CN116300688A - Method for collecting, storing and applying numerical control machine tool data - Google Patents
Method for collecting, storing and applying numerical control machine tool data Download PDFInfo
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- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
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Abstract
The invention relates to a method for collecting, storing and applying numerical control machine tool data, which belongs to the technical field of machining center machine tools and comprises the following steps of: and a vibration sensor, a noise sensor, an alternating current transducer and an alternating voltage transducer are arranged on the machine tool, and data acquired by various sensors in real time are acquired through a serial port communication technology. The data storage method of the numerical control machine tool comprises the following steps: the real-time data and the information are processed by software data, and are displayed on a human-computer interface of the industrial personal computer and a numerical control machine tool controller in real time, so that the data are locally stored in a detection and monitoring system database of the background of the industrial personal computer; or the intelligent gateway of the internet of things uploads the data to the network cloud platform server through the Ethernet to realize data cloud storage and cloud computing, and cloud storage data of the intelligent gateway of the internet of things are displayed through software of a PC (personal computer) end or a mobile terminal. The method solves the problem of real-time automatic acquisition of key process index data of vibration, noise, output power of a spindle motor and torque in the machining process of machine tool parts.
Description
Technical Field
The invention relates to the technical field of machining center machine tools, in particular to a method for acquiring, storing and applying numerical control machine tool data.
Background
The intelligent machine tool is an integrated and deeply fused product of advanced manufacturing technology, information technology and intelligent technology, and is an advanced form of development of the numerical control machine tool. The technological base is provided for the development of intelligent machine tools by breaking through the intelligent technologies such as machine tool monitoring, measuring, compensating, diagnosing, processing optimizing and the like in the advanced state of the prior art. Along with continuous innovation of science and technology, an intelligent machine tool is used as an industrial internet intelligent terminal and becomes key processing equipment and an important link of an intelligent production system.
Vibration data, noise data and motor output power data of a machine tool in the running process of the part processing directly relate to whether a reasonable key index is set in the part processing technology. In the prior art, vibration, noise and motor power data are measured and acquired by an external detection instrument, so that the cost for purchasing the detection instruments is high, and the integrated design with a machine tool cannot be realized, so that the device is not convenient for large-scale popularization. According to the invention, key index data required by a part processing technology, namely machine tool vibration, noise, motor output power and torque, are subjected to data acquisition and storage by arranging and installing the vibration sensor, the noise sensor and the power detector on the machine tool, and after acquired data are analyzed and processed, real-time data values, graphs and data inquiry and management are displayed for a user, so that the user can reasonably optimize the part processing technology by referring to the real-time data values, the graphs and the data inquiry and management, the part processing efficiency is improved, the machine tool performance is furthest exerted, and the benefit is maximized for the user.
Disclosure of Invention
The invention mainly solves the defects of complex structure, poor equipment operation stability and low processing efficiency in the prior art, and provides a method for acquiring, storing and applying data of a numerical control machine tool, which has the characteristics of good operation stability, long service life of a cutter and high processing efficiency. The method solves the problem of real-time automatic acquisition of key process index data of vibration, noise and motor output power in the machining process of machine tool parts. After analyzing and processing the acquired data, the real-time data value, the graph and the data query and the data management are displayed for the user, so that the user can reasonably optimize the part processing technology for reference, the part processing efficiency is improved, the machine tool performance is brought into full play to the maximum extent, and the benefit maximization is created for the user. And meanwhile, parameter comparison is carried out by combining a processing test knowledge database, and the most reasonable processing technological parameter recommendation and technological scheme are provided for users. When the sensor detection data in the machining process of the machine tool reaches an abnormal state, the system gives a warning prompt to a user and controls the machine tool to carry out machining pause or stop treatment, so that the protection of the workpiece, the cutter and the machine tool is realized.
The technical problems of the invention are mainly solved by the following technical proposal:
A method for collecting, storing and applying data of a numerical control machine tool comprises the following steps:
the data acquisition method of the numerical control machine tool comprises the following steps: the vibration sensor, the noise sensor, the alternating current transmitter and the alternating voltage transmitter are arranged on the machine tool, and data acquired by various sensors in real time are acquired through a serial port communication technology, wherein the data comprise actual current values of a spindle motor, actual voltage values of the spindle motor, real-time vibration values generated in a machining process and noise values are transmitted to an industrial personal computer or an intelligent gateway of the Internet of things through communication lines. The industrial personal computer or the intelligent gateway of the Internet of things simultaneously carries out network communication with the numerical control machine tool controller, and the numerical control machine tool controller transmits the actual rotating speed value, the actual feeding speed value, the cutter service life, the current cutter number, the cutter compensation value, the system alarm state, the warning information and other contents to the industrial personal computer or the intelligent gateway of the Internet of things in real time.
The data storage method of the numerical control machine tool comprises the following steps: real-time data and information are processed by software data, are displayed on a human-computer interface of an industrial personal computer and a numerical control machine controller in real time, and after the data information is calibrated for time and preprocessed by data cleaning, data integration, data conversion, data protocol and the like, the data is locally stored in a detection and monitoring system database of the background of the industrial personal computer; or the industrial personal computer is changed into the intelligent gateway of the Internet of things, and the intelligent gateway is wirelessly uploaded to the network cloud platform server through the Ethernet cable or the gateway 4G module, so that cloud storage and cloud computing of data are realized, and cloud storage data are displayed through software of a PC (personal computer) end or a mobile terminal.
The real-time data application method of the numerical control machine tool comprises the following steps: comparing the real-time collected data with standard parameters of a processing database, recommending the most reasonable processing technological parameter value to a user according to the difference value, giving warning reminding to the user when the detection data of a sensor in the processing process of the machine tool is higher than the upper limit value, and controlling the numerical control machine tool to carry out processing stopping treatment after the timing is reached if the detection data is not interfered for a long time, so that the protection of the workpiece, the cutter and the machine tool is realized.
1. The application method of the data acquisition and storage part of the numerical control machine tool comprises the following steps:
data acquisition configuration connection channel one: the numerical control machine controller is connected with an industrial personal computer or an intelligent gateway of the Internet of things through an API interface function and an Ethernet to realize network data communication, and processing data and detailed parameters of the numerical control machine controller are collected and read in real time, wherein the numerical control machine controller comprises numerical control machine operation processing time statistics, part processing number statistics, main shaft actual rotating speed, machine tool feeding speed, current cutter number, cutter compensation value and the like.
And a data acquisition configuration connection channel II:
1) And the vibration sensor is connected with an industrial personal computer or an intelligent gateway of the Internet of things through 485 serial port communication, and vibration data of the spindle box in the part machining process are read in real time.
2) The noise sensor is connected with an industrial personal computer or an intelligent gateway of the Internet of things through 495 serial port communication, and internal environment noise data of the machine tool in the machining process are read in real time.
3) And the alternating current transmitter is connected with an industrial personal computer or an intelligent gateway of the Internet of things through 485 serial port communication, and the output current value data of the spindle motor is read in real time.
4) And the alternating voltage transmitter is connected with an industrial personal computer or an intelligent gateway of the Internet of things through 485 serial port communication, and the output voltage value data of the spindle motor is read in real time.
The data stored in the numerical control machine tool are mainly of two types:
1) And data acquired by real-time acquisition of various machine tool sensors, including vibration sensors, noise sensors, alternating current transmitters and alternating voltage transmitters.
2) The internal processing data of the numerical control machine controller comprises actual rotating speed of a main shaft, actual feeding rate of the numerical control machine, cutter information, cutter compensation value, machine position information and the like; the storage of the numerical control machine tool data comprises the steps of reading and displaying the internal information and the data of the numerical control machine tool controller in real time by reading the data of the numerical control machine tool controller and the data of the numerical control machine tool controller, reading the data information of a machine tool vibration sensor, a noise sensor, an alternating current transmitter and an alternating voltage transmitter, displaying the data in real time, and drawing and outputting a real-time graph; including data management functions such as data querying, data deleting, data exporting, etc.
2. Application part of numerical control machine tool data:
the application of the numerical control machine tool data is to establish a numerical control machining knowledge database, which comprises real-time data acquired by a machine tool sensor, process test data and knowledge accumulation data obtained by production practice; the method is mainly used for providing necessary data reference basis for improving the machining efficiency and precision of the machine tool and is used for self-diagnosis of machine tool faults and physical examination of machine tool running states; the system comprises a real-time display main interface, a user management module, a data processing module, a vibration curve graph module, a noise curve graph module, a motor current curve graph module and a motor voltage curve graph module.
Preferably, the numerical control machine controller is arranged on the side of the machine tool, which is opposite to an operator, and is connected with an industrial personal computer or an intelligent gateway of the Internet of things through an Ethernet, the industrial personal computer or the intelligent gateway of the Internet of things establishes data communication with the numerical control machine controller through an API interface function protocol, and relevant information data of the machining process of the numerical control machine is read in real time; reading data includes: the numerical control machine tool running processing time statistics, the part processing number statistics, the main shaft actual rotation speed, the machine tool feeding speed, the cutter information, the cutter compensation value and the like can open other data according to the user requirements; on the basis of establishing data communication between an industrial personal computer or an intelligent gateway of the Internet of things and a numerical control machine controller, data acquired and acquired by a machine tool sensor can be reversely transmitted to the numerical control machine controller, and real-time display is carried out on a human-computer interface of the numerical control machine controller: noise value, vibration value, spindle motor output voltage value, spindle motor output current value, spindle motor output power value, spindle motor output torque value.
Preferably, the industrial personal computer or the intelligent gateway of the internet of things is arranged on the side, facing the operator, of the machine tool, is connected with a numerical control machine tool controller through an Ethernet cable, and is connected with a noise sensor, a vibration sensor, an alternating current transmitter and an alternating voltage transmitter through 485 serial port communication; the method comprises the steps of processing the acquired real-time data and information through software data, displaying the acquired real-time data and information on a human-computer interface of an industrial personal computer and a numerical control machine tool controller in real time, and realizing the local storage of the data in a detection and monitoring system database of the background of the industrial personal computer; or the industrial personal computer is changed into the intelligent gateway of the Internet of things, and the intelligent gateway is wirelessly uploaded to the network cloud platform server through the Ethernet cable or the gateway 4G module, so that cloud storage and cloud computing of data are realized, and cloud storage data are displayed through software of a PC (personal computer) end or a mobile terminal.
Preferably, the vibration sensor is arranged on the side surface of a main shaft box body of the machine tool, the direction is vertical to the side surface of the main shaft box body, and the vibration sensor is rigidly arranged and connected by adopting threads; the sensor function is to accurately measure vibration data generated in the machining process of the machine tool in real time, so that the machining states of a cutter and a workpiece in the machining process can be monitored better; the vibration sensor is required to be selected to have vibration resistance, impact resistance and high stability, has good low-frequency output characteristics, and can directly output vibration displacement signals and amplitude signals; the vibration sensor is used for receiving vibration and displaying vibration data and curve images of a machine tool spindle.
Preferably, the noise sensor is arranged at a sheet metal part in the machine tool, and the water-proof and oil-proof environment is considered; the sensor is used for detecting noise data in the part machining process in real time, and detecting abnormal noise in the machining process so as to assist in judging whether abnormal problems exist in the machining process, whether a cutter is worn or not and the like; the noise sensor is internally provided with a capacitance microphone sensitive to sound, the sound wave vibrates a film in the microphone, the capacitance is changed, a tiny voltage corresponding to the change is generated, the voltage is then converted into a voltage of 0-5V, the voltage is received by the data acquisition device through A/D conversion and is transmitted to the industrial personal computer, and the noise sensor is used for receiving the sound wave and displaying vibration data and curve images of the environmental sound in the machine tool.
Preferably, the alternating current transmitter is arranged at the output end U V W of the spindle motor in the electric cabinet of the machine tool, and is fixed by a caliper groove, so that strong and weak current separation is considered in wiring, signal interference is avoided, and the data acquisition accuracy of the sensor is affected; the sensor function is to measure the current value output by the spindle motor in real time, so that the actual power output value of the spindle motor at any moment is calculated subsequently; the alternating current transducer is used for detecting current and displaying current data and curve images output by the spindle motor.
Preferably, the alternating voltage transmitter is arranged at the output end U V W of a spindle motor in an electric cabinet of the machine tool and is fixed by a caliper groove; the routing needs to consider strong and weak current separation, so that signal interference is avoided, and the data acquisition accuracy of the sensor is affected; the sensor function is to measure the voltage value output by the spindle motor in real time, so that the actual power output value of the spindle motor at any moment can be obtained through subsequent calculation. The alternating voltage transmitter is used for detecting voltage and displaying voltage data and curve images output by the spindle motor.
Preferably, the output power value of the spindle motor can be calculated through the output voltage value and the current value of the spindle motor acquired by the current transducer and the voltage transducer; the rotating speed value of the spindle motor is obtained from the numerical control machine controller through API interface communication, and the real-time output torque value of the spindle motor can be calculated and obtained by combining the output power value of the spindle motor, so that the real-time output torque data and curve images of the spindle motor are displayed.
Preferably, the real-time display main interface mainly comprises a basic information and setting area, a data real-time display area, a curve display area and an alarm information area of the acquisition equipment. The basic information and the setting area comprise the IP address of the acquisition equipment, the port of the acquisition equipment, the real-time, a test button for detecting whether the database connection is successful or not and a button for starting or ending acquisition. The data real-time display area comprises the starting time, cutting time, processing time, alarm state and information of a numerical control controller of the machine tool, the feeding rate of the actual machine tool, the actual spindle rotating speed value, the position information of the tool coordinates, the actual current, voltage, power and the like of a spindle motor, and provides data for a production informatization management MS system; the curve display area contains real-time data curve drawing charts of the collected vibration data, noise data and power data, and provides support data basis for improving the machining efficiency and the precision of the numerical control machine tool. The alarm information area contains whether the numerical control machine controller is in an alarm state or not and the specific alarm information content in the alarm state, and provides support data basis for normal use of the numerical control machine, fault diagnosis, machine self-checking and physical examination.
Preferably, the user management module mainly comprises functions of adding and deleting software login user information and exiting the system.
Preferably, the vibration curve graph module reads real-time data values through 485 serial communication with the vibration sensor, displays the vibration data values in a text box, draws the latest 15 data points in a display area in real time, and the number of collected data points can be modified according to user requirements; when the vibration data value of the machine tool exceeds the upper limit value A in the part machining process, the system gives a warning prompt to a user, and if the overload state is kept for a long time to reach the time setting D, the system controls the machine tool to carry out machining pause or stopping treatment; the system can give a recommended value H of machine tool vibration data or a process cutting scheme to a user according to experience data of a machining process knowledge base, and guide the user to optimize own machining process cutting parameters of the part.
Preferably, the noise graph module mainly reads real-time data values through 485 serial communication with the noise sensor, displays the noise values in a text box, displays the latest 15 data in a display area in real time, and the number of collected data points can be modified according to the requirements of users; when the noise data value of the machine tool exceeds the upper limit value B in the part machining process, the system gives a warning prompt to a user, and if the overload state is kept for a long time to reach the time setting D, the system controls the machine tool to carry out machining pause or stop treatment. The system can give a recommended value I of machine tool noise data or a process cutting scheme to a user according to experience data of a machining process knowledge base, and guide the user to optimize own machining process cutting parameters of the part.
Preferably, the motor current and voltage curve graph module is used for reading real-time data values through communication with an alternating current transducer and an alternating voltage transducer through 485 serial ports, respectively displaying the current values and the voltage values in a text box, displaying the latest 15 data in a display area in real time, and the number of collected data points can be modified according to user requirements; calculating the acquired current and voltage data values and the acquired spindle rotating speed value to obtain a real-time output power value of the spindle motor; when detecting that the power data value of the spindle motor of the machine tool exceeds the upper limit value C in the part machining process, the system sends out warning reminding to a user, and if the overload state is kept for a long time to reach the time setting D, the system controls the machine tool to carry out machining pause or shutdown treatment; the system can give a machine tool vibration data recommended value J or a process cutting scheme to a user according to experience data of a machining process knowledge base, and guide the user to optimize own machining process cutting parameters of the part.
A. B, C, D, H, I, J is a range interval number.
The invention can achieve the following effects:
compared with the prior art, the method for acquiring, storing and applying the numerical control machine tool data has the characteristics of good operation stability, long service life of the cutter and high processing efficiency. The method solves the problem of real-time automatic acquisition of key process index data of vibration, noise and motor output power in the machining process of machine tool parts. After analyzing and processing the acquired data, the real-time data value, the graph and the data query and the data management are displayed for the user, so that the user can reasonably optimize the part processing technology for reference, the part processing efficiency is improved, the machine tool performance is brought into full play to the maximum extent, and the benefit maximization is created for the user. And meanwhile, parameter comparison is carried out by combining a processing test knowledge database, and the most reasonable processing technological parameter recommendation and technological scheme are provided for users. When the sensor detection data in the machining process of the machine tool reaches an abnormal state, the system gives a warning prompt to a user and controls the machine tool to carry out machining pause or stop treatment, so that the protection of the workpiece, the cutter and the machine tool is realized.
Drawings
Fig. 1 is a schematic structural view of the present invention.
In the figure: the machine tool comprises a machine tool housing 1, a noise sensor 2, a numerical control machine tool 3, a vibration sensor 4, a machine tool electrical cabinet 5, an alternating current transmitter 6, an alternating voltage transmitter 7, an industrial personal computer 8, an intelligent gateway 9 of the Internet of things and a numerical control machine tool controller 10.
Detailed Description
The technical scheme of the invention is further specifically described below through examples and with reference to the accompanying drawings.
Examples: as shown in fig. 1, a method for collecting, storing and applying data of a numerically-controlled machine tool includes: the data acquisition method of the numerical control machine tool comprises the following steps: the vibration sensor 4, the noise sensor 2, the alternating current transmitter 6 and the alternating voltage transmitter 7 are arranged on the numerical control machine tool 3, and data acquired by various sensors in real time are acquired through a serial port communication technology, wherein the data comprise actual current values of a spindle motor, actual voltage values of the spindle motor, real-time vibration values generated in a processing process and noise values are transmitted to the industrial personal computer 8 or the intelligent gateway 9 of the Internet of things through communication lines. The industrial personal computer 8 or the intelligent gateway 9 of the internet of things simultaneously performs network communication with the numerical control machine controller 10, and the numerical control machine controller 10 transmits the actual rotation speed value, the actual feeding degree, the cutter service life, the current cutter number, the cutter compensation value, the system alarm state and the warning information content of the spindle motor to the industrial personal computer 8 or the intelligent gateway 9 of the internet of things in real time.
The numerical control machine controller 10 is arranged on the side, facing the operator, of the machine tool, and is connected with the industrial personal computer 8 or the intelligent gateway 9 of the Internet of things through an Ethernet cable, the industrial personal computer 8 or the intelligent gateway 9 of the Internet of things establishes data communication with the numerical control machine controller 10 through an API interface function protocol, and relevant information data of the machining process of the numerical control machine tool is read in real time; reading data includes: the numerical control machine tool operation processing time statistics, part processing number statistics, main shaft actual rotation speed, machine tool feeding speed and the like can open other data according to user requirements, and on the basis that the industrial personal computer 8 or the internet of things intelligent gateway 9 and the numerical control machine tool controller 10 establish data communication, the data acquired by the machine tool sensor can be reversely transmitted to the numerical control machine tool controller 10 and displayed on a human-computer interface of the numerical control machine tool controller 10 in real time: noise value, vibration value, spindle motor output voltage value, spindle motor output current value, spindle motor output power value, spindle motor output torque value.
The industrial personal computer 8 or the intelligent gateway 9 of the internet of things is arranged on the side of the machine tool, which is opposite to an operator, and is connected with the controller 10 of the numerical control machine tool through an Ethernet cable, and is connected with the noise sensor 2, the vibration sensor 4, the alternating current transmitter 6 and the alternating voltage transmitter 7 through 485 serial communication; the method comprises the steps of processing the acquired real-time data and information through software data, displaying the acquired real-time data and information on a human-computer interface of the industrial personal computer 8 and the numerical control machine controller 10 in real time, and realizing the local storage of the data in a detection and monitoring system database of the background of the industrial personal computer 8; or the industrial personal computer 8 is changed into the intelligent gateway 9 of the internet of things, and the intelligent gateway 9 is uploaded to a network cloud platform server in a wireless way through an Ethernet cable or a gateway 4G module, so that cloud storage and cloud computing of data are realized, and cloud storage data are displayed through software of a PC (personal computer) end or a mobile terminal.
The vibration sensor 4 is arranged on the side surface of the main shaft box body of the machine tool, the direction is vertical to the side surface of the main shaft box body, and the vibration sensor is rigidly arranged and connected by adopting threads; the sensor function is to accurately measure vibration data generated in the machining process of the machine tool in real time, so that the machining states of a cutter and a workpiece in the machining process can be monitored better; the vibration sensor 4 is required to be selected to have vibration resistance, impact resistance and high stability, has good low-frequency output characteristics, and can directly output vibration displacement signals and amplitude signals; the vibration sensor 4 is used for receiving vibration and displaying vibration data and curve images of the machine tool spindle.
The noise sensor 2 is arranged at a sheet metal part in the machine tool, and the water-proof and oil-proof environment is needed to be considered; the sensor is used for detecting noise data in the part machining process in real time, and detecting abnormal noise in the machining process so as to assist in judging whether abnormal problems exist in the machining process, whether a cutter is worn or not and the like. The noise sensor 2 is internally provided with a capacitance microphone sensitive to sound, the sound wave vibrates a film in the microphone, so that capacitance changes to generate tiny voltage corresponding to the capacitance changes, the voltage is then converted into voltage of 0-5V, the voltage is received by the data acquisition device through A/D conversion and is transmitted to the industrial personal computer 8, and the noise sensor 2 is used for receiving the sound wave and displaying vibration data and curve images of the environmental sound in the machine tool.
The alternating current transmitter 6 is arranged at the output end U V W of the spindle motor in the machine tool electric cabinet 5, is fixed by a caliper groove, and is required to consider strong and weak current separation, so that signal interference is avoided, and the data acquisition accuracy of the sensor is affected; the sensor function is to measure the current value output by the spindle motor in real time, so that the actual power output value of the spindle motor at any moment is calculated subsequently; the alternating current transducer 6 is used for detecting current and displaying current data and curve images output by the spindle motor.
The alternating voltage transmitter 7 is arranged at the output end U V W of the spindle motor in the machine tool electric cabinet 5 and is fixed by a caliper groove; the routing needs to consider strong and weak current separation, so that signal interference is avoided, and the data acquisition accuracy of the sensor is affected; the sensor function is to measure the voltage value output by the spindle motor in real time, so that the actual power output value of the spindle motor at any moment can be obtained through subsequent calculation. The alternating voltage transducer 7 is used for detecting voltage and displaying voltage data and curve images output by the spindle motor.
The data storage method of the numerical control machine tool comprises the following steps: the real-time data and information are processed by software data, are displayed on a human-computer interface of the industrial personal computer 8 and the numerical control machine controller 10 in real time, and the data information is calibrated for time, and after pretreatment such as data cleaning, data integration, data conversion, data protocol and the like, the data is locally stored in a real-time detection and monitoring system database of the background of the industrial personal computer 8. Or the industrial personal computer 8 is changed into the intelligent gateway 9 of the internet of things, and the intelligent gateway 9 is uploaded to a network cloud platform server in a wireless way through an Ethernet cable or a gateway 4G module, so that cloud storage and cloud computing of data are realized, and cloud storage data are displayed through software of a PC (personal computer) end or a mobile terminal.
The real-time data application method of the numerical control machine tool comprises the following steps: comparing the real-time collected data with standard parameters of a processing database 5, recommending the most reasonable processing technological parameter value for a user according to the difference value, when the sensor detection data in the processing process of the machine tool is higher than the upper limit value, giving warning reminding to the user by the system, and if the processing is not interfered for a long time, controlling the numerical control machine tool to carry out processing stopping processing after timing arrives, thereby realizing the protection of the workpiece, the cutter and the machine tool.
1. The application method of the data acquisition and storage part of the numerical control machine 4 comprises the following steps:
data acquisition configuration connection channel one: the numerical control machine controller 10 is connected with the industrial personal computer 8 or the intelligent gateway 9 of the internet of things through an API interface function and an Ethernet to realize network data communication, and processing data and detailed parameters of the numerical control machine controller 10 are collected and read in real time, wherein the processing data and the detailed parameters comprise statistics of the running processing time of the numerical control machine 4, statistics of the number of parts processing pieces, actual rotation speed of a main shaft, feeding speed of the machine tool and the like. Other data may be opened according to user needs. On the basis that the industrial personal computer 8 or the internet of things intelligent gateway 9 and the numerical control machine controller 10 establish data communication, the data acquired and acquired by the machine tool sensor can be reversely transmitted to the numerical control machine controller 10 and displayed on the man-machine interface of the numerical control machine controller 10 in real time: noise value, vibration value, spindle motor output voltage value, spindle motor output current value, spindle motor output power value, spindle motor output torque value.
And a data acquisition configuration connection channel II:
1) The vibration sensor 4 is connected with the industrial personal computer 8 or the intelligent gateway 9 of the Internet of things through 485 serial communication, and vibration data of the spindle box in the part machining process are read in real time.
2) The noise sensor 2 is connected with the industrial personal computer 8 or the intelligent gateway 9 of the Internet of things through 485 serial communication, and internal environment noise data of the machine tool in the machining process are read in real time.
3) The alternating current transmitter 6 is connected with the industrial personal computer 8 or the intelligent gateway 9 of the Internet of things through 485 serial communication, and the output current value data of the spindle motor is read in real time.
4) The alternating voltage transmitter 7 is connected with the industrial personal computer 8 or the intelligent gateway 9 of the Internet of things through 485 serial communication, and the output voltage value data of the spindle motor is read in real time.
The data stored in the numerical control machine tool are mainly of two types:
1) The real-time acquisition and acquisition data of various machine tool sensors comprise a vibration sensor 4, a noise sensor 2, an alternating current transmitter 6 and an alternating voltage transmitter 7.
2) Internal processing data of the numerical control machine controller 10, including actual spindle rotation speed, actual feeding speed of the numerical control machine, cutter information, cutter compensation value, machine position information and the like; the storage of the numerical control machine tool data comprises the steps of reading and displaying the internal information and the data of the numerical control machine tool controller 10 in real time by reading the data of the numerical control machine tool controller 10 and the sensors, reading the data information of the machine tool vibration sensor 4, the noise sensor 2, the alternating current transmitter 6 and the alternating voltage transmitter 7, displaying the data in real time, and drawing and outputting a real-time graph; including data management functions such as data querying, data deleting, data exporting, etc.
2. Application part of numerical control machine tool data:
the application of the numerical control machine tool data is to establish a numerical control machining knowledge database, which comprises real-time data acquired by a machine tool sensor, process test data and knowledge accumulation data obtained by production practice; the method is mainly used for providing necessary data reference basis for improving the machining efficiency and precision of the machine tool and is used for self-diagnosis of machine tool faults and physical examination of machine tool running states; the system comprises a real-time display main interface, a user management module, a data processing module, a vibration curve graph module, a noise curve graph module, a motor current curve graph module and a motor voltage curve graph module. The user management module mainly comprises functions of adding and deleting information of the software login user and exiting the system.
The real-time display main interface mainly comprises a basic information and setting area of acquisition equipment, a data real-time display area, a curve display area and an alarm information area. The basic information and the setting area comprise an IP address of the acquisition equipment, an acquisition equipment port, real-time, a test button for detecting whether the database connection is successful and a button for starting or ending acquisition; the data real-time display area comprises the starting time, cutting time, processing time, alarm state and information of the numerical control controller 10 of the machine tool, the feeding rate of the actual machine tool, the actual spindle rotating speed value, the position information of the tool coordinates, the actual current, voltage, power and the like of the spindle motor, and provides data for the production informatization management MS system; the curve display area contains real-time data curve drawing charts of the collected vibration data, noise data and power data, and provides support data basis for improving the machining efficiency and the precision of the numerical control machine tool. The alarm information area contains whether the numerical control machine controller 10 is in an alarm state or not and the specific alarm information content in the alarm state, and provides support data basis for normal use of the numerical control machine, fault diagnosis, machine self-checking and physical examination.
The vibration curve graph module is mainly used for reading real-time data values through 485 serial communication with the vibration sensor 3, displaying the vibration data values in a text box, drawing the latest 15 data points in a display area in real time, and modifying the number of collected data points according to user requirements; when the vibration data value of the machine tool exceeds the upper limit value A in the part machining process, the system gives a warning prompt to a user, and if the overload state is kept for a long time to reach the time setting D, the system controls the machine tool to carry out machining pause or stopping treatment; the system can give a recommended value H of machine tool vibration data or a process cutting scheme to a user according to experience data of a machining process knowledge base, and guide the user to optimize own machining process cutting parameters of the part.
The noise graph module is mainly used for reading real-time data values through 485 serial communication with the noise sensor 2, displaying the noise values in a text box, displaying the latest 15 data in a display area in real time, and the number of collected data points can be modified according to user requirements; when the noise data value of the machine tool exceeds the upper limit value B in the part machining process, the system gives a warning prompt to a user, and if the overload state is kept for a long time to reach the time setting D, the system controls the machine tool to carry out machining pause or stop treatment. The system can give a recommended value I of machine tool noise data or a process cutting scheme to a user according to experience data of a machining process knowledge base, and guide the user to optimize own machining process cutting parameters of the part.
The motor current and voltage curve graph module is mainly used for reading real-time data values through communication with an alternating current transducer 6 and an alternating voltage transducer 7 through 485 serial ports, respectively displaying the current values and the voltage values in a text box, displaying the latest 15 data in a display area in real time, and the number of collected data points can be modified according to the requirements of users; calculating the acquired current and voltage data values and the acquired spindle rotating speed value to obtain a real-time output power value of the spindle motor; when detecting that the power data value of the spindle motor of the machine tool exceeds the upper limit value C in the part machining process, the system sends out warning reminding to a user, and if the overload state is kept for a long time to reach the time setting D, the system controls the machine tool to carry out machining pause or shutdown treatment; the system can give a machine tool vibration data recommended value J or a process cutting scheme to a user according to experience data of a machining process knowledge base, and guide the user to optimize own machining process cutting parameters of the part.
In conclusion, the method for acquiring, storing and applying the data of the numerical control machine tool has the characteristics of good operation stability, long service life of the cutter and high processing efficiency. The method solves the problem of real-time automatic acquisition of key process index data of vibration, noise and motor output power in the machining process of machine tool parts. After analyzing and processing the acquired data, the real-time data value, the graph and the data query and the data management are displayed for the user, so that the user can reasonably optimize the part processing technology for reference, the part processing efficiency is improved, the machine tool performance is brought into full play to the maximum extent, and the benefit maximization is created for the user. And meanwhile, parameter comparison is carried out by combining a processing test knowledge database, and the most reasonable processing technological parameter recommendation and technological scheme are provided for users. When the sensor detection data in the machining process of the machine tool reaches an abnormal state, the system gives a warning prompt to a user and controls the machine tool to carry out machining pause or stop treatment, so that the protection of the workpiece, the cutter and the machine tool is realized.
The above embodiments are merely examples of the present invention, but the present invention is not limited thereto, and any changes or modifications made by those skilled in the art are included in the scope of the present invention.
Claims (13)
1. The method for collecting, storing and applying the data of the numerical control machine tool is characterized by comprising the following steps of:
the data acquisition method of the numerical control machine tool comprises the following steps: a vibration sensor (4), a noise sensor (2), an alternating current transducer (6) and an alternating voltage transducer (7) are arranged on a numerical control machine tool (3), and data acquired in real time by various sensors are acquired through a serial port communication technology, wherein the data comprise actual current values of a spindle motor, actual voltage values of the spindle motor, real-time vibration generated in a machining process and noise values are transmitted to an industrial personal computer (8) or an intelligent gateway (9) of the Internet of things through communication lines; the industrial personal computer (8) or the intelligent gateway (9) of the internet of things simultaneously performs network communication with the numerical control machine controller (10), and the numerical control machine controller (10) transmits the contents such as the actual rotating speed value, the actual feeding speed value, the cutter service life, the current cutter number, the cutter compensation value, the system alarm state, the warning information and the like of the spindle motor to the industrial personal computer (8) or the intelligent gateway (9) of the internet of things in real time;
The data storage method of the numerical control machine tool comprises the following steps: the method comprises the steps that real-time data and information are subjected to software data processing, real-time display is carried out on a human-computer interface of an industrial personal computer (8) and a numerical control machine tool controller (10), and after the data information is calibrated, the data is subjected to pretreatment such as data cleaning, data integration, data conversion and data protocol, the data is locally stored in a detection and monitoring system database of the background of the industrial personal computer (8); or the industrial personal computer (8) is changed into the intelligent gateway (9) of the Internet of things, the intelligent gateway is uploaded to a network cloud platform server in a wireless way through an Ethernet cable or a gateway 4G module, so that cloud storage and cloud calculation of data are realized, and cloud storage data are displayed through software of a PC (personal computer) end or a mobile terminal;
the real-time data application method of the numerical control machine tool comprises the following steps: comparing the real-time collected data with standard parameters of a processing database (5), recommending the most reasonable processing technological parameter value for a user according to the difference value, giving warning reminding to the user by a system when the sensor detection data in the processing process of the machine tool is higher than the upper limit value, and controlling the numerical control machine tool to carry out processing stopping treatment after the timing is reached if the processing is not interfered for a long time, so that the protection of the workpiece, the cutter and the machine tool is realized;
1. The application method of the data acquisition and storage part of the numerical control machine tool comprises the following steps:
data acquisition configuration connection channel one: the numerical control machine controller (10) is connected with the industrial personal computer (8) or the intelligent gateway (9) of the internet of things through an API interface function and an Ethernet to realize network data communication, and processing data and detailed parameters of the numerical control machine controller (10) are collected and read in real time, wherein the processing data and the detailed parameters comprise statistics of the running processing time of the numerical control machine, statistics of the number of parts to be processed, actual rotation speed of a main shaft, cutter information, cutter compensation value, feeding speed of the machine and the like;
and a data acquisition configuration connection channel II:
1) The vibration sensor (4) is connected with the industrial personal computer (8) or the intelligent gateway (9) of the Internet of things through 485 serial port communication, and vibration data of the spindle box in the part machining process are read in real time;
2) The noise sensor (2) is connected with the industrial personal computer (8) or the intelligent gateway (9) of the Internet of things through 495 serial port communication, and internal environment noise data of the machine tool in the machining process are read in real time;
3) The alternating current transmitter (6) is connected with the industrial personal computer (8) or the intelligent gateway (9) of the Internet of things through 485 serial port communication, and the output current value data of the spindle motor is read in real time;
4) The alternating voltage transmitter (7) is connected with the industrial personal computer (8) or the intelligent gateway (9) of the Internet of things through 485 serial port communication, and the output voltage value data of the spindle motor are read in real time;
The data stored in the numerical control machine tool are mainly of two types:
1) The real-time acquisition of all types of machine tool sensors obtains data, and the data comprise a vibration sensor (4), a noise sensor (2), an alternating current transmitter (6) and an alternating voltage transmitter (7);
2) Internal processing data of the numerical control machine controller (10) comprises actual rotation speed of a main shaft, actual feeding rate of the numerical control machine, cutter information, cutter compensation value, machine position information and the like; the storage of the numerical control machine tool data comprises the steps of reading the data of a numerical control controller (9) and a sensor of the numerical control machine tool, reading and displaying the internal information and the data of the numerical control controller (9) in real time, reading the data information of a vibration sensor (4), a noise sensor (2), an alternating current transmitter (6) and an alternating voltage transmitter (7) of the numerical control machine tool, displaying the data in real time, and drawing and outputting a real-time graph; the method comprises the functions of data inquiry, data deletion and data export;
2. application part of numerical control machine tool data:
the application of the numerical control machine tool data is to establish a numerical control machining knowledge database, which comprises real-time data acquired by a machine tool sensor, process test data and knowledge accumulation data obtained by production practice; the method is mainly used for providing necessary data reference basis for improving the machining efficiency and precision of the machine tool and is used for self-diagnosis of machine tool faults and physical examination of machine tool running states; the system comprises a real-time display main interface, a user management module, a data processing module, a vibration curve graph module, a noise curve graph module, a motor current curve graph module and a motor voltage curve graph module.
2. The method for acquiring, storing and applying the numerical control machine tool data according to claim 1, wherein the method comprises the following steps: the numerical control machine controller (10) is arranged on the side, facing the operator, of the machine tool, and is connected with the industrial personal computer (8) or the intelligent gateway (9) of the Internet of things through an Ethernet, the industrial personal computer (8) or the intelligent gateway (9) of the Internet of things establishes data communication with the numerical control machine controller (10) through an API interface function protocol, and relevant information data of the machining process of the numerical control machine is read in real time; reading data includes: the numerical control machine tool running processing time statistics, the part processing number statistics, the main shaft actual rotation speed, the machine tool feeding speed, the cutter information, the cutter compensation value and the like can open other data according to the user requirements; on the basis that the industrial personal computer (8) or the internet of things intelligent gateway (9) and the numerical control machine controller (10) establish data communication, data acquired and acquired by a machine tool sensor can be reversely transmitted to the numerical control machine controller (10), and real-time display is carried out on a human-computer interface of the numerical control machine controller (10): noise value, vibration value, spindle motor output voltage value, spindle motor output current value, spindle motor output power value, spindle motor output torque value.
3. The method for acquiring, storing and applying the numerical control machine tool data according to claim 1, wherein the method comprises the following steps: the industrial personal computer (8) or the intelligent gateway (9) of the internet of things is arranged on the side, facing an operator, of the machine tool, is connected with the numerical control machine tool controller (10) through an Ethernet cable, and is connected with the noise sensor (2), the vibration sensor (4), the alternating current transmitter (6) and the alternating voltage transmitter (7) through 485 serial communication; the method comprises the steps of processing acquired real-time data and information through software data, displaying the acquired real-time data and information on a human-computer interface of an industrial personal computer (8) and a numerical control machine tool controller (10) in real time, and realizing the local storage of the data in a detection and monitoring system database of a background of the industrial personal computer (8); or the industrial personal computer (8) is changed into the intelligent gateway (9) of the Internet of things, the intelligent gateway is uploaded to the network cloud platform server in a wireless way through an Ethernet cable or a gateway 4G module, cloud storage and cloud computing of data are realized, and cloud storage data are displayed through software of a PC (personal computer) end or a mobile terminal.
4. The method for acquiring, storing and applying the numerical control machine tool data according to claim 1, wherein the method comprises the following steps: the vibration sensor (4) is arranged on the side surface of the main shaft box body of the machine tool, the direction of the vibration sensor is vertical to the side surface of the main shaft box body, and the vibration sensor is rigidly connected by adopting threads; the sensor function is to accurately measure vibration data generated in the machining process of the machine tool in real time, so that the machining states of a cutter and a workpiece in the machining process can be monitored better; the vibration sensor (4) is required to be selected to have vibration resistance, impact resistance and high stability, has good low-frequency output characteristics, and can directly output vibration displacement signals and amplitude signals; the vibration sensor (4) is used for receiving vibration and displaying vibration data and curve images of the machine tool spindle.
5. The method for acquiring, storing and applying the numerical control machine tool data according to claim 1, wherein the method comprises the following steps: the noise sensor (2) is arranged at a sheet metal part in the machine tool, and the water-proof and oil-proof environment is needed to be considered; the sensor is used for detecting noise data in the part machining process in real time, and detecting abnormal noise in the machining process so as to assist in judging whether abnormal problems exist in the machining process, whether a cutter is worn or not and the like; the noise sensor (2) is internally provided with a capacitance microphone sensitive to sound, the sound wave vibrates a film in the microphone, so that capacitance changes to generate tiny voltage corresponding to the capacitance changes, the voltage is then converted into voltage of 0-5V, the voltage is received by the data acquisition device through A/D conversion and is transmitted to the industrial personal computer (8), and the noise sensor (2) is used for receiving the sound wave and displaying vibration data and curve images of the environmental sound in the machine tool.
6. The method for acquiring, storing and applying the numerical control machine tool data according to claim 1, wherein the method comprises the following steps: the alternating current transmitter (6) is arranged at the output end U V W of the spindle motor in the machine tool electric cabinet (5), is fixed by a caliper groove, and the routing needs to consider strong and weak current separation, so that signal interference is avoided, and the data acquisition accuracy of the sensor is affected; the sensor function is to measure the current value output by the spindle motor in real time, so that the actual power output value of the spindle motor at any moment is calculated subsequently; the alternating current transducer (6) is used for detecting current and displaying current data and curve images output by the spindle motor.
7. The method for acquiring, storing and applying the numerical control machine tool data according to claim 1, wherein the method comprises the following steps: the alternating voltage transmitter (7) is arranged at the output end U V W of the spindle motor in the machine tool electric cabinet (5) and is fixed by a caliper groove; the routing needs to consider strong and weak current separation, so that signal interference is avoided, and the data acquisition accuracy of the sensor is affected; the sensor function is to measure the voltage value output by the spindle motor in real time, so that the actual power output value of the spindle motor at any moment is calculated subsequently; the alternating voltage transducer (7) is used for detecting voltage and displaying voltage data and curve images output by the spindle motor.
8. The method for acquiring, storing and applying the numerical control machine tool data according to claim 1, wherein the method comprises the following steps: the output power value of the spindle motor can be calculated through the output voltage value and the current value of the spindle motor acquired by the current transducer (6) and the voltage transducer (7); the rotating speed value of the spindle motor is obtained from the numerical control machine controller (10) through API interface communication, and the real-time output torque value of the spindle motor can be calculated and obtained by combining the output power value of the spindle motor, so that the real-time output torque data and curve images of the spindle motor are displayed.
9. The method for acquiring, storing and applying the numerical control machine tool data according to claim 1, wherein the method comprises the following steps: the real-time display main interface mainly comprises a basic information and setting area of acquisition equipment, a data real-time display area, a curve display area and an alarm information area. The basic information and the setting area comprise an IP address of the acquisition equipment, an acquisition equipment port, real-time, a test button for detecting whether the database connection is successful and a button for starting or ending acquisition; the data real-time display area comprises the starting time, cutting time, processing time, alarm state and information of a machine tool numerical control controller (10), the actual machine tool feed rate, the actual spindle rotating speed value, the cutter coordinate position information, the actual current, voltage, power and the like of a spindle motor, and provides data for the production informatization management MS system; the curve display area contains real-time data curve drawing charts of the collected vibration data, noise data and power data, and provides support data basis for improving the machining efficiency and the precision of the numerical control machine tool. The alarm information area contains whether the numerical control machine controller (10) is in an alarm state or not and the specific alarm information content in the alarm state, and provides support data basis for normal use of the numerical control machine, fault diagnosis, machine self-checking and physical examination.
10. The method for acquiring, storing and applying the numerical control machine tool data according to claim 1, wherein the method comprises the following steps: the user management module mainly comprises functions of adding and deleting information of the software login user and exiting the system.
11. The method for acquiring, storing and applying the numerical control machine tool data according to claim 1, wherein the method comprises the following steps: the vibration curve graph module is mainly used for reading real-time data values through 485 serial port communication with the vibration sensor (4), displaying the vibration data values in a text box, drawing the latest 15 data points in a display area in real time, and modifying the number of collected data points according to user requirements; when the vibration data value of the machine tool exceeds the upper limit value A in the part machining process, the system gives a warning prompt to a user, and if the overload state is kept for a long time to reach the time setting D, the system controls the machine tool to carry out machining pause or stopping treatment; the system can give a recommended value H of machine tool vibration data or a process cutting scheme to a user according to experience data of a machining process knowledge base, and guide the user to optimize own machining process cutting parameters of the part.
12. The method for acquiring, storing and applying the numerical control machine tool data according to claim 1, wherein the method comprises the following steps: the noise graph module is mainly used for reading real-time data values through 485 serial communication with the noise sensor (2), displaying the noise values in a text box, displaying the latest 15 data in a display area in real time, and the number of collected data points can be modified according to user requirements; when the noise data value of the machine tool exceeds the upper limit value B in the part machining process, the system gives a warning prompt to a user, and if the overload state is kept for a long time to reach the time setting D, the system controls the machine tool to carry out machining pause or stop treatment. The system can give a recommended value I of machine tool noise data or a process cutting scheme to a user according to experience data of a machining process knowledge base, and guide the user to optimize own machining process cutting parameters of the part.
13. The method for acquiring, storing and applying the numerical control machine tool data according to claim 1, wherein the method comprises the following steps: the motor current and voltage curve graph module is mainly used for reading real-time data values through communication with an alternating current transducer (6) and an alternating voltage transducer (7) through 485 serial ports, respectively displaying the current values and the voltage values in a text box, displaying the latest 15 data in a display area in real time, and the number of collected data points can be modified according to user requirements; calculating the acquired current and voltage data values and the acquired spindle rotating speed value to obtain a real-time output power value of the spindle motor; when detecting that the power data value of the spindle motor of the machine tool exceeds the upper limit value C in the part machining process, the system sends out warning reminding to a user, and if the overload state is kept for a long time to reach the time setting D, the system controls the machine tool to carry out machining pause or shutdown treatment; the system can give a machine tool vibration data recommended value J or a process cutting scheme to a user according to experience data of a machining process knowledge base, and guide the user to optimize own machining process cutting parameters of the part.
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116880357A (en) * | 2023-09-04 | 2023-10-13 | 潍柴动力股份有限公司 | Equipment debugging method, device, equipment and storage medium |
| CN117055470A (en) * | 2023-09-22 | 2023-11-14 | 隆昌精机有限公司 | Intelligent Internet of things docking system applied to numerical control equipment |
| CN117872962A (en) * | 2024-03-11 | 2024-04-12 | 南通钜盛数控机床有限公司 | Control system of numerical control machine tool |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116880357A (en) * | 2023-09-04 | 2023-10-13 | 潍柴动力股份有限公司 | Equipment debugging method, device, equipment and storage medium |
| CN116880357B (en) * | 2023-09-04 | 2023-12-15 | 潍柴动力股份有限公司 | Equipment debugging method, device, equipment and storage medium |
| CN117055470A (en) * | 2023-09-22 | 2023-11-14 | 隆昌精机有限公司 | Intelligent Internet of things docking system applied to numerical control equipment |
| CN117872962A (en) * | 2024-03-11 | 2024-04-12 | 南通钜盛数控机床有限公司 | Control system of numerical control machine tool |
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