable innovation.
Drawings
Fig. 1 is a technical flow chart of a real-time monitoring system for working states of a cold stamping die.
Detailed Description
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.
The embodiment 1 of the system for monitoring the working state of the cold stamping die in real time comprises a physical entity module, a sensor and communication module, a data analysis and processing module and a data display and control module;
the physical entity module is a cold stamping die implemented on a cold stamping production site;
the sensor and the communication module are used for collecting, storing, researching and transmitting key parameters of a cold stamping die which is set in the implementation of the physical entity module and is in a working state on a stamping production line in real time and reliably;
the data analysis and processing module is used for realizing the real-time monitoring of the working state of the physical entity module working state real-time monitoring system, the intelligent diagnosis of the operation fault of the die and the real-time verification of the cold stamping process requirements;
the data display and control module is used for visually displaying each key parameter, the working state history data and the real-time data of the cold stamping die, and simultaneously, the control module is used for stopping the physical entity module under an abnormal state.
The sensor comprises a pressure sensor for collecting stamping die closing pressure of the cold stamping die, a strain sensor for collecting deformation degree of the cold stamping die, a vibration sensor for collecting vibration condition of the cold stamping die and a sound sensor for collecting sound during stamping die closing of the cold stamping die.
The data display and control module is a computer installed on the physical entity module.
The data display and control module establishes mathematical models for data acquired by the sensor by using software and algorithm modeling as the basis for judging whether the working state of the cold stamping die is normal or not.
The data display and control module is arranged on the data analysis and processing module and comprises interface development, data display and calling and data evaluation.
The interface development is used for developing a required data display and control interface, so that the computer terminal displays the key parameters, the historical data and the real-time data of the working state of the cold stamping die, and the state that the cold stamping die is in normal work or is required to be shut down and maintained due to the abnormal key parameters.
And displaying and calling the historical data and the real-time data of each key parameter stored in the computer storage equipment, and performing visual display on a display interface.
The data evaluation is used for displaying normal and abnormal on a display interface after the working state of the real-time data acquired by the sensor channel is judged by the mathematical model; and for the abnormal state, feeding back a control signal to the press of the physical entity module, controlling the press to stop automatically, and enabling the cold stamping die to enter a stop maintenance state.
Referring to fig. 1, the main implementation contents for the physical entity module include: (1-1) determining a mold and a press: based on the production takt, station arrangement and process requirements of the stamping production line, the type, structure, function and process requirements of a cold stamping die with monitoring requirements on the production line, important influences on the quality of cold stamping products and frequent fault points are defined; (1-2) selecting key state parameters: based on a cold stamping die design theory and a plastic forming theory, aiming at the characteristics of the type, structure, function and process requirement of the monitored cold stamping die, key parameters capable of accurately reflecting the working state of the cold stamping die are selected, wherein the key parameters comprise the size of stamping force, the deformation degree of the die, the vibration frequency of the die, the sound during stamping and die closing and the like, and the key parameters are used as the basis for the acquisition and implementation of the key parameters provided by a subsequent sensor and a communication module; (1-3) assessing feasibility: and carrying out feasibility assessment on whether the set key parameters can accurately reflect the working state of the cold stamping die in real time and whether the equipment sites of the die and the press have the software and hardware conditions for collecting the key parameters, and adjusting the key parameters which are not feasible.
The main implementation contents for the sensor and the communication module include: (2-1) selection sensor: the type and model of the sensor used are determined according to the established key parameters of the physical entity module capable of accurately reflecting the working state of the cold stamping die, wherein the sensor comprises a pressure sensor (model KP 43P-010-F1), a strain sensor (model X-113-H07-440) for collecting the deformation degree of the die, a vibration sensor (model SK48-JDS 10-SDJ-SG-2) for collecting the vibration condition of the die and a sound sensor (model TZ-2 KA) for collecting the sound during stamping and die closing; (2-2) mounting a sensor: the pressure sensor and the vibration sensor are arranged on the lower die, the strain sensor is arranged on the upper die and the lower die, and the sound sensor is arranged on the lower die: (2-3) transmitting data: according to the communication mode of the sensor, the data transmission between the sensor and the computer is carried out by using a communication system with wire transmission preferentially, and under the condition of not having the wire transmission condition, the communication system with wireless transmission can also be used, and the transmitted data is stored in a computer terminal and can be displayed and called by a data analysis and processing module and a data display and control module.
The main implementation contents of the data analysis and processing module include: (3-1) modeling using software and algorithms: based on matlab software and a data mining algorithm, data mining is carried out on data acquisition results of key parameters of a die in a normal working state (namely, in a state that a cold stamping product meets a quality requirement standard) of the 1 st-3000 th cold stamping process, namely, regression analysis is carried out on field data of key parameters such as stamping force, die deformation, die vibration frequency, stamping die closing sound decibels and the like acquired in real time in the 1 st-3000 th cold stamping process by using a support vector machine, specifically, the 3000 th data are firstly read by using matlab software, abnormal data are cleared through visualization processing, then, after normalization processing, a support vector machine program is compiled, upper boundary data points and lower boundary data points are respectively input, a sigmoid kernel function of the support vector machine is utilized for carrying out data training and testing, a regression model of the support vector machine is established, an internal rule between stamping force and key parameters such as die deformation, die vibration frequency and amplitude, stamping die closing sound decibels and the like is identified, and a function relation formula representing upper boundary curve and lower boundary curve of the 1 st-3000 th field data is generated as a system state model to judge the working state of the system. The upper and lower limit curve function relation of the system state model can be uniformly expressed as:
F u ＝f u (Δx,n,h,B) (1)
F d ＝f d (Δx,n,h,B) (2)
wherein: f (F) u To the upper limit of the punching force, f u Representing an upper limit curve function relation, F d To the lower limit of the pressing force, f d The lower limit curve functional relation is expressed, deltax is the deformation of the die, h is the vibration frequency of the die, l is the vibration amplitude of the die, and B is the stamping die closing sound. If the newly acquired key parameters of the system are between the upper limit curve and the lower limit curve, the working state of the standard cold stamping die is normal; otherwise, if the working state of the cold stamping die is abnormal, the working state of the cold stamping die is abnormal: (3-2) test run: substituting the data acquisition result of the key parameters of the system of the die in the working state of 3001-6000 times of cold stamping process into the system state model for test operation, automatically diagnosing whether the working state of the cold stamping die is normal, synchronously measuring whether the produced cold stamping product meets the quality requirement standard, and thus (3-3) verifying the rationality and accuracy of each mathematical model; (3-4) perfecting and iterating:along with the continuous working process of the cold stamping die, continuously collecting data of each key parameter, and automatically judging whether the working state of the cold stamping die is normal or not based on an established system state model, so that the real-time monitoring of the working state is realized; judging abnormal key parameters of the system state model, namely, the key parameters are the induction factors of the operation faults of the die, and stopping and maintaining should be carried out; the method has the advantages that key parameters which are definitely specified in cold stamping process requirements such as the size of stamping force and the deformation degree of a die are checked in real time, and whether the parameters meet the cold stamping process requirements is judged. Meanwhile, in order to maintain the accuracy of a system state model in a long working process of the cold stamping die, carrying out visual processing on 3001-6000 times of data, removing abnormal data, comparing upper and lower limit curve functions (1) and (2) of the system state model by combining a verification result, dividing the maximum value of stamping force in the processed 3001-6000 times of acquired actual data by the stamping force upper limit F obtained by using the system state model (1) u The quotient obtained is taken as the adjustment coefficient k u (1) The method comprises the steps of carrying out a first treatment on the surface of the Dividing the minimum value of the stamping force in the processed 3001-6000 times of acquired actual data by the lower limit F of the stamping force obtained by using the system state model (2) d The quotient obtained is taken as the adjustment coefficient k d (1). Using adjustment coefficients and upper and lower limit curve functions F u And F d The product of the (2) is used for correcting the upper and lower limit curve functions of the system state model, so that the range of the system state model is adjusted in real time, and the fitting work is practical. According to the same method, the above analysis is further carried out on 8 groups of data such as 6001-9000 th data, 9001-12000 th data, 12001-15000 th data, … … th data, 27001-30000 th data and the like, so as to obtain the upper limit and lower limit boundary curve adjustment coefficients of the system state model of each stage. Let the system initial state model adjustment coefficient obtained from the 1 st to 3000 th data be k u ＝k d On the basis of the above, fitting analysis is carried out on the 9 groups of adjustment coefficients to obtain an adjustment coefficient k u And k d And the relation between the phase times n and the initial system state model is integrated to obtain a system state correction model as follows:
F u ＝k u (n)f u (Δx,h,l,B) (3)
F d ＝k u (n)f d (Δx,h,l,B) (4)
wherein: k (k) u An adjustment coefficient k of an upper limit curve d And n is the number of times stage (one node is used for every 3000 times) for the adjustment coefficient of the lower limit curve, so that the cold stamping die is ensured to be changed along with the change of the die (caused by the normal reasons of creep, fatigue, abrasion and the like of the die material) in the normal design service life of 10-30 ten thousand times, and the system state model is continuously updated to ensure the long-acting rationality and accuracy of the cold stamping die and avoid the misjudgment of the system.
The main implementation contents of the data display and control module comprise: (4-1) interface development: and (3) developing a required data display and control interface according to the key state parameters selected in the step (1-2), so that the computer terminal displays the key parameters, historical data and real-time data of the working state of the cold stamping die, and displays the state that the cold stamping die is in normal working or is in a state that the cold stamping die needs to be shut down for maintenance due to abnormal key parameters. (4-2) data call and display: and calling historical data and real-time data of each key parameter stored in the computer storage equipment, and performing visual display on a display interface. (4-3) data evaluation: after the working state of the real-time data collected by each sensor channel is judged by a mathematical model, the display interface is displayed as normal and abnormal; and for the abnormal state, feeding back a control signal to the press of the physical entity module, controlling the press to stop automatically, and enabling the cold stamping die to enter a stop maintenance state.
The foregoing is only a preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art, who is within the scope of the present invention, should make equivalent substitutions or modifications according to the technical scheme of the present invention and the inventive concept thereof, and should be covered by the scope of the present invention.
Claims (8)
1. The cold stamping die working state real-time monitoring system is characterized by comprising a physical entity module, a sensor and communication module, a data analysis and processing module and a data display and control module;
the physical entity module is a cold stamping die implemented on a cold stamping production site;
the sensor and communication module is used for collecting, storing, researching and transmitting key parameters of a cold stamping die which is set in the physical entity module implementation and is in a working state on a stamping production line in real time and reliably;
the data analysis and processing module is used for monitoring the working state of the physical entity module in real time, diagnosing the operation fault of the die and checking the cold stamping process requirement in real time;
the data display and control module is used for visually displaying each key parameter, the working state history data and the real-time data of the cold stamping die, and simultaneously, the control module is used for stopping the physical entity module under an abnormal state.
2. The system for monitoring the working state of the cold stamping die in real time according to claim 1, wherein the sensor comprises a pressure sensor for collecting stamping die clamping pressure of the cold stamping die, a strain sensor for collecting deformation degree of the cold stamping die, a vibration sensor for collecting vibration condition of the cold stamping die and a sound sensor for collecting sound during stamping die clamping of the cold stamping die.
3. The system for monitoring the working state of a cold stamping die in real time according to claim 1, wherein the data display and control module is a computer installed on a physical entity module.
4. The system for monitoring the working state of the cold stamping die in real time according to claim 3, wherein the data display and control module establishes mathematical models for the data collected by the sensor by using software and algorithm modeling as a basis for judging whether the working state of the cold stamping die is normal.
5. The system for monitoring the working state of the cold stamping die in real time according to claim 4, wherein the data display and control module is installed on the data analysis and processing module, and the data display and control module comprises interface development, data display and calling and data evaluation.
6. The system according to claim 5, wherein the interface development is used for developing a required data display and control interface, so that the computer terminal displays the key parameters, the historical data and the real-time data of the working state of the cold stamping die, and displays whether the cold stamping die is in a normal working state or a state requiring shutdown maintenance due to abnormal key parameters.
7. The system for monitoring the working state of the cold stamping die in real time according to claim 5, wherein the data display and call are used for calling historical data and real-time data of each key parameter stored in the computer storage device, and visual display is performed on a display interface.
8. The system for monitoring the working state of the cold stamping die in real time according to claim 5, wherein the data evaluation is used for displaying normal and abnormal on a display interface after the working state of the real-time data collected by the sensor channel is judged by a mathematical model; and for the abnormal state, a control signal is fed back to the press of the physical entity module, and the press is controlled to stop automatically, so that the cold stamping die enters a state of stopping and maintaining.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116651971A (en) * | 2023-08-01 | 2023-08-29 | 苏州利来汽车配件有限公司 | Online detection method and system for automobile stamping die |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116651971A (en) * | 2023-08-01 | 2023-08-29 | 苏州利来汽车配件有限公司 | Online detection method and system for automobile stamping die |
| CN116651971B (en) * | 2023-08-01 | 2023-10-24 | 苏州利来汽车配件有限公司 | Online detection method and system for automobile stamping die |
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